Developments in cyclone technology

improve FCC unit reliability

Developments in FCC cyclone technology reduce problems of abrasion that
cause unscheduled unit shutdowns

Ye-Mon Chen and Mart Nieskens Shell Global Solutions

S B Reddy Karri and Ted M Knowlton PSRI

U
S refineries are facing the
difficult challenges of
reduced demand and low
refining margins. Projection for
future gasoline demand in the US is
relatively flat at best, while regula-
tory ethanol requirements will cut
into refining supply to the gasoline
market. This has a direct impact on
fluid catalytic cracking (FCC) unit
operation.
In this challenging environment,
improving unit reliability and
reducing both operational and
maintenance costs are the key focus
for refiners. This article introduces
a FCC cyclone technology with a
proven track record of helping
refineries to improve unit reliability
while reducing operational and
maintenance costs
Conventional cyclones:
a weak link in FCC operation
Two recent industry surveys reveal
the pervasive problems of cyclones
used in FCC operation. Table 1
summarises the survey results by
Grace Davison as presented at its
2002 Dublin FCC conference. The
results indicate that catalyst losses
from cyclones were the number one
problem in FCC operation. The
2008 NPRA survey again revealed
that FCC cyclone reliability is a
major concern for member
companies.
Cyclones are commonly consid-
ered a mature technology in the
industry. As a result, most FCC
technology licensors rely on
vendors to provide cyclones that
are categorised as conventional
cyclones in this article. Recent
surveys indicate that these conven-
tional cyclones have not met
Grace Davison 2002 Survey
Cat losses 15
Cat circulation 12
Transfer line coking 11
Coking/slurry fouling 10
Low coke 6
High regenerator temperature 5
Poor stripping 5
High corrosion 5
High coke 4
Main fractionator fouling 4
Catalyst deactivation 4
Expander vibration 4
Excessive afterburn 3
Other 4
Table 1
refineries’ needs, both in terms of
performance (catalyst loss) and reli-
ability. Shell Global Solutions has
developed an innovative cyclone
technology, which is categorised as
improved cyclone technology here.
PSRI cyclone study
Particulate Solid Research Inc
Figure 1 First- and second-stage cyclone operation
(PSRI) is an independent industrial
consortium serving 28 member
companies, which include:
• Oil companies, such as Shell,
ExxonMobil, BP, Total, Chevron,
ConocoPhillips, Marathon, Sunoco,
Syncrude, Petrobras
• Chemical companies, such as
Dow, BASF, SABIC, Sasol
• Technology providers, such as
Shell Global Solutions, UOP, Shaw
Stone Webster, KBR, CPFD, Solutia,
IFP, INEOS, Cristal Global.
PSRI conducts research and test-
ing programmes that address the
common concerns of member
companies. These programmes are
guided by elected technical advi-
sors from member companies. One
recent PSRI programme studied
and benchmarked different FCC
cyclone technologies, since cyclone
erosion and reliability are high-
lighted as the major concerns of
FCC operation for member compa-
nies in recent surveys. The most

