[{"data":1,"prerenderedAt":505},["ShallowReactive",2],{"site-footer-common":3,"glossary:fcc-regenerator":45,"glossary-related:fcc-regenerator":165},{"id":4,"extension":5,"footer":6,"meta":40,"navbar":41,"stem":43,"__hash__":44},"common\u002Fcommon.yml","yml",{"tagline":7,"links":8,"sections":9},"Acoustic cleaning intelligence for industrial fouling, soot, ash, dust and build-up.",[],[10,19,31],{"title":11,"links":12},"Product",[13,16],{"label":14,"to":15},"How it works","\u002F#product",{"label":17,"to":18},"Cost assessment","\u002F#hero",{"title":20,"links":21},"Company",[22,25,28],{"label":23,"to":24},"What we build","\u002F#about",{"label":26,"to":27},"Careers","\u002F#careers",{"label":29,"to":30},"Contact","\u002F#contact",{"title":32,"links":33},"Resources",[34,37],{"label":35,"to":36},"Blog","\u002Fresources\u002Fblog",{"label":38,"to":39},"Glossary","\u002Fglossary",{},{"links":42},[],"common","YocmZRy1AYfBbpgGVms-zhdiABlF8VTxHx6h4rDmZBA",{"id":46,"title":47,"aliases":48,"body":51,"category":146,"description":147,"extension":148,"meta":149,"navigation":150,"path":151,"relatedTerms":152,"seo":156,"sources":159,"stem":163,"term":47,"__hash__":164},"glossary\u002Fglossary\u002Ffcc-regenerator.md","FCC regenerator",[49,50],"FCCU regenerator","catalyst regenerator (FCC)",{"type":52,"value":53,"toc":139},"minimark",[54,73,78,106,110,117,121],[55,56,57,58,61,62,67,68,72],"p",{},"The ",[59,60,47],"strong",{}," burns coke deposits off spent ",[63,64,66],"a",{"href":65},"\u002Fglossary\u002Ffluid-catalytic-cracking","FCC"," catalyst circulating in the unit. Combustion at ~700 °C restores the catalyst's cracking activity for return to the riser-reactor. The hot flue gas produced is routed through cyclone separators (primary and secondary inside the regenerator, then ",[63,69,71],{"href":70},"\u002Fglossary\u002Fthird-stage-separator","third-stage"," external) before going to either a CO boiler or a power-recovery expander.",[74,75,77],"h2",{"id":76},"fouling-concerns","Fouling concerns",[79,80,81,88,94,100],"ul",{},[82,83,84,87],"li",{},[59,85,86],{},"Catalyst fines accumulation"," in the regenerator cyclone hoppers",[82,89,90,93],{},[59,91,92],{},"Refractory-debris accretion"," in flue-gas paths after major outages",[82,95,96,99],{},[59,97,98],{},"Pluggage"," in the third-stage separator's dipleg",[82,101,102,105],{},[59,103,104],{},"Dust hopper bridging"," below catalyst recovery equipment",[74,107,109],{"id":108},"sonic-horn-duty","Sonic-horn duty",[55,111,112,116],{},[63,113,115],{"href":114},"\u002Fglossary\u002Fsonic-horn","Sonic horns"," on regenerator-flue-gas-train hoppers and on the third-stage separator catalyst-fines hopper keep catalyst fines flowing reliably back into the unit or to disposal.",[74,118,120],{"id":119},"related-terms","Related terms",[79,122,123,128,133],{},[82,124,125],{},[63,126,127],{"href":65},"Fluid catalytic cracking (FCC)",[82,129,130],{},[63,131,132],{"href":70},"Third-stage separator (TSS)",[82,134,135],{},[63,136,138],{"href":137},"\u002Fglossary\u002Fcyclone-separator","Cyclone separator",{"title":140,"searchDepth":141,"depth":141,"links":142},"",2,[143,144,145],{"id":76,"depth":141,"text":77},{"id":108,"depth":141,"text":109},{"id":119,"depth":141,"text":120},"steel-refining","The FCC regenerator burns coke deposits off spent FCC catalyst circulating in the unit. Combustion at ~700 °C restores the catalyst's cracking activity for return to the riser-reactor. The hot flue gas produced is routed through cyclone separators (primary and secondary inside the regenerator, then third-stage external) before going to