[{"data":1,"prerenderedAt":742},["ShallowReactive",2],{"site-footer-common":3,"glossary:fluid-catalytic-cracking":45,"glossary-related:fluid-catalytic-cracking":179},{"id":4,"extension":5,"footer":6,"meta":40,"navbar":41,"stem":43,"__hash__":44},"common\u002Fcommon.yml","yml",{"tagline":7,"links":8,"sections":9},"Acoustic cleaning intelligence for industrial fouling, soot, ash, dust and build-up.",[],[10,19,31],{"title":11,"links":12},"Product",[13,16],{"label":14,"to":15},"How it works","\u002F#product",{"label":17,"to":18},"Cost assessment","\u002F#hero",{"title":20,"links":21},"Company",[22,25,28],{"label":23,"to":24},"What we build","\u002F#about",{"label":26,"to":27},"Careers","\u002F#careers",{"label":29,"to":30},"Contact","\u002F#contact",{"title":32,"links":33},"Resources",[34,37],{"label":35,"to":36},"Blog","\u002Fresources\u002Fblog",{"label":38,"to":39},"Glossary","\u002Fglossary",{},{"links":42},[],"common","YocmZRy1AYfBbpgGVms-zhdiABlF8VTxHx6h4rDmZBA",{"id":46,"title":47,"aliases":48,"body":52,"category":158,"description":159,"extension":160,"meta":161,"navigation":162,"path":163,"relatedTerms":164,"seo":169,"sources":172,"stem":176,"term":177,"__hash__":178},"glossary\u002Fglossary\u002Ffluid-catalytic-cracking.md","Fluid catalytic cracking (FCC)",[49,50,51],"FCC","fluid catalytic cracker","cat cracker",{"type":53,"value":54,"toc":151},"minimark",[55,68,73,113,117,125,129],[56,57,58,61,62,67],"p",{},[59,60,47],"strong",{}," is the central process of a fuels refinery, cracking heavy hydrocarbons (vacuum gas oil, residue) into lighter products — primarily gasoline, with valuable C₃–C₄ olefin streams as co-products. The reaction takes place at ~520 °C over a fluidised bed of zeolite catalyst circulated between a riser-reactor and a ",[63,64,66],"a",{"href":65},"\u002Fglossary\u002Ffcc-regenerator","regenerator",".",[69,70,72],"h2",{"id":71},"cleaning-targets-in-the-fcc-complex","Cleaning targets in the FCC complex",[74,75,76,83,92,101,107],"ul",{},[77,78,79,82],"li",{},[59,80,81],{},"Riser-reactor cyclones"," — separate spent catalyst from hydrocarbon vapour",[77,84,85,91],{},[59,86,87,90],{},[63,88,89],{"href":65},"Regenerator"," primary and secondary cyclones"," — separate regenerated catalyst from flue gas",[77,93,94,100],{},[59,95,96],{},[63,97,99],{"href":98},"\u002Fglossary\u002Fthird-stage-separator","Third-stage separator (TSS)"," — recovers catalyst fines from flue gas",[77,102,103,106],{},[59,104,105],{},"CO boiler"," — burns regenerator flue-gas CO for energy recovery",[77,108,109,112],{},[59,110,111],{},"Catalyst fines hopper"," — fine catalyst recovered from the gas-cleaning train",[69,114,116],{"id":115},"sonic-horn-fit","Sonic-horn fit",[56,118,119,120,124],{},"Refinery FCC units are demanding applications: high temperature, abrasive catalyst, continuous 24\u002F7 operation, very high economic stakes per outage hour. ",[63,121,123],{"href":122},"\u002Fglossary\u002Fsonic-horn","Sonic horns"," on the third-stage separator and on catalyst-fines hoppers help maintain flue-gas-cleaning efficiency and avoid the unplanned slowdowns associated with hopper bridging.",[69,126,128],{"id":127},"related-terms","Related terms",[74,130,131,136,140,146],{},[77,132,133],{},[63,134,135],{"href":65},"FCC regenerator",[77,137,138],{},[63,139,99],{"href":98},[77,141,142],{},[63,143,145],{"href":144},"\u002Fglossary\u002Fcyclone-separator","Cyclone separator",[77,147,148],{},[63,149,150],{"href":122},"Sonic