www.digitalrefining.com/article/1000492 PTQ Q3 2010 65


16
1st stage cyclone
Diverter valve
4th He radial
3rd He radial
Receiving tank
Figure 2 Cyclone erosion test unit
pervasive problem is erosion in the
secondary cyclone, particularly in
the lower cone and in the transition
to the dipleg, which is the focus of
the study.
There is a fundamental difference
between first- and second-stage
FCC cyclones in their erosion
patterns. Highly loaded first-stage
cyclones normally experience little
to no cone erosion, whereas lightly
loaded second-stage cyclones can
exhibit severe cone erosion. This
seems to be counter-intuitive at
first. However, the key difference in
erosion pattern lies in the differ-
ences in the solids flow patterns
and vortex formation, as shown in
Figure 1.
As a result of high solids loading
and low gas velocity in a typical
FCC primary cyclone, gravitational
force plays a key role; the solids
appear to fall rapidly down into the
cyclone cone and dipleg, as shown
in Figure 1, taking only one to two
full turns to exit the bottom of the
66 PTQ Q3 2010
17
15
2nd stage
14R
cyclone
7’ - 73/16“
13R
12R
3-foot bed
6’ - 10“
11R
6th radial
cyclone. The vortex length in the
highly loaded primary cyclone is
much shorter because the high
solids loading dampens the forma-
tion of a robust vortex. Therefore,
As a result of high
solids loading and
low gas velocity in a
typical FCC primary
cyclone, gravitational
force plays a key role
the vortex does not whip the solids
at a high velocity around the cone
in the primary cyclone.
In a typical FCC second-stage
cyclone, the solids loading is
approximately 1/1000 to 1/10 000
of the loading in the first-stage
cyclone. Due to light solids loading
and high gas velocity, the vortex is
18
relatively long, energetic and, more
importantly, unstable, moving
asymmetrically about its axis. As
the swirling solids in the outer
vortex approach the cone in a
second-stage cyclone, the long,
rapidly rotating vortex accelerates
the solids stream and causes it to
intensify its rotation. (The solids
spin faster, similar to the motion of
a figure skater pulling inwards.)
The outer vortex in a second-stage
cyclone typically takes from four to
six turns before exiting the bottom
cone (see Figure 1), and the spin-
ning continues into the top portion
of the dipleg below the cone. The
concentrated solids stream rotates
at a high velocity, and the unstable,
continuous movement of the vortex
causes the significant erosion
observed in the cone and the top of
the dipleg of second-stage cyclones.
The PSRI cyclone test programme
was structured to benchmark three
different solutions to mitigate the
damaging erosion occurring in FCC
second-stage cyclones:
• Increasing the cyclone length (L/
D) of a conventional cyclone
• Increasing the angle of the cone
of a conventional cyclone
• Adding a vortex stabiliser to a
conventional cyclone simulating the
improved cyclone technology.
The cyclone test facility is shown
in Figure 2. It consists of:
• A 3ft-diameter fluidised bed
• An 8in-diameter standpipe,
approximately 55ft in length
• A slide valve to control the solids
flow rate around the unit
• An 8in-diameter riser approxi-
mately 70ft tall
• A 19in-diameter first-stage
cyclone
• A 17in-diameter second-stage
cyclone.
Air was used as the conveying
gas in the test unit. The solids used
were equilibrium FCC catalyst with
a median (Dp50) particle size of
approximately 75 microns. The fines
(material <44 microns) concentra-
tion in the catalyst was
approximately 8 wt%. The particle
density of the catalyst was 93 lb/ft3.
Loadings to the second-stage
cyclone varied between 0.5 and
90 g/ft3 (0.00007–0.013 lb/ft3).
www.digitalrefining.com/article/1000492
 “
4 1/4“ 6 4 1/4“
1/4“ 7” 7”
7”
“ “
“ 1’–5 1’–5
1’–5
“ “
“ 9 9
1’– 9“
“ “ “
9
“
9 9 9 “ 1’– 9“ 6
“ 1’– 9“
6 6 1’– 5“
1’– 5“
1’– 5“
2’– 81/4“
Lv = 34 Lv = 52 Lv = 52

“ 2’– 81/4“ 2’– 81/4“

4
“ “
4 4
L/Db = 3.1 L/Db = 4.1 L/Db = 5.1

Figure 3 Cyclone configurations used to test different cyclone L/Ds

The secondary cyclone was found to be much lower than the

constructed in modules for easy erosion rates in the cone, as Figure
change of dimensions. Figure 3 5 also shows. The measured barrel
shows the cyclone with several erosion ranged between 85g/h and Figure 4 Erosion of drywall joint compound
different barrel lengths. Multiple 105 g/h, which is approximately in the cone of a second-stage cyclone
coatings of drywall joint compound 15% of the cone erosion rate for the
were added to the inside of the cyclone with an L/D of 3.1, and comparing the two cone configura-
cyclone before each test. The approximately 20% for the cyclone tions, the overall length of the
amount of erosion occurring in the with an L/D of 5.1. cyclone was held constant (see
cyclone was measured by weight Figure 6).
loss in the drywall compound over Effect of a longer cone Figure 7 shows that the longer
a specified period of time. conventional cyclone cone has a higher erosion rate than
The effect of a longer cone of a the shorter (but longer barrelled)
Results of PSRI cyclone study conventional cyclone on cyclone cone at lower gas velocities.
Effect of increased cyclone length cone erosion was tested by adding However, the erosion rate becomes
The study found that erosion took a longer cone so that the cone angle approximately equal to the erosion
place primarily in the bottom third from the horizontal increased from rate of the shorter cone at the high-
of the cone of a secondary conven- 79º to 84º. This increased the cone est gas velocity. The trend of the
tional cyclone. This effect is shown length from 2.69ft to 5.5ft. When two curves was exactly opposite.
in Figure 4. The photo shows that
the drywall coating was completely
eroded from the bottom third of the

