FCC reactor product-catalyst separation: Ten years of commercial experience with closed cyclones

FCC reactor closed cyclones were first commercialized ten years ago and have now been installed in over 22 FCC units worldwide. Cumulative commercial experience has shown significant yield benefits, in some cases higher than first estimated, and excellent reliability. By nearly eliminating post-riser cracking, they reduce dry gas make and produce higher yields of desirable liquid products. Trouble-free operation with closed cyclones is attributed to proper design, instrumentation, and operating procedures. The Mobil-Kellogg Closed Cyclone technology is the only design offered for license which uses the positive-pressure riser cyclone system which has proven to be least sensitive to upsets. This paper traces the development and commercialization of closed cyclones, discusses differences between competing closed cyclone designs, and documents the benefits which have been observed for Mobil-Kellogg Closed Cyclones.