Fluid Catalytic Cracking Units (FCC Cyclones) are the principal technologies that enable the critical process within heavy oil refining of converting the heavy oils into more valuable gasoline and lighter products. More than half of the refinery’s heavy petroleum is processed through the FCC Cyclones, and the FCC Cyclones are also an important source of butene and pentene olefins used in refinery processes.

Our Emtrol-Buell brand has supplied more FCC Cyclones to refineries and petrochemical plants worldwide than any other supplier, so our experience in this area is unequaled. They are designed to enhance separation efficiency, accommodate increased catalyst loading, and are tailored to meet the application needs of refineries and petrochemical plants.

We custom-engineer the following products at the highest quality:

• FCC Cyclones – Patented Beam Hanger Support System
• FCC Cyclones – Reactor
• FCC Cyclones – Regenerator
• FCC Cyclones – Third Stage Separator Systems
• FCC Cyclones – Fourth Stage & Catalyst Hopper Cyclones

The Concept of Fluid Catalytic Cracking

Heavy gas oils and vacuum gas oils are heated to more than 600 °F and then mixed with a catalyst before they enter the main FCC reactor. Chemical reactions “crack” the large molecules in the oil into smaller molecules, and carbon forms on the surface of the catalyst.

Inside the reactor, steam is injected to separate the oil from the catalyst, forcing the catalyst to move like a fluid. The “cracked” oil vapors flow out the top of the reactor. The used catalyst flows out the bottom of the reactor mixed with air and enters the regenerator vessel where surface carbon on the catalyst is burned off. The regenerated catalyst leaves the bottom of the regenerator to be mixed with the heavy oil feed.

Exiting the top of the regenerator is a hot flue gas stream that heats other boilers in the plant. While the catalyst is being regenerated, the hot oil vapors exit the top of the reactor and enter the main fractionator. This fractionator separates the “cracked” petroleum stream into lighter products such as gasoline.

Our Emtrol-Buell brand Fluid Catalytic Cracking Units (FCC Cyclones)

Our FCC Cyclones are designed with innovative enhancements to ensure optimal performance, efficiency and reliability. We are also expert at the evaluation of existing cyclone systems in order to recommend modifications to maximize performance and minimize erosion problems.

We are approved by all the FCC process licensing companies as a qualified supplier of cyclone equipment, namely

• ABB Lummus
• ExxonMobil
• IFP
• Kellogg Brown & Root (formerly M.W. Kellogg)
• Stone and Webster (Shaw Groups)
• UOP

FCC Cyclones from CECO Emtrol-Buell

For more than a century, Emtrol-Buell has carved a path of innovation in developing reliable, highly advanced refining equipment. Facilities that use Emtrol-Buell FCC Cyclone equipment to process heavy petroleum are employing meticulously produced equipment that is head and shoulders above anything else on the market today. We apply pioneering engineering to build processing equipment capable of running for years without maintenance. This attention to detail and quality enables us to provide peace of mind and ensure the quality of an essential piece of equipment in the petroleum refining process.

Due to the broad range of potential issues that can halt the oil refining process, it is crucial that your facility uses only the most advanced, proven systems. You must demand the best systems in the industry. The Emtrol-Buell brand is at the forefront of the industry because they provide acclaimed, custom-designed Cyclone system to refineries and petrochemical plants around the world.

We build the finest FCC Cyclone models for every stages of refining so you can employ exemplary technology throughout the process. The customized products we build will be ideally suited to your specific needs. We have the perfect equipment for all refineries. When you choose a brand to equip your refinery, choose the company that supplies more FCC Cyclones to refineries and plants than any other. You should be proud of the equipment you use. Choose Emtrol-Buell.

Fluid Catalytic Cracking Units (FCC Cyclones) are the principal technologies that enable the critical process within heavy oil refining of converting the heavy oils into more valuable gasoline and lighter products. More than half of the refinery’s heavy petroleum is processed through the FCC Cyclones, and the FCC Cyclones are also an important source of butene and pentene olefins used in refinery processes.

Our Emtrol-Buell brand has supplied more FCC Cyclones to refineries and petrochemical plants worldwide than any other supplier, so our experience in this area is unequaled. Our FCC Cyclones are designed to enhance separation efficiency, accommodate increased catalyst loading, and are tailored to meet the application needs of refineries and petrochemical plants.

We custom-engineer the following products at the highest quality:

• FCC Cyclones – Patented Beam Hanger Support System
• FCC Cyclones – Reactor
• FCC Cyclones – Regenerator
• FCC Cyclones – Third Stage Separator Systems
• FCC Cyclones – Fourth Stage & Catalyst Hopper Cyclones

 FCC Cyclones – Third Stage Separator Systems

Third Stage Separator Systems include cyclones, a containment vessel, an underflow system, catalyst storage and evacuation.

Unlike traditional third stage units designed to eliminate particles >10 micron diameter and high inlet and outlet velocities, characterized by a large number of small cyclone, Emtrol-Buell brand Third Stage Separator Systems are designed to collect as much catalyst as possible while limiting system erosion and catalyst attrition.

