FCC Cyclone Lining Loss

FCC Unit · Cyclones

Problem Details

Background

FCC cyclone separators are the core gas-solid separation equipment. Their linings endure high-velocity, catalyst-laden hot-gas scouring and thermal shock, detaching in sheets. Lining loss shortens equipment life; detached blocks may plug diplegs or hurt separation efficiency.

Failure Mechanism

High-velocity catalyst scouring: gas rotating at high speed in the cyclone carries catalyst, strongly abrading barrel and cone linings. Thermal shock: start/stop and temperature swings shock the lining, accelerating cracking and spalling. Anchor failure: weld defects or high-temperature failure of hexmetal and anchors let linings detach in sheets. Structural defects: initial defects from poor vibration or excess water grow in service.

Consequences

After sheet detachment, walls thin and overheat, separation efficiency drops and catalyst loss rises; detached blocks plug diplegs, interrupting catalyst circulation and forcing shutdown for repair.

Solution

Material Selection and Parameters

Select cyclone lining for "wear resistance + thermal-shock resistance + reliable anchoring":

Material system: hexmetal + wear castable structure with corundum or SiC wear castable (Al₂O₃≥80%) at 20–40mm;
Anchors: full welding of hexmetal and densified anchors with 100% weld inspection; heat-resistant steel anchors in hot zones;
Structural design: smooth barrel-cone transition to reduce local scouring.

Installation Essentials

Wear-layer placement: control water strictly (datasheet lower limit), vibrate fully for tight wrapping of hexmetal. Layered placement: insulation and wear layers placed separately with reliable bonding. Bake-out: follow the curve to prevent wear-layer spalling. Quality check: check wear-layer thickness uniformity and hexmetal wrapping after placement.

Maintenance

Monitor cyclone pressure drop and catalyst loss; investigate on anomalies. At maintenance, check lining thickness and hexmetal condition, patching thinned zones and repairing damaged hexmetal; record data to optimize anchor design and grade.

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