horn",{"title":152,"searchDepth":153,"depth":153,"links":154},"",2,[155,156,157],{"id":71,"depth":153,"text":72},{"id":115,"depth":153,"text":116},{"id":127,"depth":153,"text":128},"steel-refining","Fluid catalytic cracking (FCC) is the central process of a fuels refinery, cracking heavy hydrocarbons (vacuum gas oil, residue) into lighter products — primarily gasoline, with valuable C₃–C₄ olefin streams as co-products. The reaction takes place at ~520 °C over a fluidised bed of zeolite catalyst circulated between a riser-reactor and a regenerator.","md",{},true,"\u002Fglossary\u002Ffluid-catalytic-cracking",[165,166,167,168],"fcc-regenerator","third-stage-separator","cyclone-separator","sonic-horn",{"title":170,"description":171},"Fluid catalytic cracking (FCC) — heart of the refinery, cracking heavy hydrocarbons","Fluid catalytic cracking (FCC) cracks heavy hydrocarbons into gasoline and lighter products over a fluidised catalyst bed. The associated regenerator and separators benefit from sonic-horn cleaning.",[173],{"title":174,"url":175},"Wikipedia — Fluid catalytic cracking","https:\u002F\u002Fen.wikipedia.org\u002Fwiki\u002FFluid_catalytic_cracking","glossary\u002Ffluid-catalytic-cracking","Fluid catalytic cracking","diPDdTnBdIwbDyqAnpcyroreLKX4t7Klq-iKud3gfHU",[180,271,368,505],{"id":181,"title":135,"aliases":182,"body":185,"category":158,"description":260,"extension":160,"meta":261,"navigation":162,"path":65,"relatedTerms":262,"seo":264,"sources":267,"stem":269,"term":135,"__hash__":270},"glossary\u002Fglossary\u002Ffcc-regenerator.md",[183,184],"FCCU regenerator","catalyst regenerator (FCC)",{"type":53,"value":186,"toc":255},[187,200,204,230,234,239,241],[56,188,189,190,192,193,195,196,199],{},"The ",[59,191,135],{}," burns coke deposits off spent ",[63,194,49],{"href":163}," catalyst circulating in the unit. Combustion at ~700 °C restores the catalyst's cracking activity for return to the riser-reactor. The hot flue gas produced is routed through cyclone separators (primary and secondary inside the regenerator, then ",[63,197,198],{"href":98},"third-stage"," external) before going to either a CO boiler or a power-recovery expander.",[69,201,203],{"id":202},"fouling-concerns","Fouling concerns",[74,205,206,212,218,224],{},[77,207,208,211],{},[59,209,210],{},"Catalyst fines accumulation"," in the regenerator cyclone hoppers",[77,213,214,217],{},[59,215,216],{},"Refractory-debris accretion"," in flue-gas paths after major outages",[77,219,220,223],{},[59,221,222],{},"Pluggage"," in the third-stage separator's dipleg",[77,225,226,229],{},[59,227,228],{},"Dust hopper bridging"," below catalyst recovery equipment",[69,231,233],{"id":232},"sonic-horn-duty","Sonic-horn duty",[56,235,236,238],{},[63,237,123],{"href":122}," on regenerator-flue-gas-train hoppers and on the third-stage separator catalyst-fines hopper keep catalyst fines flowing reliably back into the unit or to disposal.",[69,240,128],{"id":127},[74,242,243,247,251],{},[77,244,245],{},[63,246,47],{"href":163},[77,248,249],{},[63,250,99],{"href":98},[77,252,253],{},[63,254,145],{"href":144},{"title":152,"searchDepth":153,"depth":153,"links":256},[257,258,259],{"id":202,"depth":153,"text":203},{"id":232,"depth":153,"text":233},{"id":127,"depth":153,"text":128},"The FCC regenerator burns coke deposits off spent FCC catalyst circulating in the unit. Combustion at ~700 °C restores the catalyst's cracking activity for return to the riser-reactor. The hot flue gas produced is routed through cyclone separators (primary and secondary inside the regenerator, then third-stage external) before going to either a CO boiler or a power-recovery