IIIHIIII

USOO551427A
United States Patent (19) 11 Patent Number: 5,514,271
Buchanan et al. 45) Date of Patent: May 7, 1996
(54) UNDERFLOW CYCLONE WITH 5,055, 177 10/1991 Haddad et al. ......................... 208/16
PERFORATED BARREL 5,190,650 3/1993 Tammera et al. ....................... 210/256
5,372,707 12/1994 Buchanan et al. ...................... 208/161
(75) Inventors: John S. Buchanan; Christopher G. FOREIGN PATENT DOCUMENTS
Smalley, both of Hamilton, N.J.
997823 2/1983 U.S.S.R.
73) Assignee: Mobil Oil Corporation, Fairfax, Va.
Primary Examiner-E. Rollins Cross
Assistant Examiner-Walter D. Griffin
21) Appl. No.: 234,794 Attorney, Agent, or Firm-Malcolm D. Keen; Dennis P.
22) Filed: Apr. 28, 1994 Santini; Richard D. Stone
51 Int. Cl. ............ a a w C01G 11/00; B04C3/06 57 ABSTRACT
52) U.S. Cl. ............. - - - -- - - - -- - - - 203/113; 208/153; 208/161;
A cyclone and process for fluidized catalytic cracking of
55/452; 209/720, 209/721; 209/722; 209/723; heavy oils is disclosed. Gas and entrained solids are added
422/147
tangentially around a vapor outlet tube in a cylindrical tube
(58) Field of Search ..................................... 208/113, 153, cyclone body. Solids and some gas is withdrawn via a
208/161; 55/447, 452, 460; 209/720, 722, plurality of openings radially and longitudinally distributed
723, 721; 422/147 in the cylindrical sidewall of the cyclone body. Distributed
156) References Cited withdrawal replaces or reduces conventional underflow of
solids from an end of cyclone outlet and reduces solids
U.S. PATENT DOCUMENTS reentrainment. 0-5 micron particle removal is enhanced by
reducing eddy formation and particle bouncing near the
2,672,215 3/1954 Schmid ......................... ... 183/84 cyclone sidewall. The device may be used as an FCC
3,970,437 7/1976 Van Diepenbroek et al. ... 55/27 regenerator third stage separator.
4,151,044 4/1979 Choi......................................... 201/12
4,956,091 9/1990 Van Den Akker .... ... 210/5122
5,002,671 3/1991 de Villiers et al. ..................... 210/740 11 Claims, 5 Drawing Sheets

GAS SOLDS

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314
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1. 2
UNDERFLOW CYCLONE WITH higher temperatures. The higher temperatures cause some
PERFORATED BARREL thermal cracking, which if allowed to continue would even
tually convert all the feed to coke and dry gas. Shorter
BACKGROUND OF THE INVENTION reactor residence times in theory would reduce thermal
cracking, but the higher temperatures associated with mod
1. Field of the Invention ern units created the conditions needed to crack thermally
The field of the invention is fluidized catalytic cracking of the feed. We believed that refiners, in maximizing catalytic
heavy hydrocarbon feeds and cyclones for separating fine conversion of feed and minimizing thermal cracking of feed,
resorted to conditions which achieved the desired results in
solids from vapor streams. 0. the reactor, but caused other problems which could lead to
2. Description of Related Art unplanned shutdowns.
Catalytic cracking is the backbone of many refineries. It Emergency shutdowns cause substantial economic losses.
converts heavy feeds into lighter products by catalytically Modern FCC units must run at high throughput, and for
cracking large molecules into smaller molecules. Catalytic years between shutdowns, to be profitable. Much of the
cracking operates at low pressures, without hydrogen addi 15 output of the FCC is needed in downstream processing units,
tion, in contrast to hydrocracking, which operates at high and most of a refiners gasoline pool is usually derived from
hydrogen partial pressures. Catalytic cracking is inherently the FCC unit. It is important that the unit operate reliably for
safe as it operates with very little oil actually in inventory years, and accommodate a variety of feeds, including heavy
during the cracking process. feeds.
