Statistical techniques coupled with genetic algorithm (GA) were used to identify optimal values of key operational variables in fluid catalytic cracking (FCC) process. A Kellog Orthoflow F fluid catalytic cracking process model was considered. It is known as a highly nonlinear process with a large number of variables with strong interactions among them. A reduced process model was obtained through factorial design technique to be used as a process function in the optimisation work giving as result the operational conditions that maximise conversion without infringing operational restrictions with savings in computational burden and time. An increase of 8.71% in process conversion was achieved applying GA as optimisation technique. (c) 2012 Canadian Society for Chemical Engineering