expander.",{},[263,166,167],"fluid-catalytic-cracking",{"title":265,"description":266},"FCC regenerator — burns coke off spent catalyst in fluid catalytic cracking","The FCC regenerator burns coke deposits off spent cracking catalyst, restoring activity and producing high-temperature flue gas for downstream energy recovery.",[268],{"title":174,"url":175},"glossary\u002Ffcc-regenerator","DpReoa4qbfh8C45PkBcJ174yiPEs8Rat2sKozgNoBCM",{"id":272,"title":99,"aliases":273,"body":276,"category":158,"description":357,"extension":160,"meta":358,"navigation":162,"path":98,"relatedTerms":359,"seo":360,"sources":363,"stem":365,"term":366,"__hash__":367},"glossary\u002Fglossary\u002Fthird-stage-separator.md",[274,275],"TSS","FCC third-stage separator",{"type":53,"value":277,"toc":351},[278,288,292,304,308,328,330,335,337],[56,279,280,281,284,285,287],{},"A ",[59,282,283],{},"third-stage separator (TSS)"," is the high-efficiency cyclone vessel installed downstream of the ",[63,286,135],{"href":65}," to recover very fine catalyst fines that escape the regenerator's primary and secondary cyclones. The TSS protects downstream equipment — particularly the power-recovery expander — from catalyst erosion.",[69,289,291],{"id":290},"construction","Construction",[56,293,294,295,298,299,303],{},"A TSS typically contains 50–150 small high-efficiency ",[63,296,297],{"href":144},"cyclone separators"," in parallel inside a common vessel. Each cyclone has its own ",[63,300,302],{"href":301},"\u002Fglossary\u002Fcyclone-dipleg","dipleg"," that drains into a common collection hopper.",[69,305,307],{"id":306},"failure-modes","Failure modes",[74,309,310,316,322],{},[77,311,312,315],{},[59,313,314],{},"Individual cyclone pluggage"," — fines bridge in a single dipleg, that cyclone bypasses gas to neighbours",[77,317,318,321],{},[59,319,320],{},"Common hopper bridging"," — the collection hopper plugs, backing up all the diplegs above",[77,323,324,327],{},[59,325,326],{},"Cyclone erosion"," — the high catalyst-fines velocity wears cyclone walls",[69,329,233],{"id":232},[56,331,332,334],{},[63,333,123],{"href":122}," on the TSS common hopper prevent fines bridging. This protects the entire TSS-and-expander train from the cascading consequences of single-point hopper failures.",[69,336,128],{"id":127},[74,338,339,343,347],{},[77,340,341],{},[63,342,135],{"href":65},[77,344,345],{},[63,346,47],{"href":163},[77,348,349],{},[63,350,145],{"href":144},{"title":152,"searchDepth":153,"depth":153,"links":352},[353,354,355,356],{"id":290,"depth":153,"text":291},{"id":306,"depth":153,"text":307},{"id":232,"depth":153,"text":233},{"id":127,"depth":153,"text":128},"A third-stage separator (TSS) is the high-efficiency cyclone vessel installed downstream of the FCC regenerator to recover very fine catalyst fines that escape the regenerator's primary and secondary cyclones. The TSS protects downstream equipment — particularly the power-recovery expander — from catalyst erosion.",{},[165,263,167],{"title":361,"description":362},"Third-stage separator (TSS) — catalyst fines recovery downstream of FCC regenerator","A third-stage separator recovers very fine catalyst fines from the FCC regenerator flue gas using high-efficiency cyclones. Pluggage of the underflow leg is a chronic operational issue.",[364],{"title":174,"url":175},"glossary\u002Fthird-stage-separator","Third-stage