There are two main variants of the catalytic cracking 20
The unit must also operate without exceeding local limits
process: moving bed and the far more popular and efficient on pollutants or particulates. The catalyst is somewhat
fluidized bed process. expensive, and most units have hundred tons of catalyst in
In the fluidized catalytic cracking (FCC) process, catalyst, inventory. FCC units circulate tons of catalyst per minute,
having a particle size and color resembling table salt and the large circulation being necessary because feed rates are
pepper, circulates between a cracking reactor and a catalyst 25 large and for every ton of oil cracked roughly 5 tons of
regenerator. In the reactor, hydrocarbon feed contacts a catalyst are needed.
source of hot, regenerated catalyst. The hot catalyst vapor These large amounts of catalyst must be removed from
izes and cracks the feed at 425 C-600° C., usually 460 cracked products lest the heavy hydrocarbon products be
C.-560° C. The cracking reaction deposits carbonaceous contaminated with catalyst and fines. Even with several
hydrocarbons or coke on the catalyst, thereby deactivating 30
stages of cyclone separation some catalyst and catalyst fines
the catalyst. The cracked products are separated from the invariably remain with the cracked products. These concen
coked catalyst. The coked catalyst is stripped of volatiles, trate in the heaviest product fractions, usually in the Syn
usually with steam, in a catalyst stripper and the stripped tower (or main FCC fractionator) bottoms, sometimes called
catalyst is then regenerated. The catalyst regenerator burns the slurry oil because so much catalyst is present. Refiners
coke from the catalyst with oxygen containing gas, usually 35
frequently let this material sit in a tank to allow more of the
air. Decoking restores catalyst activity and simultaneously entrained catalyst to drop out, producing CSO or clarified
heats the catalyst to, e.g., 500° C.-900° C., usually 600 slurry oil.
C.-750° C. This heated catalyst is recycled to the cracking The problems are as severe or worse in the regenerator. In
reactor to crack more fresh feed. Flue gas formed by burning addition to the large amounts of catalyst circulation needed
coke in the regenerator may be treated for removal of 40
to satisfy the demands of the cracking reactor, there is an
particulates and for conversion of carbon monoxide, after additional internal catalyst circulation that must be dealt
which the flue gas is normally discharged into the atmo with. In most bubbling bed catalyst regenerators, an amount
sphere. of catalyst equal to the entire catalyst inventory will pass
Catalytic cracking is endothermic, it consumes heat. The 45 through the regenerator cyclones every 15 minutes or so.
heat for cracking is supplied at first by the hot regenerated Most units have several hundred tons of catalyst inventory.
catalyst from the regenerator. Ultimately, it is the feed which Any catalyst not recovered using the regenerator cyclones
supplies the heat needed to crack the feed. Some of the feed will remain with the regenerator flue gas, unless an electro
deposits as coke on the catalyst, and the burning of this coke static precipitator, bag house, or some sort of removal stage
generates heat in the regenerator, which is recycled to the 50 is added at considerable cost. The amount of fines in most
reactor in the form of hot catalyst. FCC flue gas streams exiting the regenerator is enough to
Catalytic cracking has undergone progressive develop erode turbine blades if a power recovery system is installed
ment since the 40s. Modern fluid catalytic cracking (FCC) to recover some of the energy in the regenerator flue gas
units use Zeolite catalysts. Zeolite-containing catalysts work stream. Generally a set of cyclonic separators (known as a
best when coke on the catalyst after regeneration is less than 55 third stage separator) is installed upstream of the turbine to
0.1 wt %, and preferably less than 0.05 wt %. reduce the catalyst loading and protect the turbine blades.
To regenerate FCC catalyst to this low residual carbon While high efficiency third stage cyclones have increased
level and to burn CO completely to CO within the regen recovery of conventional FCC catalyst from the flue gas
erator (to conserve heat and reduce air pollution) many FCC leaving the regenerator they have not always reduced cata
operators add a CO combustion promoter. U.S. Pat. Nos. 60 lyst and fines losses to the extent desired. Some refiners were
4,072,600 and 4,093,535, incorporated by reference, teach forced to install electrostatic precipitators or some other
use of combustion-promoting metals such as Pi, Pd, Ir, Rh, particulate removal stage downstream of third stage sepa
Os, Ru and Rein cracking catalysts in concentrations of 0.01 rators to reduce fines emissions.