cone, whereas the remaining
-ATERIAL&##EQCATALYST
drywall was mostly intact.  5GIFTSMS
Cyclone lengths were extended 5GOFTSMS
#YCLONESIZEINCM
by increasing the length of the  )NLETTYPE4ANGENTIAL
conventional cyclone’s barrel with ,ITOGRAINSFT
,$B
L/Ds of 3.1, 4.1 and 5.1. In these 
%ROSIONRATESGH

tests, the inlet gas velocity to the   

cyclone was 65 ft/s and the outlet 

gas velocity was 88 ft/s.
The results of the testing to deter- 

mine the effect of cyclone length


are shown in Figure 5; the erosion
rate decreased with increasing

cyclone length. The measured
erosion rate at an L/D of 5.1 was 
about 70% of the erosion rate of the #ONE "ARREL
cyclone with an L/D of 3.1.
Barrel erosion rates were also
measured in the tests and were Figure 5 Effect of second-stage cyclone L/D on cone erosion and barrel erosion

www.digitalrefining.com/article/1000492 PTQ Q3 2010 67

 For the shorter cone, the erosion
“ “ rate increased with gas velocity,
4 1/4“ 4 1/4“
6
7”
6
7”
whereas for the longer cone the
erosion rate decreased with increas-
“ “ ing gas velocity. For a gas velocity
1’–5 1’–5
of approximately 88 ft/s, the
erosion rate for the short cone was
“ “ “ “
9 9 9 9
6
“ 1’– 9“ “ 1’– 9“ approximately 800 g/h, while the
6
erosion rate for the longer cone was
1’– 5“ approximately 1800 g/h — a factor
Lv = 52 Lv = 44
5’– 6“ of 2.25. However, even at the high-
1’– 5“
est gas velocities, which is outside
typical operating conditions for
2’– 81/4“ secondary cyclones, the longer cone
84°
79° did not show a significant advan-
tage over the shorter cone with
“ “
4 4
Longer barrel Longer cone regard to cone erosion.

Effect of adding a vortex stabiliser

Figure 6 Cyclones used for cone length testing to a conventional cyclone
To determine the effect on cone
erosion of adding a vortex stabiliser
5GOMS to a conventional cyclone, a

    flat-disk vortex stabiliser was
added to the cyclone, approxi-
mately a third of the cone length up

Longer cone from its bottom to simulate the
#ONEEROSIONRATEGH

improved cyclone technology (see

 Figure 8).
The rationale behind the location
 of the vortex stabiliser is as follows.
Shorter cone The cone erosion was observed to
 be caused by the rapidly spinning
solids in the outer vortex. The outer
 solids flow began at low angular
     velocities in the barrel and increased
5GOFTS
its angular velocity as it moved
down the cone. The lower third of
Figure 7 Effect of cone length on second-stage cyclone cone erosion the cone has the highest solids
velocities because it spins on a
tighter radius. Therefore, adding
the vortex stabiliser at one-third of
Vortex stabiliser disk
0.5 in (1.27 cm) annular gap the height of the cone could reduce
high-velocity spinning solids and
6ORTEX reduce erosion. The purpose of the
STABILISERDISK h flat plate (or vortex stabiliser) is to
nh
stabilise the central vortex. It is
h
² expected that the influence of the
vortex will end at the plate, and the
h number and/or intensity of solids
 spirals below the flat plate will be
reduced.
The effect on cone erosion of
adding the vortex stabiliser disk to
Three
supports
a conventional cyclone (simulating
the improved cyclone technology)
is shown in Figures 9 and 10 for a
No erosion cyclone with an L/D of 3.1 and 5.1,
respectively. It was found that cone
erosion for a cyclone with the
Figure 8 Vortex stabiliser disk and supports vortex stabiliser was significantly

