Design and Application of Type 159-G54 High-Temperature Special-shaped Gas-Solid Cyclone Separator in the Methanation Gas Flow Fluidization Process Unit

Compared to fixed-bed process units, fluidized-bed process units are highly regarded in petroleum refining due to their advantages such as high production capacity, great flexibility, ease of scale-up for industrial use, and simple operation. To capture and recover highly dispersed heavy-phase carriers from the gas stream, specialized asymmetric cyclone separators are required. For example, catalyst recovery and separation in high-temperature and low-pressure catalytic cracking units, capture and recovery of catalysts from flue gases generated during FCC/DCC regeneration, gas-phase dust and foam removal in high-temperature and high-pressure gasification units, dust removal through air flow drying in high-temperature and low-pressure systems, and dust removal from dusty exhaust gases in PP units, among others.

This post was last edited by luoli519 on 2020-8-26 at 13:25. In recent years, fluidized process units have received even more attention and favor. Some renowned research institutions at home and abroad are upgrading and developing the existing fixed-bed hydrogenation and fixed-bed methanization processes into more advanced fluidized-bed processes. As mentioned earlier, the ability to effectively capture, recover, and separate the heavy-phase materials from the gas stream – such as highly fluidized and dispersed fine catalyst particles – determines the economic viability of the process technology and is even crucial to the success or failure of process development. A few years ago, the Petroleum University and the Chinese Academy of Petroleum Sciences attempted to do this, but failed to make any breakthroughs. In 2016, the Institute of Process Engineering of the Chinese Academy of Sciences approached our company seeking cooperation. We customized and manufactured high-temperature, special-shaped swirl separators for fluidized-bed methanization processes in accordance with their technical requirements, thereby helping to make breakthroughs in their project.

About a year later, the Southwest Institute also approached our company for cooperation, under the guidance of the Institute of Process Engineering at the Chinese Academy of Sciences, in order to work together on the design of specialized high-temperature, custom-shaped swirl separators for fluidized-bed process units. This post takes the targeted design of a high-temperature, special-shaped swirl separator for use in the fluidized bed process units involved in the Southwest Institute’s projects as an example to discuss and analyze with everyone.

The relevant process technical parameters are as follows: 1. Operating pressure: 2.2 MPaG ； 2. Operating temperature: 450℃ ； 3. Gas mass flow rate: 1212 kg/h ； 4. Vapor density: 7.069 kg/m3 ； 5. Viscosity in the gas phase: 0.0236 cp. 6. Gas phase composition (volume percentage, vol%): H2: 5.49 ； CO: 0.18 ； CO2: 7.03 ； CH4: 54.45 ； N2: 6.28 ； C2H6: 0.01 ； H2O: 26.56. Separation efficiency requirement: The solid separation efficiency must be over 99%.

The main performance parameters of the high-temperature shaped gas-solid cyclone separator developed by our company, based on the process parameters provided by the Southwest Research Institute and using NOVEL’s specialized precise kinetic separation technology for calculation and system configuration, are as follows: 1. Type of separation technology: G54 type high-temperature shaped cyclone separator (patented technology)； II. Separator model: G54S-4-362.6 ； III. Separation efficiency: 4N-level separation removes particulate matter with a size of 9.62 microns and larger; the residual solid content in the outlet stream is no more than 0.1 G/MMSCF ； IV. Maximum operating pressure drop: 1.007 psi. Material: Entirely SS304.

This post was last edited by luoli519 on 2024-4-7 at 10:54. The customized configuration plan for the high-temperature, irregular-shaped gas-solid swirl separator, developed by our company using the specialized NOVEL precise dynamics separation technology and based on the process parameters provided by the Southwest Research Institute, is presented in the following ‘Table of Figures and Data’

The diagram in “Numerical and Graphical Summary” shows two red circles along with the key technical points. Key core technology point 1: The shape, configuration type, installation position of the inlet diversion internals, as well as the degree to which they are tightly welded to the inner wall of the inlet pipe, all have a significant impact on the operating performance of the separator. Key core technology point 2: The shape, configuration type, installation position of the full-section rectifying internals on the inner side of the separator shell, as well as the degree to which they are tightly welded to the inner wall of the separator shell, have a significant impact on the operating performance of the separator. This precisely reflects the essence of dynamic separation technology.

For information on the key patent-related technical components of this high-temperature special-shaped cyclone separator, please refer to the following document: «NB17-1-135 Technical Proposal for a High-Temperature Special-Shaped Cyclone Separator Specifically Designed for Novel G54 Fluidized-Bed Methanization Units (Excerpt 1)»

This post was last edited by luoli519 on 2020-8-26 at 14:18. The high-temperature, custom-shaped cyclone separator used in the Southwest Institute has a structure that is similar to that of the high-temperature, custom-shaped cyclone separator devices manufactured by the Institute of Process Engineering, Chinese Academy of Sciences; the only difference is that the temperature and pressure in the former are slightly lower. The image below shows the nameplate of a similar high-temperature, custom-shaped cyclone separator manufactured by the Institute of Process Engineering, Chinese Academy of Sciences:

The gas-solid cyclone separators used in many million-ton-scale plants employ multi-factor cyclone parent and child separators. Examples include: the cyclone dust and foam removal separator in gasification units; the three-cyclone separator in fluidized-bed catalytic cracking units for heavy oil; the cyclone dust removal separator for flue gas from catalyst regeneration in heavy oil catalytic cracking units; the three-cyclone separator for catalyst capture in diesel catalytic cracking units; the cyclone dust removal separator for flue gas from catalyst regeneration in diesel catalytic cracking units; the three-cyclone separator for catalyst capture in wax oil catalytic cracking units; the cyclone dust removal separator for flue gas from catalyst regeneration in wax oil catalytic cracking units; the three-cyclone separator for catalyst capture in naphtha catalytic cracking units; the cyclone dust removal separator for flue gas from catalyst regeneration in naphtha catalytic cracking units; the dry cyclone dust collector for flue gas in circulating fluidized-bed coal-fired boilers; the cyclone dust and oil removal separator for high-temperature, dusty, and oily coke oven gas/raw gas; the cyclone gas-solid separator in industrial air-drying rotary kilns; the cyclone gas-solid separator in rotary kilns used for air drying in the pharmaceutical and food industries; the cyclone gas-solid separator for exhaust gases from calcination and roasting rotary kilns/multi-stage furnaces; and the large-capacity cyclone gas-solid separator installed after bag filters.