either a CO boiler or a power-recovery expander.","md",{},true,"\u002Fglossary\u002Ffcc-regenerator",[153,154,155],"fluid-catalytic-cracking","third-stage-separator","cyclone-separator",{"title":157,"description":158},"FCC regenerator — burns coke off spent catalyst in fluid catalytic cracking","The FCC regenerator burns coke deposits off spent cracking catalyst, restoring activity and producing high-temperature flue gas for downstream energy recovery.",[160],{"title":161,"url":162},"Wikipedia — Fluid catalytic cracking","https:\u002F\u002Fen.wikipedia.org\u002Fwiki\u002FFluid_catalytic_cracking","glossary\u002Ffcc-regenerator","DpReoa4qbfh8C45PkBcJ174yiPEs8Rat2sKozgNoBCM",[166,271,368],{"id":167,"title":127,"aliases":168,"body":171,"category":146,"description":258,"extension":148,"meta":259,"navigation":150,"path":65,"relatedTerms":260,"seo":263,"sources":266,"stem":268,"term":269,"__hash__":270},"glossary\u002Fglossary\u002Ffluid-catalytic-cracking.md",[66,169,170],"fluid catalytic cracker","cat cracker",{"type":52,"value":172,"toc":253},[173,182,186,222,226,232,234],[55,174,175,177,178,181],{},[59,176,127],{}," is the central process of a fuels refinery, cracking heavy hydrocarbons (vacuum gas oil, residue) into lighter products — primarily gasoline, with valuable C₃–C₄ olefin streams as co-products. The reaction takes place at ~520 °C over a fluidised bed of zeolite catalyst circulated between a riser-reactor and a ",[63,179,180],{"href":151},"regenerator",".",[74,183,185],{"id":184},"cleaning-targets-in-the-fcc-complex","Cleaning targets in the FCC complex",[79,187,188,194,203,210,216],{},[82,189,190,193],{},[59,191,192],{},"Riser-reactor cyclones"," — separate spent catalyst from hydrocarbon vapour",[82,195,196,202],{},[59,197,198,201],{},[63,199,200],{"href":151},"Regenerator"," primary and secondary cyclones"," — separate regenerated catalyst from flue gas",[82,204,205,209],{},[59,206,207],{},[63,208,132],{"href":70}," — recovers catalyst fines from flue gas",[82,211,212,215],{},[59,213,214],{},"CO boiler"," — burns regenerator flue-gas CO for energy recovery",[82,217,218,221],{},[59,219,220],{},"Catalyst fines hopper"," — fine catalyst recovered from the gas-cleaning train",[74,223,225],{"id":224},"sonic-horn-fit","Sonic-horn fit",[55,227,228,229,231],{},"Refinery FCC units are demanding applications: high temperature, abrasive catalyst, continuous 24\u002F7 operation, very high economic stakes per outage hour. ",[63,230,115],{"href":114}," on the third-stage separator and on catalyst-fines hoppers help maintain flue-gas-cleaning efficiency and avoid the unplanned slowdowns associated with hopper bridging.",[74,233,120],{"id":119},[79,235,236,240,244,248],{},[82,237,238],{},[63,239,47],{"href":151},[82,241,242],{},[63,243,132],{"href":70},[82,245,246],{},[63,247,138],{"href":137},[82,249,250],{},[63,251,252],{"href":114},"Sonic horn",{"title":140,"searchDepth":141,"depth":141,"links":254},[255,256,257],{"id":184,"depth":141,"text":185},{"id":224,"depth":141,"text":225},{"id":119,"depth":141,"text":120},"Fluid catalytic cracking (FCC) is the central process of a fuels refinery, cracking heavy hydrocarbons (vacuum gas oil, residue) into lighter products — primarily gasoline, with valuable C₃–C₄ olefin streams as co-products. The reaction takes place at ~520 °C over a fluidised bed of zeolite catalyst circulated between a riser-reactor and a regenerator.",{},[261,154,155,262],"fcc-regenerator","sonic-horn",{"title":264,"description":265},"Fluid catalytic cracking (FCC) — heart of the refinery, cracking heavy hydrocarbons","Fluid catalytic