68 PTQ Q3 2010 www.digitalrefining.com/article/1000492

 rotating in the cone. This reduction
in force on the solids would explain
5GOMS
    the decrease in cone erosion with
 gas outlet velocity for the cyclone
 with the vortex stabiliser (see
Figures 9 and 10).
#ONEEROSIONRATEGH


W/O disk For the shorter cyclone, the cone
 erosion rate was approximately
 2100 g/h for the conventional
W/ disk cyclone without a vortex stabiliser

at a gas velocity in the outlet tube
 of 50 ft/s. The corresponding cone
 erosion rate for the cyclone with a
     vortex stabiliser at the same gas
5GOFTS
velocity was about 1400 g/h. The
cone erosion rate with the vortex
Figure 9 Effect of gas outlet velocity on second-stage cyclone cone erosion for cyclones stabiliser inserted was about 67% of
with and without a flat-plate vortex stabiliser (cyclone L/D = 3.1) the cone erosion for the cyclone
without the vortex stabiliser.
However, at an outlet gas velocity
closer to actual practice, the cone
 
5GOMS
 
erosion rate for an outlet gas veloc-
 ity of about 150 ft/s for the cyclone
 -ATERIAL&##EQCATALYST with the vortex stabiliser was only
5GIFTSMS
 #YCLONESIZEINCM
about 600 g/h. The corresponding
#ONEEROSIONRATEGH

)NLETTYPE4ANGENTIAL cone erosion rate for the conven-

 ,IGRAINSFT
W/O disk tional cyclone without the vortex
,$B
 stabiliser was about 2900 g/h. This
 is a factor of about 4.8 — or nearly
 five times the rate.
W/ disk
For the cyclone with an L/D of

5.1, overall cone erosion rates were

    
lower. This was to be expected
5GOFTS because the tests with a longer
cyclone described earlier gave lower
cone erosion rates than shorter
Figure 10 Effect of gas outlet velocity on second-stage cyclone cone erosion for cyclones cyclones. As with the shorter
with and without a flat-plate vortex stabiliser (cyclone L/D = 5.1) cyclone, the trendlines of cone
erosion rates with outlet gas veloc-
lower than that for a conventional intuitive at first; however, this can ity were linear. Similarly, the curve
cyclone without a vortex stabiliser. be explained by the fact that the for the conventional cyclone with-
Cone erosion increased linearly vortex diameter is smaller when the out a vortex stabiliser increased
with increasing gas velocity for a diameter of the outlet tube is with increasing gas velocity, and
conventional cyclone without a decreased to increase the gas outlet the curve for the cyclone with the
vortex stabiliser. However, cone velocity. This increases the distance vortex stabiliser decreased slightly
erosion of a cyclone with a vortex between the vortex and the cone with increasing gas velocity.
stabiliser decreases slightly with wall, which then reduces the However, as with the shorter
increasing gas outlet velocity. The centrifugal force (and, therefore, cyclone, the cyclone with the vortex
decrease in erosion is counter- the solids velocity) on the solids stabiliser was found to exhibit
much lower erosion rates than the
conventional cyclone without the
Comparison of cone erosion rates for different cyclone configurations
vortex stabiliser. Comparing the
cone erosion rates at an outlet gas
L/D (-) Velocity Velocity Erosion reduction Cone erosion velocity of 150 ft/s, the conven-
inlet, ft/s outlet, ft/s factor rate, g/h
Short cyclone 3.1 65 150 Base 2850 tional cyclone without a vortex
Long cyclone 5.1 65 150 >2 1200 stabiliser had a cone erosion rate of
Long cone 5.1 65 150 >2 1200 approximately 1200 g/h, while the
Vortex stabiliser 3.1 65 150 >4 650 cyclone with the vortex stabiliser
Vortex stabiliser 5.1 65 150 >11 240
had a cone erosion rate of about 240
g/h. This is a factor of approxi-
Table 2 mately five, which is similar to