separator","yToxyEBVBQDrPPM3N30Kt7IP32yOq9Lkr-84ytzrJOE",{"id":369,"title":145,"aliases":370,"body":374,"category":488,"description":489,"extension":160,"meta":490,"navigation":162,"path":144,"relatedTerms":491,"seo":496,"sources":499,"stem":503,"term":145,"__hash__":504},"glossary\u002Fglossary\u002Fcyclone-separator.md",[371,372,373],"cyclone","cyclones","gas cyclone",{"type":53,"value":375,"toc":482},[376,385,389,421,425,445,449,454,456],[56,377,280,378,381,382,384],{},[59,379,380],{},"cyclone separator"," removes particulate from a gas stream by centrifugal force: gas enters tangentially at the top of a vertical cylinder, spirals downward, and exits axially at the top through an inner pipe (vortex finder); heavier particles are thrown outward to the wall, slide down the conical bottom, and discharge through the ",[63,383,302],{"href":301}," below.",[69,386,388],{"id":387},"where-cyclones-are-used","Where cyclones are used",[74,390,391,398,405,418],{},[77,392,393,397],{},[63,394,396],{"href":395},"\u002Fglossary\u002Fcfb-boiler","CFB boiler"," primary separators — large-diameter, high-temperature",[77,399,400,404],{},[63,401,403],{"href":402},"\u002Fglossary\u002Fpreheater-cyclone","Cement preheater cyclones"," — multi-stage gas-to-meal heat exchange",[77,406,407,408,412,413,417],{},"Pre-cleaners ahead of ",[63,409,411],{"href":410},"\u002Fglossary\u002Fbaghouse","baghouses"," and ",[63,414,416],{"href":415},"\u002Fglossary\u002Felectrostatic-precipitator","ESPs"," — knock out coarse dust to reduce downstream load",[77,419,420],{},"Process gas separation in chemical and refining duty",[69,422,424],{"id":423},"cyclone-fouling","Cyclone fouling",[74,426,427,433,439],{},[77,428,429,432],{},[59,430,431],{},"Wall build-up"," — dust accretes on the wall and gradually narrows the gas path; flow re-organises and efficiency drops",[77,434,435,438],{},[59,436,437],{},"Dipleg pluggage"," — separated material backs up in the dipleg, eventually re-entraining",[77,440,441,444],{},[59,442,443],{},"Vortex finder fouling"," — alters internal swirl pattern",[69,446,448],{"id":447},"cleaning","Cleaning",[56,450,451,453],{},[63,452,123],{"href":122}," installed on the cyclone shell or dipleg keep wall deposits from consolidating. On cement preheater cyclones particularly, sonic horns are the standard preventive against the coatings that form under alternative-fuel firing.",[69,455,128],{"id":127},[74,457,458,464,469,473,478],{},[77,459,460],{},[63,461,463],{"href":462},"\u002Fglossary\u002Fmulti-cyclone-multiclone","Multi-cyclone \u002F multiclone",[77,465,466],{},[63,467,468],{"href":301},"Cyclone dipleg",[77,470,471],{},[63,472,396],{"href":395},[77,474,475],{},[63,476,477],{"href":402},"Preheater cyclone",[77,479,480],{},[63,481,150],{"href":122},{"title":152,"searchDepth":153,"depth":153,"links":483},[484,485,486,487],{"id":387,"depth":153,"text":388},{"id":423,"depth":153,"text":424},{"id":447,"depth":153,"text":448},{"id":127,"depth":153,"text":128},"hrsg-gas-path","A cyclone separator removes particulate from a gas stream by centrifugal force: gas enters tangentially at the top of a vertical cylinder, spirals downward, and exits axially at the top through an inner pipe (vortex finder); heavier particles are thrown outward to the wall, slide down the conical bottom, and discharge through the dipleg below.",{},[492,493,494,495,168],"multi-cyclone-multiclone","cyclone-dipleg","cfb-boiler","preheater-cyclone",{"title":497,"description":498},"Cyclone separator — centrifugal particulate-removal device","A cyclone separator removes particulate from a gas stream by centrifugal force. Wall build-up and re-entrainment from the dipleg are the dominant operational issues.",[500],{"title":501,"url":502},"Wikipedia — Cyclonic separation","https:\u002F\u002Fen.wikipedia.org\u002Fwiki\u002FCyclonic_separation","glossary\u002Fcyclone-separator","q8drrAFN5eVbx6KETEHT-VxRny2DelPTSLsYv0Fj2dU",{"id":506,"title":150,"aliases":507,"body":511,"category":717,"description":718,"extension":160,"meta":719,"navigation":162,"path":122,"relatedTerms":720,"seo":727,"sources":730,"stem":740,"term":150,"__hash__":741},"glossary\u002Fglossary\u002Fsonic-horn.md",[508,509,510],"sonic horns","sonic cleaning horn","industrial sonic horn",{"type":53,"value":512,"toc":710},[513,542,546,554,558,626,630,666,670,678,680],[56,514,280,515,518,519,523,524,526,527,526,530,526,534,412,538,67],{},[59,516,517],{},"sonic horn"," is a pneumatically-driven sound emitter that produces high-intensity, low-frequency sound waves — typically between 60 and 400 Hz at sound pressure levels of 140 to 180 dB — used to dislodge particulate fouling from inside industrial process equipment. Sonic horns are the most common form of ",[63,520,522],{"href":521},"\u002Fglossary\u002Facoustic-cleaner","acoustic cleaner"," and the default specification for cleaning ",[63,525,416],{"href":415},", ",[63,528,411],{"href":529},"\u002Fglossary\u002Ffabric-filter",[63,531,533],{"href":532},"\u002Fglossary\u002Fselective-catalytic-reduction","SCR catalysts",[63,535,537],{"href":536},"\u002Fglossary\u002Fsuperheater","boiler heat-transfer surfaces",[63,539,541],{"href":540},"\u002Fglossary\u002Fhopper","hoppers and silos",[69,543,545],{"id":544},"how-a-sonic-horn-works","How a sonic horn works",[56,547,548,549,553],{},"Compressed plant air admitted through a ",[63,550,552],{"href":551},"\u002Fglossary\u002Fsolenoid-valve","solenoid valve"," drives a metal diaphragm — typically titanium or 316 stainless — into resonant oscillation at the horn's fundamental frequency. The oscillating pressure field is amplified by an exponential bell horn and projected into the vessel as a near-spherical sound wave. Particulate already deposited on internal surfaces receives an oscillating acceleration that overcomes adhesion; loosened material is then carried out with the gas flow before it can sinter, bridge or bond. Because the cleaning is acoustic and non-contact, the horn can fire while the plant is online without tube erosion, refractory damage or thermal shock.",[69,555,557],{"id":556},"key-parameters","Key parameters",[559,560,561,574],"table",{},[562,563,564],"thead",{},[565,566,567,571],"tr",{},[568,569,570],"th",{},"Parameter",[568,572,573],{},"Typical range",[575,576,577,586,594,602,610,618],"tbody",{},[565,578,579,583],{},[580,581,582],"td",{},"Fundamental frequency",[580,584,585],{},"60–400 Hz",[565,587,588,591],{},[580,589,590],{},"Sound pressure level",[580,592,593],{},"140–180 dB",[565,595,596,599],{},[580,597,598],{},"Compressed-air consumption",[580,600,601],{},"8–14 Nm³\u002Fmin at 4–7 bar",[565,603,604,607],{},[580,605,606],{},"Operating temperature (with appropriate materials)",[580,608,609],{},"−40 °C to +500 °C",[565,611,612,615],{},[580,613,614],{},"Firing cycle",[580,616,617],{},"5–15 s burst, repeated every 3–15 minutes",[565,619,620,623],{},[580,621,622],{},"Mass",[580,624,625],{},"15–60 kg depending on horn size",[69,627,629],{"id":628},"frequency-selection","Frequency selection",[56,631,632,633,526,636,640,641,526,645,649,650,526,653,657,658,412,662,67],{},"Lower frequencies (60–125 Hz) project longer wavelengths and penetrate further into large open vessels — ",[63,634,635],{"href":402},"preheater cyclones",[63,637,639],{"href":638},"\u002Fglossary\u002Frecovery-boiler","recovery-boiler