cracking (FCC) cracks heavy hydrocarbons into gasoline and lighter products over a fluidised catalyst bed. The associated regenerator and separators benefit from sonic-horn cleaning.",[267],{"title":161,"url":162},"glossary\u002Ffluid-catalytic-cracking","Fluid catalytic cracking","diPDdTnBdIwbDyqAnpcyroreLKX4t7Klq-iKud3gfHU",{"id":272,"title":132,"aliases":273,"body":276,"category":146,"description":357,"extension":148,"meta":358,"navigation":150,"path":70,"relatedTerms":359,"seo":360,"sources":363,"stem":365,"term":366,"__hash__":367},"glossary\u002Fglossary\u002Fthird-stage-separator.md",[274,275],"TSS","FCC third-stage separator",{"type":52,"value":277,"toc":351},[278,288,292,304,308,328,330,335,337],[55,279,280,281,284,285,287],{},"A ",[59,282,283],{},"third-stage separator (TSS)"," is the high-efficiency cyclone vessel installed downstream of the ",[63,286,47],{"href":151}," to recover very fine catalyst fines that escape the regenerator's primary and secondary cyclones. The TSS protects downstream equipment — particularly the power-recovery expander — from catalyst erosion.",[74,289,291],{"id":290},"construction","Construction",[55,293,294,295,298,299,303],{},"A TSS typically contains 50–150 small high-efficiency ",[63,296,297],{"href":137},"cyclone separators"," in parallel inside a common vessel. Each cyclone has its own ",[63,300,302],{"href":301},"\u002Fglossary\u002Fcyclone-dipleg","dipleg"," that drains into a common collection hopper.",[74,305,307],{"id":306},"failure-modes","Failure modes",[79,309,310,316,322],{},[82,311,312,315],{},[59,313,314],{},"Individual cyclone pluggage"," — fines bridge in a single dipleg, that cyclone bypasses gas to neighbours",[82,317,318,321],{},[59,319,320],{},"Common hopper bridging"," — the collection hopper plugs, backing up all the diplegs above",[82,323,324,327],{},[59,325,326],{},"Cyclone erosion"," — the high catalyst-fines velocity wears cyclone walls",[74,329,109],{"id":108},[55,331,332,334],{},[63,333,115],{"href":114}," on the TSS common hopper prevent fines bridging. This protects the entire TSS-and-expander train from the cascading consequences of single-point hopper failures.",[74,336,120],{"id":119},[79,338,339,343,347],{},[82,340,341],{},[63,342,47],{"href":151},[82,344,345],{},[63,346,127],{"href":65},[82,348,349],{},[63,350,138],{"href":137},{"title":140,"searchDepth":141,"depth":141,"links":352},[353,354,355,356],{"id":290,"depth":141,"text":291},{"id":306,"depth":141,"text":307},{"id":108,"depth":141,"text":109},{"id":119,"depth":141,"text":120},"A third-stage separator (TSS) is the high-efficiency cyclone vessel installed downstream of the FCC regenerator to recover very fine catalyst fines that escape the regenerator's primary and secondary cyclones. The TSS protects downstream equipment — particularly the power-recovery expander — from catalyst erosion.",{},[261,153,155],{"title":361,"description":362},"Third-stage separator (TSS) — catalyst fines recovery downstream of FCC regenerator","A third-stage separator recovers very fine catalyst fines from the FCC regenerator flue gas using high-efficiency cyclones. Pluggage of the underflow leg is a chronic operational issue.",[364],{"title":161,"url":162},"glossary\u002Fthird-stage-separator","Third-stage separator","yToxyEBVBQDrPPM3N30Kt7IP32yOq9Lkr-84ytzrJOE",{"id":369,"title":138,"aliases":370,"body":374,"category":488,"description":489,"extension":148,"meta":490,"navigation":150,"path":137,"relatedTerms":491,"seo":496,"sources":499,"stem":503,"term":138,"__hash__":504},"glossary\u002Fglossary\u002Fcyclone-separator.md",[371,372,373],"cyclone","cyclones","gas