to 50 ppm, based on total catalyst inventory. Many refiners now use high efficiency third stage
Most FCC's units are all riser cracking units. This is more 65 cyclones to decrease loss of FCC catalyst fines to acceptable
selective than dense bed cracking. Refiners maximize riser levels and/or protect power recovery turbine blades. How
cracking benefits by going to shorter residence times, and ever, current and future legislation will probably require
 5,514,271
3 4
another removal stage downstream of the third stage flue gas to produce a flue gas stream containing entrained
cyclones unless significant improvements in efficiency can catalyst fines, the improvement comprising use of a third
be achieved. stage separator to remove at least a portion of the catalyst
When a third stage separator is used a fourth stage fines from the flue gas, said third stage separator comprising
separator is typically used to process the underflow from the a cylindrical cyclone body having a length and a cylindrical
third stage separator. The fourth stage separator is generally axis; a tangential vapor inlet connective with an inlet end of
a bag house. said cyclone body for a stream of vapor and entrained fines;
Third stage separators typically have 50 or 100 or more a cylindrical vapor outlet tube within said inlet end of said
small diameter cyclones. One type of third stage separator is cylindrical cyclone body for withdrawal of gas with a
described in "Improved hot-gas expanders for cat cracker 10 reduced entrained fines content, said outlet tube having a
flue gas' Hydrocarbon Processing, March 1976. The device cylindrical axis aligned with said cylindrical axis of said
is fairly large, a 26 foot diameter vessel. Catalyst aden flue cyclone body; and a plurality of radially and longitudinally
gas passes through many swirl tubes. Catalyst is thrown distributed fines outlets for removing most of said entrained
against the tube wall by centrifugal force. Clean gas is fines and a minor amount of gas, comprising at least two sets
withdrawn up via a central gas outlet tube while solids are 15 of openings over at least a third of the length of said cyclone
discharged through two blowdown slots in the base of an body and wherein said sets of openings are radially distrib
outer tube. The device was required to remove most of the uted by at least 60°.
10 micron and larger particles. The unit processed about
550,000 lbs./hour of flue gas containing 300 lbs/hour of BRIEF DESCRIPTION OF THE DRAWINGS
20
catalyst particles ranging from sub-micron to 60 micron FIG. 1 (prior art) is a simplified schematic view of an FCC
sized particles. unit of the prior art.
We wanted to improve the operation of cyclones, espe FIG. 2 (prior art) is a simplified schematic view of a third
cially their performance on the less than 5 micron particles, stage separator of the prior art.
which are difficult to remove in conventional cyclones and, 25
to some extent, difficult to remove using electrostatic pre FIG. 3 (invention) is a simplified sectional view of a
cipitation. preferred underflow cyclone.
Based on observations and testing of a horizontal, trans FIG. 4 (invention) is an end view of the FIG. 3 cyclone.
parent, positive pressure cyclone, we realized cyclones had FIG. 5 and 6 (prior art) show particle flow in the cyclone
a problem handling this 5 micron and smaller size material. 30 barrel of conventional cyclones.
We discovered that turbulent vortices grow along the wall FIG. 7 (invention) shows particle flow as stabilized by the
of the cyclones and then shed into the main tangential flow. perforated cyclone barrel of the invention.
This caused the particles to hop and bounce away from the FIG. 8 and 9 (invention) show preferred slot configura
wall, reducing collection efficiency. tions.
We wanted to attack the root cause of the problem, and 35
FIG. 10 (invention) shows a preferred placement of slots
improve the stability of the flow pattern through the cyclone. in the cyclone barrel.
We discovered that perforations in the body of the cyclone
could be used to remove minor amounts of gas with the DETAILED DESCRIPTION
solids, and have a major impact on stabilizing flow patterns.