We utilize a pressure vessel to contain fewer, larger diameter, high efficiency cyclones sized to maintain inlet velocity (with refractory lined cyclones, erosion on cyclone surface is reduced to an acceptable level).

Unlike other systems, our technologies do not require underflow for proper operation, as solids can be discharged directed through a valve. From the final collection hopper, the fines can be off-loaded to a truck or disposal container.

By designing and building trustworthy, innovative hardware for over 120 years, Emtrol-Buell has lead the way in modernizing refining equipment. Businesses that employ Emtrol-Buell FCC Cyclone solutions to process heavy petroleum utilize painstakingly designed equipment that exceeds all other products on the market. We design and build state-of-the-art processing equipment that operates continually and faithfully. This attention to detail is how we ensure the standard of performance of a crucial piece of equipment in the petroleum refining process.

It is important that your facility employs the most advanced systems to meet the exacting industry standards and avoid possible issues that can stop the oil refining process. Never settle for anything but finest in the industry. Emtrol-Buell leads in manufacturing and providing custom-designed Cyclone solutions to refineries and petrochemical plants on a global scale.

Emtrol-Buell builds better FCC Cyclone resources for every part of the refining industry so you can apply better technology from beginning to end. We provide custom equipment perfectly designed for your unique application. We make ideal equipment for any and all refineries. When picking a brand for your refinery’s equipment needs, pick the industry innovator that provides more FCC Cyclone units to refineries and plants than any other institution. You should be proud of the equipment you use. Choose Emtrol-Buell.

Fluid Catalytic Cracking Units (FCC Cyclones) are the principal technologies that enable the critical process within heavy oil refining of converting the heavy oils into more valuable gasoline and lighter products. More than half of the refinery’s heavy petroleum is processed through the FCC Cyclones, and the FCC Cyclones are also an important source of butene and pentene olefins used in refinery processes.

Our Emtrol-Buell brand has supplied more FCC Cyclones to refineries and petrochemical plants worldwide than any other supplier, so our experience in this area is unequaled. Our FCC Cyclones are designed to enhance separation efficiency, accommodate increased catalyst loading, and are tailored to meet the application needs of refineries and petrochemical plants.

We custom-engineer the following products at the highest quality:

• FCC Cyclones – Patented Beam Hanger Support System
• FCC Cyclones – Reactor
• FCC Cyclones – Regenerator
• FCC Cyclones – Third Stage Separator Systems
• FCC Cyclones – Fourth Stage & Catalyst Hopper Cyclones

FCC Cyclones – Regenerator

Regenerator Cyclones are used to separate catalyst from flue gas created when the carbon or coke is burned with air from the FCC catalyst. They are designed to withstand very abrasive service at a temperature of 1,450 degrees F.

Emtrol-Buell has blazed the path as industry leader for over 120 years by providing reliable, cutting-edge refining equipment. Companies that choose Emtrol-Buell FCC Cyclone solutions to process heavy petroleum are choosing meticulously crafted hardware that performs better than anything else on the market. We use highly advanced engineering techniques to build processing equipment able to run for years without maintenance. This attention to detail and quality means that we can ensure the integrity of a critical piece of the petroleum refining process.

With the long list of inherent issues that can slow or stop the oil refining process, it is crucial that your equipment perform to exacting standards and that demands the industry’s best, most advanced systems. The industry leader in building celebrated, custom-designed Cyclone system, Emtrol-Buell supplies equipment to refineries and petrochemical plants all over the world.

We builds first-class FCC Cyclone models for each and every step of refining so your company can put superior technology in place start to finish. Our FCC Cyclone Regenerator is a prime example. We can design and manufacture custom hardware perfectly suited to your specific requirements. Our equipment and products lines are ideal systems for any and all refineries. When it’s time to select equipment for your refinery’s equipment needs, go with the industry leader who provides more FCC Cyclone units to refineries and plants than any other company. You should be proud of the equipment you use. Choose Emtrol-Buell.

Fluid Catalytic Cracking Units (FCC Cyclones) are the principal technologies that enable the critical process within heavy oil refining of converting the heavy oils into more valuable gasoline and lighter products. More than half of the refinery’s heavy petroleum is processed through the FCC Cyclones, and the FCC Cyclones are also an important source of butene and pentene olefins used in refinery processes.

Our Emtrol-Buell brand has supplied more FCC Cyclones to refineries and petrochemical plants worldwide than any other supplier, so our experience in this area is unequaled. Our FCC Cyclones are designed to enhance separation efficiency, accommodate increased catalyst loading, and are tailored to meet the application needs of refineries and petrochemical plants.

We custom-engineer the following products at the highest quality:

• FCC Cyclones – Patented Beam Hanger Support System
• FCC Cyclones – Reactor
• FCC Cyclones – Regenerator
• FCC Cyclones – Third Stage Separator Systems
• FCC Cyclones – Fourth Stage & Catalyst Hopper Cyclones

FCC Cyclones – Reactor

Reactor Cyclones are cyclone separators used to separate hydrocarbon vapors and stripping steam from FCC catalyst. Reactor Cyclones are constructed from refractory lined carbon steel or low alloy steel or even stainless steel and come in many different configurations.

