High-Temperature Cyclone for Biofuels Conversion
Heumann Environmental was selected to fabricate a pilot-scale cyclone for a biofuels conversion process in San Antonio, TX. Known for our expertise in building durable particle separation devices for extreme conditions, we were approached to construct a cyclone capable of withstanding the severe temperatures and pressures of a biofuels conversion process.
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Quick overview of the project, key specs, and outcomes.
The Challenge
The client required a precleaner cyclone that could operate reliably at 750°C (1382°F) and 10 bar (145 psi) — conditions that pushed the design into pressure vessel territory. Speed was critical to ensure the unit was ready for scheduled testing. While collection efficiency was less crucial, ensuring structural integrity under extreme conditions was paramount.
Solution Provided
Leveraging our fabrication expertise, we constructed the biofuels conversion cyclone unit using 316H stainless steel, a high-carbon alloy known for enhanced strength and thermal resistance. The client provided key dimensions and material specifications, which we verified against ASME Section VIII Division 1 Code to ensure structural integrity and suitability for the design temperature.
Key Cyclone System Features
System Specifications
Material of Construction:
Chosen for its exceptional strength and high-temperature resilience, 316H stainless steel is a high-carbon variant of 316, offering superior tensile and yield strength while maintaining outstanding toughness. Its durability under extreme conditions makes it well-suited for the petrochemical, gas, and chemical industries.
ASME Code Verified:
While the client provided the initial design and dimensions, we conducted meticulous ASME Section VIII Division 1 calculations to verify metal thickness and ensure compliance with best practices. The extreme temperature and pressure pushed this cyclone into pressure vessel territory, requiring extensive engineering validation. Additionally, the cyclone unit underwent and successfully passed a 1,974 psi hydrotest, confirming its structural integrity under high-stress conditions.
Fabrication Expertise:
Thicker stainless steel poses a higher risk of warpage and shrinkage during welding, and the thicker the material, the greater the risk of warpage. Our expert technicians are trained to anticipate and counteract these challenges, ensuring precise fabrication and uncompromised structural integrity. This expertise is one of the many reasons the client relied on us for this critical project.
Results and Outcomes
Through expert engineering and proactive collaboration, Heumann Environmental provided a high-performance cyclone that met stringent ASME standards, overcame fabrication complexities, and earned ongoing client trust.
Successful Fabrication & Delivery: Despite the complexity of the project and some schedule adjustments, the biofuels conversion cyclone was delivered within a timeframe that met the client’s needs. The customer remained informed throughout the process and was pleased with the final product.
Client Satisfaction & Ongoing Collaboration: Post-installation, the client made modifications to the piping loads, requiring updated mechanical calculations. Heumann Environmental provided the design of a reinforcing stiffener to accommodate the changes, demonstrating flexibility and commitment to project success. The client has continued working with Heumann on other equipment for the project, indicating confidence in the company’s expertise.
Lessons & Refinements: An outlet flange experienced minor warping from welding heat, resulting in a slight tilt, but it was still within industry alignment tolerances. Rather than delaying the project by immediately refabricating the flange, we documented the adjustment and provided as-built marked drawings to the customer, who had no concerns. This reinforced the value of client collaboration and highlighted the importance of proactive planning for welding-induced distortions in future projects.
Fabricating High-Performance Cyclones to Power Biofuels Conversion Processes
Heumann Environmental’s technical expertise in fabricating particle separation equipment under extreme conditions ensured the successful delivery of this high-performance cyclone for biofuels processing. Our deep understanding of ASME standards, advanced fabrication techniques, and proactive problem-solving solidify our reputation as the go-to industry experts for challenging applications.
If you require a precision-engineered cyclone solution built to withstand the most demanding environments, contact Heumann Environmental today, where innovation meets reliability.
Beyond Off-the-Shelf: Solutions for Tough Applications
The same engineering and fabrication expertise behind this custom-built high-temperature cyclone for biofuels conversion applies to a wide range of extreme industrial challenges. When your process demands solutions that withstand high temperatures, endure relentless abrasion, hold intense pressure, or have specialized surface finishes, off-the-shelf equipment won’t cut it.
Explore Our High TAPS Solutions
At Heumann Environmental, we specialize in High TAPS applications—custom-engineered systems built for the most demanding environments. From high-pressure gas streams to abrasive particulates and precision sanitary finishes, our solutions are designed for long-term durability, efficiency, and compliance across industries like oil & gas, chemical processing, and pharmaceuticals.
Learn more about our High TAPS expertise and how we engineer solutions to thrive under the toughest conditions.