In addition, by withdrawing some of the gas, and essentially 40 The present invention can be better understood by review
all of the solids, from a plurality of radially distributed ing it in conjuction with a conventional riser cracking FCC
openings we eliminated particle reentrainment. unit. FIG. 1 illustrates a fluid catalytic cracking system of the
prior art. There are myriad other FCC units which can
BRIEF SUMMARY OF THE INVENTION benefit from the process of the present invention, but the
45 process of the present invention works well with this type of
The present invention provides a cyclone separator com FCC unit,
prising a cylindrical cyclone body having a length and a
cylindrical axis; a tangential vapor inlet connective with an A heavy feed in line 2 such as a gas oil, vacuum gas oil
inlet end of said cyclone body for a stream of vapor and is added to riser reactor 4 via feed injection nozzles. The
entrained solids; a cylindrical vapor outlet tube within said 50
cracking reaction is completed in the riser reactor. Spent
inlet end of said cylindrical cyclone body for withdrawal of catalyst and cracked products discharged from the riser
gas with a reduced entrained solids content, said outlet tube reactor pass through cyclones 9 which efficiently separate
having a cylindrical axis aligned with said cylindrical axis of most of the spent catalyst from cracked product. Cracked
said cyclone body; a plurality of radially and longitudinally product is discharged via conduit 11 to the fractionator.
distributed solids outlets for removing most of said entrained 55 Spent catalyst is discharged down from a dipleg of
solids and a minor amount of gas, comprising at least two cyclones 9 into catalyst stripper 13 where stripping steam is
sets of openings, slots or perforations traversing a vertical added via line 41. The stripped hydrocarbons, and stripping
distance equal to at least one half of said diameter of said steam are removed with cracked.
cyclone body, and wherein said sets of openings are radially Stripped catalyst is discharged via line 7 into catalyst
distributed by at least 60°. 60 regenerator 6.
In another embodiment, the present invention provides in Catalyst is regenerated in coke combustor 17 by contact
a fluidized catalytic cracking process wherein a heavy feed with air, added via line 25. Regenerated catalyst is dis
is catalytically cracked by contact with a regenerated crack charged into upper vessel 21. Some catalyst is recycled via
ing catalyst in a cracking reactor to produce lighter products line 15 to the base 110 of the coke combustor. Some catalyst
and spent catalyst, and wherein spent catalyst is regenerated 65 is withdrawn from the regenerator via line 5 and charged
in a catalyst regeneration means containing primary and into the base of the riser reactor 4 to contact and crack fresh
secondary separators for recovery of catalyst and fines from feed. Flue gas, and some entrained catalyst, is discharged
 5,514,271
5 6
into multiple stages of cyclones 19 and discharged via line streamline 700, can continue without reentrainment of par
10. ticulates. Particulates, and a minor amount of gas, flow to the
Cracked products removed from the reactor via line 11 are walls of cyclone barrel 714, but are allowed to exit the walls
charged into the main column 30, which produces a gas via a plurality of openings 716. Exit streamlines 702, 704,
product in line 31, a naphtha product in line 32, a light cycle and 706 are able to pass out of the cyclone, so the tendency
oil product in line 33, a heavy cycle oil product in line 34 for particles to bounce or for gas to form eddy currents or
and a main column bottoms product in line 35. vortices is reduced or eliminated.
FIG. 1 does not show a third stage separator. Line 10 in FIG. 8 and 9 (invention) show preferred slot configura
most refineries would go to some type of third stage sepa tions, those which optimize removal of gas and solids from
rator (not shown), usually one involving 50 or 100 (or more) 10 the device. The distinctive factor in FIG. 8 is that each hole
small diameter horizontal cyclones. Purified flue gas would or slot has an axis, or plane of the opening, perpendicular to
then pass through an optical power recovery turbine (not the barrel surface. The slot may increase in cross sectional
shown) then go to a stack for discharge to the atmosphere, area as it passes from the interior opening 816 to the cyclone
via some flue gas clean up devices, such as an SOX scrubber, barrel to the outer opening 818 as it passed through the walls
or elastrostatic precipitator. 15
FIG. 2 (Prior Art) is similar to FIG. 1 of Improved hot-gas 814 of the cyclone barrel, as shown in FIG.8. The bulk flow
expanders for cat cracker flue gas, Hydrocarbon Processing, of gas is shown as streamline 800.