70 PTQ Q3 2010 www.digitalrefining.com/article/1000492

what was observed with the shorter
cyclone.
Why does the vortex stabiliser
decrease cone erosion? It appears
that the stabiliser prevents the
vortex from whipping the solids
around at high velocities below the
stabiliser in the region where high
cone erosion rates are experienced
for a conventional cyclone. Below
the stabiliser, the high-velocity
central vortex does not really exist.
Therefore, this reduction in spin-
ning solid velocity in the outer
vortex leads to a significant reduc-
tion in erosion.
A comparison of the cone erosion
rates for various second-stage
cyclone configurations is shown in
Table 2. Drywall joint compound
was also added to the disk to see if
the upper surface of the vortex
stabiliser would be eroded by the
vortex. However, essentially no
erosion was measured on the
upper surface of the disk, nor was
erosion found on the supporting
rods.
Experience with conventional
cyclones and improved cyclone
technology
In the 1980s, Shell had more than
30 FCC units, mostly with conven-
tional cyclones that were found to
be the number one cause of all
unscheduled shutdowns of FCC
units. The company decided to
develop the improved cyclone tech-
nology, using the vortex stabiliser,
and began implementing the
technology in the early 1990s.
Figure 11 shows how improved
cyclone technology reduced
unscheduled downtime in FCC
units. Taking 1992 data as the base
line, Figure 11 shows that the
improved cyclone technology, with
the vortex stabiliser, reduced total
downtime for all FCC units in
Shell’s fleet by a factor of ten over a
period of eight years.
Conclusion
Recent surveys reveal that conven-
tional cyclones are the root cause of
pervasive problems in FCC opera-
tion, indicated by high catalyst
losses and severe damage. In many
cases, these effects could lead to
unscheduled shutdowns with a
www.digitalrefining.com/article/1000492
100
Number of events duration 1992 = 100%
90
80
Severity (incl. near misses)
70
60
50
40
30
20
10
0
1992 1993 1994 1995 1996 1997 1998 1999
Figure 11 Total severity of cyclone problems
significant effect on operational and Ye-Mon Chen is Cat Cracking Regional
financial performance. Manager, US/North America, and Global
FCC cyclones are high- Licensing Technology Manager, Shell Global
maintenance components of the Solutions (US) Inc, Houston. He has 25 years’
unit and have to be replaced over FCC/refining-related experience and a PhD in
time. Refineries can consider using chemical engineering.
Mart Nieskens is Global Technology Manager,
conventional cyclones with longer
Cat Cracking, Shell Global Solutions (US)
barrels/hoppers, which can reduce
Inc, Houston. He has 32 years’ experience in
erosion damage and the risks of the refining business and a MSc in chemical
unscheduled shutdown. However, engineering.
many FCC units have gone through S B Reddy Karri is Technical Director of
debottlenecking projects and the Particulate Solid Research Inc (PSRI), Chicago,
existing vessel may not be able to with experience in fluid-particle systems such
accommodate longer cyclones with- as fluid beds, cyclones, diplegs, standpipes and
out major modifications. This could risers.
lead to a larger and more expensive Ted Knowlton is President of Particulate Solid
project scope to replace the vessel Research Inc (PSRI), Chicago, with experience
in high-pressure and high-temperature
in order to implement longer
fluidisation processes, standpipes, gas-solid
conventional cyclones.
separation, gas-solid flow systems, pneumatic
A more cost-effective solution is conveying, and non-mechanical valves.
to consider improved cyclone tech-
nology with a vortex stabiliser.
Refineries can benefit from:
• Potential project cost savings by
reusing existing vessels — the
improved cyclone technology does
not increase the cyclone length and
can be installed inside existing
vessels in most cases
• Reduced operating costs of fresh
catalyst addition and downstream
cleaning via improved cyclone
performance
• Reduced maintenance costs via
substantially reduced erosion
damage (by a factor of >4) to the
cyclones Links
• Potential reduction in turnaround
duration and costs, if cyclone repair More articles from the following
is on the critical path of the entire categories:
turnaround Fluid Catalytic Cracking
• Potential reduction in unsched- Reliability & Asset Management
uled shutdown.
PTQ Q3 2010 71