FCC Process Role

Fluid catalytic cracking converts heavy oil to lighter products using fluidized catalyst. Reactor vapors carry entrained catalyst particles requiring removal before fractionation. Cyclone separators capture catalyst using centrifugal force. Clean vapors flow to fractionator while recovered catalyst returns to process.

Cyclone Design

Two-stage separation with primary and secondary cyclones. Gas enters tangentially creating high-speed rotation. Centrifugal force throws particles to walls. Cleaned gas exits through center vortex finder. Particles slide down walls into diplegs. Collection hoppers gather catalyst for return.

Multi-Cyclone Assembly

Multiple cyclone tubes arranged in parallel handling total reactor vapor flow. Each tube operates independently. Combined capacity handles gas rates from reactor. Redundancy allows continued operation if individual cyclone fails. Modular design suits various FCC capacities.

Operating Conditions

Reactor conditions typically 500-550C and 2-3 bar. High temperature requires refractory lining and alloy materials. Design withstands thermal cycling during startup and shutdown. Expansion joints accommodate thermal growth.

Material Selection

Carbon steel shells with refractory lining protect from high temperature and catalyst erosion. Wear-resistant materials in high-velocity zones. Diplegs use abrasion-resistant alloys. Design handles erosive catalyst particles at extreme conditions.

Separation Efficiency

Primary cyclones remove 95-99% of catalyst particles. Secondary stage polishes gas to under 50 ppm catalyst carryover. Combined efficiency protects downstream fractionator from fouling while maximizing catalyst retention.

Dipleg Function

Vertical pipes below cyclones prevent gas backflow while allowing catalyst flow to hoppers. Proper length maintains pressure seal. Flapper valves or J-bends prevent vapor short-circuiting. Critical for separation integrity.

Catalyst Return

Collection hoppers gather separated catalyst. Slide valves control flow back to regenerator or reactor. Level management prevents hopper overflow. Continuous catalyst circulation maintains FCC operation.

Erosion Management

High-velocity catalyst-laden gas causes erosion. Wear-resistant linings extend life. Regular inspection monitors erosion rates. Design includes replaceable wear sections. Typical life 5-10 years between major maintenance.

Construction Standards

Design per ASME Section VIII for pressure service. Refractory installation per API standards. Materials for high-temperature erosive service. Complete structural analysis and thermal design. Comprehensive documentation with performance guarantees.

ERGIL FCC cyclone separators provide reliable catalyst recovery ensuring efficient fluid catalytic cracking operations in refinery conversion units.