Introduction

Catalyst management is a critical pillar in modern refinery operations, directly influencing hydrocarbon conversion efficiency, process optimization, emissions control, and operational profitability. As refineries evolve toward digital transformation, energy transition, and sustainability-driven operations, effective catalyst selection, handling, regeneration, and lifecycle optimization have become essential competencies. Poor catalyst management can lead to reduced throughput, increased downtime, higher energy consumption, and suboptimal product yields making this training vital for refinery engineers and operational leaders.

Catalyst Management in Refineries Training Course is designed to equip professionals with advanced knowledge of refinery catalysts, deactivation mechanisms, regeneration strategies, performance monitoring, and troubleshooting techniques. It integrates real-world refinery scenarios, industry best practices, and case-driven learning to enhance decision-making in FCC, hydrocracking, hydrotreating, reforming, and petrochemical integration units. Participants will gain the capability to optimize catalyst life cycle performance while aligning with asset integrity, process safety, and sustainability goals.

Programme Curriculum

Catalyst Management in Refineries Training Course

Introduction

Course Duration

5 days

Course Objectives

Understand fundamentals of refinery catalysts and reaction engineering
Analyze catalyst deactivation mechanisms
Optimize catalyst life cycle management strategies
Improve FCC, hydrocracking, and hydrotreating performance
Apply best practices in catalyst handling, loading, and unloading
Enhance process efficiency through catalyst optimization
Implement advanced catalyst regeneration techniques
Monitor catalyst performance using KPI and digital analytics tools
Reduce operational costs through predictive catalyst management
Strengthen process safety in catalyst operations
Identify and troubleshoot catalyst-related process failures
Align catalyst management with decarbonization and ESG goals
Integrate AI and data-driven refinery optimization techniques

Target Audience

Refinery Process Engineers
Chemical Engineers in Petrochemical Plants
Operations and Production Supervisors
Maintenance and Reliability Engineers
FCC / Hydroprocessing Unit Operators
Plant Managers and Technical Superintendents
HSE and Process Safety Professionals
Energy and Sustainability Analysts

Course Modules

Module 1: Refinery Catalysts Fundamentals

Types of refinery catalysts
Catalyst role in hydrocarbon processing
Reaction kinetics and selectivity principles
Catalyst support structures and formulation
Industry catalyst innovations overview
Case Study: FCC catalyst performance improvement in a Middle East refinery

Module 2: Catalyst Deactivation Mechanisms

Coke formation and fouling impacts
Poisoning by sulfur, nitrogen, metals
Thermal degradation and sintering effects
Feedstock-related catalyst stress factors
Detection and diagnosis techniques
Case Study: Hydrotreating catalyst poisoning in sour crude processing unit

Module 3: Catalyst Selection and Optimization

Feedstock-catalyst compatibility analysis
Activity vs selectivity trade-offs
Vendor selection and benchmarking
Catalyst grading and performance specs
Optimization under refinery constraints
Case Study: Catalyst selection optimization in hydrocracking unit

Module 4: Catalyst Loading, Unloading & Handling

Safe handling and inerting procedures
Reactor loading patterns and distribution
Dust control and exposure risks
Catalyst storage and transportation standards
Shutdown and turnaround best practices
Case Study: Catalyst loading failure prevention during FCC turnaround

Module 5: Catalyst Regeneration Technologies

In-situ and ex-situ regeneration methods
Burn-off techniques and oxidation control
Regeneration efficiency monitoring
Environmental compliance in regeneration
Catalyst reuse and recycling strategies
Case Study: FCC regenerator optimization improving yield recovery

Module 6: Catalyst Performance Monitoring

Key performance indicators (KPI) tracking
Pressure drop and conversion efficiency analysis
Advanced process control systems
Digital twins and predictive analytics
Real-time monitoring tools
Case Study: AI-based catalyst performance monitoring in refinery operations

Module 7: Troubleshooting Catalyst Failures

Identifying early warning signals
Root cause analysis (RCA) methods
Process upset correlation
Mitigation strategies and corrective actions
Incident documentation and learning systems
Case Study: Rapid catalyst deactivation in hydrotreater due to feed contamination

Module 8: Sustainable Catalyst Management & Digital Refining

ESG integration in catalyst lifecycle
Low-emission catalyst technologies
Waste minimization and recycling
AI and machine learning in catalyst optimization
Future trends in refinery catalysis
Case Study: Digital refinery transformation using predictive catalyst lifecycle modeling

Training Methodology

This course employs a participatory and hands-on approach to ensure practical learning, including:

Interactive lectures and presentations.
Group discussions and brainstorming sessions.
Hands-on exercises using real-world datasets.
Role-playing and scenario-based simulations.
Analysis of case studies to bridge theory and practice.
Peer-to-peer learning and networking.
Expert-led Q&A sessions.
Continuous feedback and personalized guidance.

Register as a group from 3 participants for a Discount

Send us an email: info@fineskilltrainingcenter.org or call +254769199797

Certification

Upon successful completion of this training, participants will be issued with a globally- recognized certificate.

Tailor-Made Course

We also offer tailor-made courses based on your needs.

Key Notes

a. The participant must be conversant with English.

b. Upon completion of training the participant will be issued with an Authorized Training Certificate

c. Course duration is flexible and the contents can be modified to fit any number of days.

d. The course fee includes facilitation training materials, 2 coffee breaks, buffet lunch and A Certificate upon successful completion of Training.

e. One-year post-training support Consultation and Coaching provided after the course.

f. Payment should be done at least a week before commence of the training, to Fineskill Training Center account, as indicated in the invoice so as to enable us prepare better for you.

Skills & Software Covered

Catalyst performance Regeneration processes Reactor efficiency Process optimization

Programme Fee

Duration: 5 Days

Method: Online or Physical

Online Price: $1,000

Physical Price: $1,500

Certification: Accredited Certificate

View Available Dates 📄 Download Course Outline (PDF)

Available Sessions

Location

Month

Year

Oct 26 2026

26 Oct — 30 Oct 2026

💻 Online / Virtual session

Online $1,000