March 1976, p. 141. This article is incorporated by refer Alternatively, each slot may have a generally constant
Ce. cross-section, as shown in FIG. 9. Thus the inlet 916 to the
Third stage separator 200 receives a fines containing FCC 20 slot or opening has the same size as the outlet 918, as the
flue gas via inlet 210. Gas is distributed via plenum 220 to perforation passes through the walls of the cyclone barrel
the inlets of a plurality of small diameter ceramic tubes 235 914. The bulk flow of gas is shown as streamline 900.
containing swirl vanes not shown. Fines collect on the walls The perforations should be generally slanted to minimize
of tubes 235 and are discharged from the base of the tubes disruption of flow lines of particulates exiting the cyclone
as an annular stream of solids 230. A clean gas stream is 25 barrel through the perforations. Ideally, the angle theta
withdrawn via outlet tubes 239 to be removed from the shown in FIGS. 8 and 9 ranges from 10° to 60°, as measured
vessel via outlet 290. Solids are removed via solids outlet from the surface of the hole adjacent to the leading edge to
265. a line tangent to the inner wall of the barrel at the leading
FIG. 3 shows a simplified sectional view of a preferred edge of the hole or slot. Thus as shown in FIG. 8 surface 824
underflow cyclone of the invention, while FIG. 4 shows an 30 is the surface of the hole adjacent to the leading edge 820.
end view of the same cyclone. Like elements have like Line 822 is tangential to the inner wall of the barrel at the
numerals. leading edge. Theta is the angle between line 822 and
surface 824.
A flowing stream of gas and entrained solids flows FIG. 10 (invention) shows a preferred arrangement of
through tangentially aligned inlet duct 308 with inlet open 35 slots in the cyclone barrel. The perforations 1016, 1018 and
ing 312. The gas flow spirals around outlet tube 320 into 1020 are uniformly distributed about the surface of the
region 324, where centrifugal force throws particulates to cyclone barrel 1014. In the arrangement shown there is some
the wall 314 of the cyclone 310. Solids collect in region 326, overlap between perforated slot elements. Elements 1016
a relatively thin, circulating layer of particles, which are and 1020 overlap with perforated elements 1018 in the
discharged through a plurality of openings 316 which are 40 central portion of the device. Generally about 2-20% over
radially and longitudinally distributed about the cyclone lap will prevent localized stagnant regions.
barrel. A minor amount of gas, typically in the 2 to 20%
range, is discharged with the solids through the holes or slots Having provided an overview of the FCC process and the
in the cyclone barrel. End plate 330 seals the end of the new cyclone design, a more detailed review of the FCC
cyclone barrel opposite the clean gas outlet 322. Opposing process and of preferred cyclone separators follows.
45 FCC FEED
end plate 333 contains outlet pipe 320, forming opening 322.
FIG. 4, an end view of the cyclone, gives a better idea of Any conventional FCC feed can be used. The feeds may
the interplay between the tangential inlet duct 308 and the range from typical petroleum distillates or residual stocks,
outlet pipe 320 in cyclone 310. It also shows that four sets either virgin or partially refined, to coal oils and shale oils.
of openings 316 are evenly radially distributed about 50
Preferred feeds are gas oil, vacuum gas oil, atmospheric
cyclone barrel 314, and that all cylindrical parts of the resid, and vacuum resid. The invention is most useful with
device have a common axis. feeds having an initial boiling point above about 650 F.
FIGS. 5 and 6 (prior art) show particle flow in the cyclone FCC CATALYST
barrel of conventional cyclones. FIG. 5 shows one type of Any commercially available FCC catalyst may be used.
reentrainment mechanism, whereby the bulk flow of gas, 55 The catalyst can be 100% amorphous, but preferably
indicated as streamline 500, against the barrel 514 of the includes some zeolite in a porous refractory matrix such as
cyclone induces the formation of localized eddies 510 and silica-alumina, clay, or the like. The zeolite is usually 5-40
512. This gas phase turbulence, combined with elastic wt % of the catalyst, with the rest being matrix. Conven
collisions with the wall, can lead to an erratic particle "path, tional zeolites include X and Y zeolites, with ultra stable, or
shown as streamline 600 in FIG. 6. These mechanisms will 60 relatively high silica Y zeolites being preferred. Dealumi
transport particulates from the walls 614 of the cyclone nized Y (DEALY) and ultrahydrophobic Y (UHPY) zeolites
barrel back into the main body of the cyclone to be reen may be used. The zeolites may be stabilized with Rare
trained by gas flowing therethrough.' Earths, e.g., 0.1 to 10 wt % RE.
