Oxychlorination Reactor Cyclones
In 2022, Heumann Environmental fabricated a two-stage cyclone assembly consisting of two sets of two cyclones for a premier chemical manufacturer in the United States. The project aimed to replace an aging system in a reactor performing an oxychlorination process.
The Challenge
The abrasive nature of filtering particulate means that no cyclone can last indefinitely. Our goal is to delay the inevitable with clever engineering and superior materials while keeping operational costs in check. In 2022, a leading U.S. supplier of PVC and VCM approached Heumann Environmental to design a replacement for a dual two-stage cyclone assembly, which was nearing the end of its lifecycle in a reactor vessel used for oxychlorination.
The challenge was to design a reliable replacement system that could endure the oxychlorination process, effectively remove catalysts, and operate continuously under high temperatures and pressures. The new reactor Built for a premier US chemical manufacturer, this custom oxychlorination reactor cyclone promises durability, reliability, and seamless integration.cyclones also needed to precisely match the existing components to ensure seamless integration without significant modifications, minimizing downtime.
Balancing these technical demands with cost-effectiveness was critical to meeting our client’s needs while upholding their high standards of safety, reliability, and sustainability.
Solution Provided
With access to performance metrics and specifications from the current interior reactor cyclones slated for replacement, this made the redesign of the system a straightforward process. Leveraging existing insights into effective design parameters, our team focused on ensuring that the new cyclones met the rigorous demands of the Oxychlorination process. Priority was given to engineering replacements that seamlessly integrated into the current reactor setup, ensuring minimal disruption and optimal performance efficiency.
Key Cyclone System Features
System Specifications
Material of Construction:
Known for its reliability in moderate to low-temperature settings, carbon steel SA516 Grade 70 is a staple in refineries, chemical plants, and power generation facilities. This material is revered in the pressure vessel industry for its durability and widespread use, making it the logical choice as the base material for the cyclone system.
Refractory Lining:
The reactor cyclones and diplegs were lined at strategic locations inside and outside of the systems using 3/4″ Rescobond AA-22S refractory, anchored by 3/4″ x 14 Ga. CS Hex Mesh. This Rescobond refractory lining plays a crucial role in protecting the base metal from abrasion and effectively managing internal temperatures. By utilizing this lining, we optimized the use of cost-effective base steel materials, reducing the need for more expensive specialty metals and significantly enhancing overall cost efficiency.
Dual Two-Stage Cyclone Configuration:
Our dual two-stage cyclone configuration is engineered for optimal catalyst recovery. It includes two first-stage and two second-stage cyclones, each equipped with dipleg stubs, allowing for seamless integration with the customer-supplied diplegs and bracings. The first-stage cyclone is outfitted with a splash plate, while the second-stage cyclone features a partially shrouded trickle valve. This design enables in-bed discharge while preventing gas from flowing back up the diplegs. The configuration ensures superior particle separation and maximizes the return of catalysts to the fluid bed reactor, achieving peak performance in the oxychlorination process.
Results and Outcomes
Successfully installed in November 2024, the newly constructed oxychlorination reactor cyclone assembly is now fully operational and performing as anticipated. This system has significantly enhanced the efficiency and reliability of the catalyst removal process, meeting all performance expectations. Key achieved outcomes include:
Reliable Performance: The system is designed to operate efficiently at high temperatures and pressures, maintaining optimal performance round the clock.
Improved Durability: The combination of SA516 Grade 70 material and Rescobond Refractory lining will extend the system’s lifespan, reducing the frequency of replacements.
Cost-Effectiveness: The design has successfully leveraged existing diplegs, dipleg bracings, and hangars in the reactor vessel, utilizing economical materials without compromising quality, resulting in overall cost savings.
Seamless Integration: The replacement cyclone was precisely engineered to fit the existing reactor. Installation was completed smoothly, and we anticipate minimal operational disruption during future maintenance.
A Strong Foundation for Future Success
With the transition from the retired cyclone systems completed ahead of schedule, the new assembly is now fully operational and performing as expected. By combining innovative design with a deep understanding of the client’s needs, we’ve constructed a system that promises exceptional performance, durability, and value. The anticipated seamless integration and long-term reliability of this assembly will ensure that the client’s operations continue to thrive, setting a new benchmark for efficiency and excellence in the chemical manufacturing industry.
Custom Solutions for Superior Performance and Reliability
Learn how our engineering expertise can help you achieve flawless system upgrades with minimal disruption. Contact us today to explore customized solutions for your operations.