Process Units

An engaging and accessible e-learning program designed to improve our clients’ Performance, Safety & Reliability; the central components of successful operations.

Process Units

Process Unit Basics is a comprehensive, 37 module program covering the Process Units found in a typical fuels refinery. The program is split into 11 sub-programs covering the 11 main Process Units; each comprising a varying number of modules.

Fluidized Catalytic Cracking (FCC) Advanced is an 8 module program that delves deeper into the complexities of the FCC – in particular the hydraulic & thermal relationships in the Reactor-Regenerator system. FCC Advanced is suitable for senior operators and graduate process engineers.

The aim of the Process Unit Basics program is to familiarize trainees with common Process Units they are likely to encounter in their plant and provide a solid foundation for assignment to a particular unit.

The first program, ‘Refinery Orientation’ teaches the trainee about the Overall Refinery Processing Configuration, describing the function of each Process Unit, the Product Slate, Unit Operations & Hydrocarbon Chemistry. For each process unit, the program addresses the following:

  • Process Description
  • Process Control Description
  • Equipment Functional Description
  • Common Operating Problems


The program utilizes animated Process Flow Diagrams (PFDs) and Process Flow Control Diagrams (PFCDs) to walk the trainee through the process, facilitating trainee understanding of the process flows and process controls while simultaneously familiarizing trainees with reading and understanding PFDs and PFCDs in general.

An important theme of the program is the optimization of throughputs, yields, conversions and product qualities, while at the same time minimizing operating costs, reducing/eliminating production, inventory, equipment, energy & environmental losses.

The Process Units program comprises the following programs/modules:

Refinery Orientation
  • Introduction
  • Overall Refinery Processing Configuration
  • Product Slate
  • Unit Operations & Hydrocarbon Chemistry
Atmospheric Distillation Unit (ADU)
  • Overview
  • Cold Preheat, Desalting, Preflashing & Hot Preheat
  • Direct Heating & Atmospheric Tower
  • Compression, Absorption & Stripping, Stabilization & Splitting
Vacuum Distillation Unit (VDU)
  • Vacuum Heater & Vacuum Tower
  • Vacuum Ejectors, Aftercoolers, Hotwell & Heat Recovery
Hydrogen Generation Unit (HGU)
  • Overview & Feed Pretreatment
  • Steam-Methane Reforming
  • Shift Conversion & Purification
Naphtha Hydrotreating Unit & Continuous Catalytic Reforming Unit (NHTU & CCRU)
  • NHTU Feed & Makeup Gas
  • NHTU Heater & Reactor
  • NHTU Separation & Compression
  • CRU Heaters, Reactor & Regenerator
  • CRU Separators, Compressors & Stabilizer
Diesel Hydrotreating Unit (DHTU)
  • Feed & Makeup Gas
  • Reaction
  • Separation & Absorption
  • Fractionation
Gas Oil Hydrotreating Unit (GOHTU)
  • Feed & Makeup Gas
  • Reaction
  • HP Separation, Absorption & Compression
  • LP Separation, Absorption & Stripping
  • Fractionation
Fluidized Catalytic Cracking Unit (FCCU) – Basics
  • Cracking Reactions
  • Reactor
  • Regenerator
  • Main Fractionator & Gas Plant
Fluidized Catalytic Cracking Unit (FCCU) – Advanced
  • Introduction
  • Orientation
  • Reactor & Regenerator
  • Catalyst
  • Feed Characteristics
  • Cracking Reactions
  • Monitoring & Control
  • Summary
Sour Processing Units (SPUs)
  • Overview, Merox & Sour Water Stripping
  • Amine Absorption & Regeneration
  • Sulfur Recovery Unit & Tail Gas Treating Unit
Delayed Coking Unit (DCU)
  • Overview, Feed Preheat, Coker Heater & Coke Drums
  • Main Fractionator & Gas Plant
Visbreaking Unit (VBU)
  • Heating & Soaking, Fractionation & Gas Concentration
  • Status Available Immediately
  • # Modules 37
  • Total Runtime 14 hrs
  • Suitable for New Hires, Operators and Graduate Process Engineers
Trainee Assessments

All our e-learning programs are supported by modular assessments to allow you to monitor trainee attainment


PSR can provide e-learning programs in SCORM 1.2, SCORM 2004 or AICC formats. These can be hosted in your LMS, or we can host for you

Support for mobile devices

Our modules are built with HTML5 rather than Flash, which means they are future-proof and work on mobile devices

About PSR Interactive

PSR deliver engaging and accessible training content that combines expert-level technical detail with 3D multimedia to communicate ideas clearly and effectively.

Our comprehensive library of hundreds of e-learning modules are targeted at the oil refining, oil & gas, petrochemical, chemical and energy industries. The modules can be purchased off-the-shelf, or can be customized to meet your needs.

Visit our homepage for more details, or contact us using the details below.


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