superheaters",", large ",[63,642,644],{"href":643},"\u002Fglossary\u002Fesp-field-bus-section","ESP fields",[63,646,648],{"href":647},"\u002Fglossary\u002Fsilo","silos",". Higher frequencies (230–400 Hz) carry more energy per unit volume and suit finer dust loads in ",[63,651,652],{"href":529},"fabric-filter compartments",[63,654,656],{"href":655},"\u002Fglossary\u002Fhoneycomb-catalyst","catalyst layers"," and smaller hopper geometries. See ",[63,659,661],{"href":660},"\u002Fglossary\u002Flow-frequency-acoustic-cleaner","low-frequency acoustic cleaner",[63,663,665],{"href":664},"\u002Fglossary\u002Fhigh-frequency-acoustic-cleaner","high-frequency acoustic cleaner",[69,667,669],{"id":668},"sonic-horn-vs-steam-sootblower","Sonic horn vs steam sootblower",[56,671,672,673,677],{},"Sonic horns are increasingly specified alongside or in place of ",[63,674,676],{"href":675},"\u002Fglossary\u002Fsteam-sootblower","steam sootblowers"," because they consume no boiler-grade steam, cause no tube erosion, require almost no moving parts and can fire every few minutes without operator intervention. They are less effective on hard, fused slag than retractable steam lances, so on furnace waterwalls and high-temperature superheaters they typically complement rather than replace mechanical cleaning.",[69,679,128],{"id":127},[74,681,682,687,693,699,705],{},[77,683,684],{},[63,685,686],{"href":521},"Acoustic cleaner",[77,688,689],{},[63,690,692],{"href":691},"\u002Fglossary\u002Fsonic-sootblower","Sonic sootblower",[77,694,695],{},[63,696,698],{"href":697},"\u002Fglossary\u002Fbell-horn","Bell horn",[77,700,701],{},[63,702,704],{"href":703},"\u002Fglossary\u002Fdiaphragm-horn","Diaphragm horn",[77,706,707],{},[63,708,709],{"href":660},"Low-frequency acoustic cleaner",{"title":152,"searchDepth":153,"depth":153,"links":711},[712,713,714,715,716],{"id":544,"depth":153,"text":545},{"id":556,"depth":153,"text":557},{"id":628,"depth":153,"text":629},{"id":668,"depth":153,"text":669},{"id":127,"depth":153,"text":128},"core-technology","A sonic horn is a pneumatically-driven sound emitter that produces high-intensity, low-frequency sound waves — typically between 60 and 400 Hz at sound pressure levels of 140 to 180 dB — used to dislodge particulate fouling from inside industrial process equipment. Sonic horns are the most common form of acoustic cleaner and the default specification for cleaning ESPs, baghouses, SCR catalysts, boiler heat-transfer surfaces and hoppers and silos.",{},[721,722,723,724,725,726],"acoustic-cleaner","acoustic-cleaning-system","sonic-sootblower","bell-horn","diaphragm-horn","low-frequency-acoustic-cleaner",{"title":728,"description":729},"Sonic horn — definition, frequency, SPL and industrial applications","A sonic horn is a pneumatically-driven low-frequency sound emitter (typically 60–400 Hz at 140–180 dB SPL) used to dislodge particulate fouling from boilers, ESPs, baghouses and process vessels.",[731,734,737],{"title":732,"url":733},"Power Engineering — Sonic Horns: A User's Introduction","https:\u002F\u002Fwww.power-eng.com\u002Fcoal\u002Fsonic-horns-a-userrsquos-introduction\u002F",{"title":735,"url":736},"Power Engineering — Tuning in to Acoustic Cleaning","https:\u002F\u002Fwww.power-eng.com\u002Fcoal\u002Ftuning-in-to-acoustic-cleaning\u002F",{"title":738,"url":739},"Wikipedia — Sonic soot blowers","https:\u002F\u002Fen.wikipedia.org\u002Fwiki\u002FSonic_soot_blowers","glossary\u002Fsonic-horn","YzrhN0kKzqSaQo0wfn0rueNZ-V43mcg5zahqeWi3lnU",1782613756973]