FIG. 7 (invention) shows how particle flow is stabilized Relatively high silica Zeolite containing catalysts are
by the perforations in the cyclone barrel. The gas, and 65 preferred for use in the present invention. They withstand
particulates, have some place to go rather than back into the the high temperatures usually associated with complete
gas mainstream. Thus the bulk flow of gas, shown as combustion of CO to CO within the FCC regenerator.
 5,514,271
7 8
The catalyst inventory may contain one or more additives, The slot area, or perforated area, should be large enough
either as separate additive particles, or mixed in with each to handle anticipated solids flow, and will typically be from
particle of the cracking catalyst. Additives can enhance 10 to 200% or more of the open area of the conventional
octane (shape selective zeolites, typified by ZSM-5, and reverse flow cyclone solids outlet.
other materials having a similar crystal structure), absorb The open area, or the slot area, of the outlets radially
SOX (alumina), or remove Ni and V (Mg and Ca oxides). distributed on the wall of the cyclone may range from
Additives for SOX removal are available commercially, perhaps 10 or 20% up to about 100% of the conventional
e.g., Katalistiks International, Inc.'s "DeSOX.” CO combus solids outlet. Preferably the slot area will be from 4 to /2
tion additives are available from catalyst vendors. The times the area of the bottom of the cyclone.
catalyst composition, per se, forms no part of the present 10 The perforations should be sized so that in use from 1 to
invention. 50% of the gas exits via the perforations. We prefer to
FCC REACTOR CONDITIONS operate with 1.5 to 25% of the gas being removed with the
solids, and ideally with 2 to 20% of the gas exiting the
Conventional cracking conditions may be used. Preferred cyclone via the perforations.
riser cracking reaction conditions include catalyst/oil weight 5 Perforations are preferably uniformly distributed both
ratios of 0.5:1 to 15:1 and preferably 3:1 to 8:1, and a radially and longitudinally. Preferably openings are present
catalyst contact time of 0.1-50 seconds, and preferably 0.5 in at least every 4 segment of the cyclone barrel, that is,
to 5 seconds, and most preferably about 0.75 to 4 seconds, present in every 120 segment of the cyclone barrel. Ideally
and riser top temperatures of 900 to about 1050 F. at least 4 sets of perforations are provided, distributed at 90°
It is best to use an atomizing feed mixing nozzle in the 20 segments. Most preferably, from 6 to 20 longitudinal slots,
base of the riser reactor. Details of a preferred nozzle are or their equivalent, are evenly distributed around the cir
disclosed in U.S. Pat. No. 5,289.976, which is incorporated cumference of the cyclone barrel.
by reference. The perforations may be slanted to minimize disruption of
It is preferred, but not essential, to have a riser catalyst flow lines of particulates exiting the cyclone barrel through
acceleration Zone in the base of the riser. 25 the perforations. The angle theta, as shown in FIGS. 8 and
It is preferred, but not essential, to have the riser reactor 9 is preferably between 5° and 70. A preferred opening is
discharge into a closed cyclone system for rapid and efficient one where the axis of the opening is angled in the direction
separation of cracked products from spent catalyst. A pre of the flow within the cyclone, at least with regard to flow
ferred closed cyclone system is disclosed in U.S. Pat. No. near the perforations, as opposed to flow within the central
5,055,177 to Haddad et al. 30 region of the cyclone, which can be very convoluted.
It may be beneficial to use a hot catalyst stripper, heating Perforations or slots may be offset in the cyclone wall, or
spent catalyst by adding some hot, regenerated catalyst to one portion of the wall of the cyclone barrel may be punched
spent catalyst. If hot stripping is used, a catalyst cooler may in somewhat toward the interior of the cyclone to "peel off
be used to cool heated catalyst upstream of the catalyst that portion of the rotating solids and gas that collects near
regenerator. Suitable designs are shown in U.S. Pat. Nos. 35 the wall. Preferably the interior of the cyclone is smooth and
3,821,103 and 4,820,404, Owen, which are incorporated by flush, save for perforations punched or drilled through it.
reference. While the perforations may be the sole solids outlet, the
FCC reactor and stripper conditions may be conventional. device works well with some solids withdrawn via a con
CATALYST REGENERATION ventional reverse flow solids outlet.