cyclone",{"type":52,"value":375,"toc":482},[376,385,389,421,425,445,449,454,456],[55,377,280,378,381,382,384],{},[59,379,380],{},"cyclone separator"," removes particulate from a gas stream by centrifugal force: gas enters tangentially at the top of a vertical cylinder, spirals downward, and exits axially at the top through an inner pipe (vortex finder); heavier particles are thrown outward to the wall, slide down the conical bottom, and discharge through the ",[63,383,302],{"href":301}," below.",[74,386,388],{"id":387},"where-cyclones-are-used","Where cyclones are used",[79,390,391,398,405,418],{},[82,392,393,397],{},[63,394,396],{"href":395},"\u002Fglossary\u002Fcfb-boiler","CFB boiler"," primary separators — large-diameter, high-temperature",[82,399,400,404],{},[63,401,403],{"href":402},"\u002Fglossary\u002Fpreheater-cyclone","Cement preheater cyclones"," — multi-stage gas-to-meal heat exchange",[82,406,407,408,412,413,417],{},"Pre-cleaners ahead of ",[63,409,411],{"href":410},"\u002Fglossary\u002Fbaghouse","baghouses"," and ",[63,414,416],{"href":415},"\u002Fglossary\u002Felectrostatic-precipitator","ESPs"," — knock out coarse dust to reduce downstream load",[82,419,420],{},"Process gas separation in chemical and refining duty",[74,422,424],{"id":423},"cyclone-fouling","Cyclone fouling",[79,426,427,433,439],{},[82,428,429,432],{},[59,430,431],{},"Wall build-up"," — dust accretes on the wall and gradually narrows the gas path; flow re-organises and efficiency drops",[82,434,435,438],{},[59,436,437],{},"Dipleg pluggage"," — separated material backs up in the dipleg, eventually re-entraining",[82,440,441,444],{},[59,442,443],{},"Vortex finder fouling"," — alters internal swirl pattern",[74,446,448],{"id":447},"cleaning","Cleaning",[55,450,451,453],{},[63,452,115],{"href":114}," installed on the cyclone shell or dipleg keep wall deposits from consolidating. On cement preheater cyclones particularly, sonic horns are the standard preventive against the coatings that form under alternative-fuel firing.",[74,455,120],{"id":119},[79,457,458,464,469,473,478],{},[82,459,460],{},[63,461,463],{"href":462},"\u002Fglossary\u002Fmulti-cyclone-multiclone","Multi-cyclone \u002F multiclone",[82,465,466],{},[63,467,468],{"href":301},"Cyclone dipleg",[82,470,471],{},[63,472,396],{"href":395},[82,474,475],{},[63,476,477],{"href":402},"Preheater cyclone",[82,479,480],{},[63,481,252],{"href":114},{"title":140,"searchDepth":141,"depth":141,"links":483},[484,485,486,487],{"id":387,"depth":141,"text":388},{"id":423,"depth":141,"text":424},{"id":447,"depth":141,"text":448},{"id":119,"depth":141,"text":120},"hrsg-gas-path","A cyclone separator removes particulate from a gas stream by centrifugal force: gas enters tangentially at the top of a vertical cylinder, spirals downward, and exits axially at the top through an inner pipe (vortex finder); heavier particles are thrown outward to the wall, slide down the conical bottom, and discharge through the dipleg below.",{},[492,493,494,495,262],"multi-cyclone-multiclone","cyclone-dipleg","cfb-boiler","preheater-cyclone",{"title":497,"description":498},"Cyclone separator — centrifugal particulate-removal device","A cyclone separator removes particulate from a gas stream by centrifugal force. Wall build-up and re-entrainment from the dipleg are the dominant operational issues.",[500],{"title":501,"url":502},"Wikipedia — Cyclonic separation","https:\u002F\u002Fen.wikipedia.org\u002Fwiki\u002FCyclonic_separation","glossary\u002Fcyclone-separator","q8drrAFN5eVbx6KETEHT-VxRny2DelPTSLsYv0Fj2dU",1782613756785]