In this session, we will discuss in detail the definition of Normalization of Deviance and how it has contributed to major accidents, including both Space Shuttle disasters. Examples will be provided of Normalization of Deviance in operating and maintaining process plants, as well as in our daily lives.
Participants will:
Gain an understanding of how to stop Normalization of Deviance
Learn how to identify and correct this behavior
Take this concept home to apply with their families
Over the past 12 years, Ketjen FCC modeling engineers have simulated over 145 FCC units globally, identifying common challenges that prevent refiners from fully leveraging kinetic FCC models to maximize profitability. These challenges often stem from structural issues in model setup, poor-quality process measurements, or a lack of detailed knowledge about the models. This presentation will highlight 4 to 6 real-world examples, offering insights on how to: 1) avoid common modeling predicaments, 2) quickly identify if problems exist, and 3) implement actionable solutions.
Moderator:
Steve Shimoda, Technip Energies
Speaker:
Alan Kramer, Ketjen Corporation
Bridget Cadigan, Marathon Petroleum Corporation
After more than 50 years of root cause analysis (RCA), you might expect problem solving to be a clear and straightforward process. It’s not. You can find yourself caught in unproductive debates. “Is that a contributing factor, or a causal factor?” “That’s a primary cause, but it’s not the main cause.” The result is frustration, inefficiency, and solutions that allow a repeat of the same problems.
A better approach to RCA is one built on evidence-based cause-and-effect relationships. The steps are simple: define the problem, explain why it happened, and identify solutions to reduce risk. Its focus is on having more reliable work processes, learning, and improving, which helps engage the frontline and minimize blame.
This session will explain the pitfalls of drifting from scientific problem solving and features a case study demonstrating how first-principles RCA leads to tangible improvements in reliability and human performance.
Participants will learn:
Four common errors that arise when explaining why an incident occurred
The biggest misconception about RCA
Why effective RCA does not require any proprietary techniques, terminology, or software
How RCA can be scaled for low-risk incidents and expanded as needed for higher-impact events.
How to reduce “human error” by involving those who perform the work
Moderator:
Bill Clark, Phillips 66
Speakers:
Bill Clark, Phillips 66
Mark Galley, ThinkReliability
Fluid Catalytic Cracking technology provides an elegant and flexible solution to meet refining and petrochemical demands but concurrently carries notable challenges. Among these challenges are contaminants produced in the process, notably particulate matter, SOx, NOx, and CO, which have potential to result in air quality emissions from the flue gas stack. This session will describe the formation mechanisms and summarize available control technology to manage emission of these species.
The FCC is a flexible machine which is adapting to fulfill the premium gasoline incentive across the USA. This session will discuss how Marathon is enhancing their FCC operations through operational adjustments and advances in catalysis to achieve optimal downstream Alkylation performance. It will also provide an overview of how maximizing alkylate feed, reducing LPG saturates, and optimizing the C4=/C3= ratio from FCC boost the alkylate octane contribution to the refinery gasoline pool.
During this prsentaion we will define good practices for
the prevention of explosive mixture formation that could result from various causes in the FCC.
Moderator:
Joe Famolaro, ExxonMobil Corporation
Richard Grove, AFPM
Review and answer submitted questions with a select panel of experts questions regarding FCC's!
Moderator:
Steve Jewell, KBR
Panelists:
CJ Farley, G. W. Aru, LLC
Ziad Jawad, Phillips 66
Andrew Mezera, Valero Energy Corporation
Patrick McSorley, Ketjen Corporation
Raj Singh, Technip Energies
Speakers:
Darin Foote, CHS Inc.
Chuck Johnston, Marathon Petroleum Corporation LP
Vidyashankar Kuppuraj, Marathon Petroleum Corporation
Johnny Serafin, Phillips 66
Nic Tognetti, CHS Inc.
Advanced process control (APC) has been employed in FCC applications for 40 years. Despite the similarities of FCC Technology and APC platforms the success of these applications varies widely. In this session we will discuss common threads that lead to poor outcomes and how to build a successful APC program on a modern FCC.
Facilitators:
Cliff Avery, Ketjen Corpotation
CJ Farley, TPM Solutions
1. Commercial Results of 100% Vegetable Oil Processing in an FCCU
Speaker: Andrea de Rezende Pinho, Petróleo Brasileiro S/A - PETROBRAS
In 2023, Petrobras and the Riograndense Refinery (RPR) successfully processed 100% vegetable oil in a Fluid Catalytic Cracking (FCC) Unit. Petrobras' technology is based on three pillars: i) triglycerides, such as soybean oil used in the commercial test, ii) ReNewFCC line catalyst and iii) unique operating conditions compared to conventional FCCUs. Biogenic products such as renewable aromatic hydrocarbons (BTX - benzene, toluene and xylene), renewable LPG, and renewable propylene were produced during the commercial trial. Commercial yields, quality of the products, operational challenges and technical adaptations for the trial will be presented.
2. U.S. HEFA Co-processing – Past, Present, and Future Projects
Speaker: Eamon Cullinane, Turner, Mason & Company
HEFA co-processing at U.S. oil refineries has historically not seen the same success as standalone RD/SAF refinery conversions. So why has co-processing in the U.S. been limited in the past and why might we see more of it in the future? We will explore historical production levels of co-processing, economics vs standalone RD/SAF facilities, the regulatory landscape and credit incentives (RINs, BTC, CFPC/45Z, CA LCFS, etc.) driving these economics, and future prospects of co-processing in the U.S.