Reactor Cyclones can be attached directly to the riser with a second stage following in a closed coupled system or can be open coupled. They can also be a single stage cyclone preceded by a riser termination device.

For over 120 years, Emtrol-Buell has blazed a path to design and build dependable, highly advanced refining equipment. Facilities that use FCC Cyclone Reactors to refine heavy petroleum are employing meticulously designed hardware that surpasses anything else available today. The cutting-edge engineering we use to build processing equipment assures it will be running for years without maintenance. This attention to detail and meticulous workmanship means that Emtrol-Buell can provide peace of mind and ensure the quality of an intricate piece of the petroleum refining process for you.

It is essential that your company meets the most exacting industry standards and employs the most advanced systems to avoid the potential problems that can interrupt the oil refining process. To do that, you should demand the industry best. Emtrol-Buell is a superior force in supplying acclaimed, custom-designed Cyclone systems to refineries and petrochemical plants all over the globe.

Emtrol-Buell produces superior FCC Cyclone models for all stages of the refining process so that your facility can benefit from their industry leading technology expertise from beginning to the end. We can customize our products to suit your specific needs. We build the perfect equipment for any and all refining facilities. When you choose equipment for your refinery’s needs, choose the proven leader that builds more FCC Cyclones for refineries and plants than anyone in the world. You should be proud of the equipment you use. Choose Emtrol-Buell.

Fluid Catalytic Cracking Units (FCC Cyclones) are the principal technologies that enable the critical process within heavy oil refining of converting the heavy oils into more valuable gasoline and lighter products. More than half of the refinery’s heavy petroleum is processed through the FCC Cyclones, and the FCC Cyclones are also an important source of butene and pentene olefins used in refinery processes.

Our Emtrol-Buell brand has supplied more FCC Cyclones to refineries and petrochemical plants worldwide than any other supplier, so our experience in this area is unequaled. Our FCC Cyclones are designed to enhance separation efficiency, accommodate increased catalyst loading, and are tailored to meet the application needs of refineries and petrochemical plants.

We custom-engineer the following products at the highest quality:

• FCC Cyclones – Patented Beam Hanger Support System
• FCC Cyclones – Reactor
• FCC Cyclones – Regenerator
• FCC Cyclones – Third Stage Separator Systems
• FCC Cyclones – Fourth Stage & Catalyst Hopper Cyclones

FCC Cyclones – Fourth Stage Cyclones

The Cyclone Vessel, which is the common hopper for the cyclone catalyst discharge, is designed to hold the catalyst collected over several days. However, normally the catalyst from the Cyclone Vessel is continuously conveyed to the Fourth Stage Cyclone by a small amount of gas, usually from 1 to 3% of the gases entering the cyclones. During the travel through the un-insulated line and the Fourth Stage Cyclone, a considerable amount of heat is lost from the catalyst and gases.

Additional cooling of the catalyst occurs in the Fines Collection Vessel. The gases from the Fourth Stage Cyclone pass through a critical orifice where the gas pressure is reduced for discharge through the stack. When the Fines Collection Vessel is to be emptied into a closed truck for transport to a land fill, the valve above the vessel is closed, a vent valve is opened to relieve the pressure, and the valve beneath the vessel is opened so that the catalyst may discharge into the truck.

FCC Cyclones – Catalyst Hopper Cyclones

Our Catalyst Hopper Cyclones are easily adaptable to a variety of applications, including loading and/or unloading of Fresh and Spent Catalyst Hoppers, or as auxiliary hoppers for special additives.  These cyclones are typically designed to minimize catalyst lost to atmosphere in the vent from the hopper during loading and/or unloading operations of the hopper.

Emtrol-Buell has blazed a path and leadership role for over 120 years by developing dependable, innovative equipment for refineries. Emtrol-Buell FCC Cyclone systems are meticulously crafted to process heavy petroleum and surpass everything else on the market. We use advanced engineering techniques to provide processing equipment like our Fourth Stage & Catalyst Hopper Cyclones that are capable of running for years and years without maintenance. This attention of detail ensures that we can provide peace of mind and satisfy you with the quality performance of a critical step in the petroleum refining process.

There are many potential problems that can suspend the oil refining process, so it is essential that your facility meets the highest industry protocols and applies advanced systems to prevent issues from arising. You deserve the best industry has to offer. Our brand leads the industry in supplying respected, custom-designed Cyclone systems to refineries and petrochemical plants around the globe.

Emtrol-Buell produces the highest quality FCC Cyclones for all stages of refining, so start to finish your company can employ the highest quality technology. Our customized equipment is perfectly designed for your unique application. We build ideal equipment for any and all facilities. When choosing a company to satisfy your refinery’s needs, choose the company that provides more FCC Cyclone units to refineries and plants than any other. You should be proud of the equipment you use. Choose Emtrol-Buell.