Regenerator Operation

FCC catalyst deactivates with coke deposits during cracking. Regenerator burns off coke restoring activity. Combustion flue gas at 650-750C carries entrained catalyst requiring removal before gas exits to energy recovery or stack. Cyclones separate catalyst returning it to regenerator bed.

Two-Stage Design

Primary cyclones remove bulk catalyst particles. Secondary cyclones polish primary discharge capturing finer particles. Combined stages achieve over 99.9% separation. Residual carryover under 100 ppm protects downstream expander or boiler.

Operating Conditions

Regenerator temperature 650-750C, pressure 2-4 bar. Flue gas contains CO2, water vapor, excess oxygen, and trace SO2. High temperature and oxygen create severe corrosive environment. Design withstands thermal and chemical stress.

Material Selection

Alloy steel construction resists high temperature oxidation. Refractory lining protects shell from extreme heat. Wear-resistant linings in high-velocity zones combat erosion. Materials handle oxidizing atmosphere with particulate loading.

Cyclone Arrangement

Multiple cyclone tubes arranged in parallel handling total flue gas flow. Each primary cyclone feeds dedicated secondary stage. Modular design suits various regenerator capacities. Typical arrangement 2-6 primary cyclones with secondaries.

Dipleg System

Diplegs below cyclones prevent gas backflow maintaining separation efficiency. High-temperature design accommodates thermal expansion. Seal legs or flapper valves prevent short-circuiting. Critical for maintaining pressure differential.

Catalyst Collection

Separated catalyst flows through diplegs into collection hoppers. Returns to dense catalyst bed in regenerator. Continuous circulation maintains regeneration efficiency. Level management prevents hopper plugging or overflow.

Separation Performance

Primary stage removes 95-98% of particles. Secondary captures additional 90-95% of remaining fines. Combined efficiency protects third-stage separator or downstream equipment. Critical for meeting environmental emissions limits.

Erosion Management

Particle-laden gas at high velocity causes severe erosion. Replaceable wear plates in critical zones. Regular inspection monitors wear rates. Design life 5-8 years between major relining. Accessible design enables maintenance.

Flue Gas Treatment

Cleaned flue gas flows to expander turbine generating power, waste heat boiler making steam, or stack after treatment. Low catalyst carryover protects equipment and meets environmental standards.

Construction Standards

Design per ASME Section VIII for pressure service. Refractory per API standards. Materials for high-temperature oxidizing service with particulates. Structural analysis for thermal cycling. Complete documentation with performance guarantees.

ERGIL regenerator cyclone separators deliver reliable catalyst recovery ensuring efficient FCC regeneration while protecting downstream equipment and meeting environmental requirements.