40
DISCUSSION
The process and apparatus of the present invention can
use conventional FCC regenerators. Most regenerators are The new cyclone is easy to fabricate via conventional
either bubbling dense bed or high efficiency. The regenera techniques. The device significantly improves removal of
tor, per se, forms no part of the present invention. fines, that is, 0-5 micron particles. These particles are
Catalyst regeneration conditions include temperatures of 45 removed as soon as they reach the cylindrical sidewall. In
1200° to 1800°F, preferably 1300° to 1400°F, and full or contrast, in conventional cyclones these solids must travel
partial CO combustion. the length of the cyclone barrel to the conventional solids
THIRD STAGE SEPARATORVESSEL outlet, where the solids must exit normal to the gas flow. The
new cyclone design will reduce erosion on power recovery
Our cyclones are preferably used in a third stage separator 50 turbine blades, and also reduce particulate emissions.
removing catalyst and fines from regenerator flue gas. In We claim:
many instances, existing equipment may be used, with the 1. In a fluidized catalytic cracking process wherein a
cyclones of the invention substituted for the prior art small heavy feed is catalytically cracked by contact with a regen
diameter, horizontal cyclones. erated cracking catalyst in a cracking reactor to produce
When used as a third stage separator in FCC there will be 55 lighter products and spent catalyst, and wherein spent cata
so little solids loading at this point in the FCC process that lyst is regenerated in a catalyst regeneration means contain
refractory lining may not be needed. ing primary and secondary separators for recovery of cata
CYCLONE DESIGN lyst and fines from flue gas to produce a flue gas stream
Much of the cyclone design is conventional, such as containing entrained catalyst fines, the improvement com
sizing of the inlet, setting ratios of ID of the outlet tube to 60 prising use of a third stage separator to remove at least a
other dimensions, etc. Further details, and naming conven portion of the catalyst fines from the flue gas, said third stage
tions, may be found in Perry's Chemical Engineers' Hand separator comprising:
book, 6th Edition, Robert H. Perry and Don Green, which is a cylindrical cyclone body having a length and a cylin
incorporated by reference. The nomenclature discussion in drical axis;
Gas-Solids Separations, from 20-75 to 20-77, FIG. 20-106 65 a tangential vapor inlet connective with an inlet end of
, 20-107 and 20-108 is referred to and incorporated by said cyclone body for a stream of vapor and entrained
reference. fines;
 5,514,271
9 10
a cylindrical vapor outlet tube within said inlet end of said 6. The process of claim 1 wherein said cyclone body is
cylindrical cyclone body for withdrawal of gas with a horizontal.
reduced entrained fines content, said outlet tube having 7. The process of claim 1 wherein the open area of said
a cylindrical axis aligned with said cylindrical axis of
said cyclone body; and openings is from 10% to 200% of a cross sectional area of
a plurality of radially and longitudinally distributed fines said vapor outlet tube.
outlets for removing most of said entrained fines and a 8. The process of claim 7 wherein the open area of said
minor amount of gas, comprising at least two sets of openings is from 20 to 100% of the open area of said vapor
openings over at least a third of the length of said outlet tube.
cyclone body and wherein said sets of openings are 10
uniformly radially distributed 9. The process of claim 1 wherein an additional fines
and wherein essentially all of said gas with a reduced outlet is provided as an opening through an end of the
entrained fines content is withdrawn via said vapor cyclone body opposing said vapor outlet tube.
outlet tube.
2. The process of claim 1 wherein said fines outlets 15 10. The process of claim 1 wherein said third stage
comprise at least 4 sets of openings uniformly distributed separator operates under a positive pressure.
radially about said cyclone body. 11. The process of claim 1 wherein said cyclone body has
3. The process of claim 1 wherein said fines outlets an interior which is flush, and slanted openings through said
comprise 6-20 sets of slots, holes or perforations radially 20 cyclone body have an axis with an angie theta between a line
distributed about said cyclone body. tangential to the inner wall of said cyclone body and a line
4. The process of claim 1 wherein said fines outlets are
holes drilled or punched in said cyclone body. parallel to said opening through said cyclone body of from
5. The process of claim 1 wherein said fines outlets are 50 to 70°.
uniformly distributed both radially and longitudinally
throughout said cylindrical cyclone body.