Internal Cyclone Function

Fluidized bed and circulating bed reactors carry catalyst particles in gas streams. Internal cyclones positioned in reactor vapor space separate solids before gas exits vessel. Captured particles drop back to bed. Clean gas flows to downstream processing.

Cyclone Design

Tangential inlet creates high-speed rotation. Centrifugal force throws particles outward to walls. Solids slide down into dipleg. Clean gas spirals upward through vortex finder tube exiting cyclone. Simple geometry with no moving parts provides reliable separation.

Operating Environment

Installed inside reactor pressure boundary operating at process conditions. High temperatures from 400-900C depending on reaction. Pressures from atmospheric to 50 bar. Must withstand corrosive atmospheres and thermal cycling.

Material Selection

High-temperature alloys resist thermal stress and corrosion. Refractory lining protects from extreme temperatures and erosion. Wear-resistant materials in high-velocity zones. Design accommodates thermal expansion without mechanical failure.

Separation Efficiency

Removes 90-99% of particles above 10 microns. Smaller particles may pass through. Multiple cyclones in parallel or series improve efficiency. Performance depends on particle size, density, gas velocity, and cyclone geometry.

Dipleg Design

Vertical tube below cyclone prevents gas backflow while allowing solids return. Proper length maintains pressure seal. Flapper valves or seal pots prevent short-circuiting. Critical for maintaining separation efficiency.

Applications

FCC reactor catalyst recovery, Fischer-Tropsch synthesis solid separation, biomass gasification char removal, polymerization reactor fines capture, and any fluidized or circulating bed reactor requiring internal solids recovery.

Multiple Cyclone Arrangement

Primary cyclones handle bulk solids. Secondary stage polishes gas from primary discharge. Tertiary stage final cleanup in critical applications. Staged separation achieves low carryover protecting downstream equipment.

Erosion Resistance

High-velocity particle-laden gas causes erosion. Replaceable wear liners extend life. Regular inspection during turnarounds. Design includes accessible wear zones. Typical life 3-7 years before liner replacement.

Performance Benefits

Maintains catalyst inventory in reactor improving conversion. Protects downstream equipment from solid damage. Reduces catalyst makeup costs by recovering fines. Simple proven technology with no moving parts.

Construction Standards

Design per reactor pressure vessel codes. Materials for high-temperature erosive service. Structural analysis ensures integrity. Refractory installation per industry standards. Complete documentation with separation guarantees.

ERGIL reactor cyclone separators provide reliable internal solids recovery protecting equipment and maintaining reactor performance in catalytic and thermal processes.