[{"data":1,"prerenderedAt":505},["ShallowReactive",2],{"site-footer-common":3,"glossary:third-stage-separator":45,"glossary-related:third-stage-separator":173},{"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":51,"category":153,"description":154,"extension":155,"meta":156,"navigation":157,"path":158,"relatedTerms":159,"seo":163,"sources":166,"stem":170,"term":171,"__hash__":172},"glossary\u002Fglossary\u002Fthird-stage-separator.md","Third-stage separator (TSS)",[49,50],"TSS","FCC third-stage separator",{"type":52,"value":53,"toc":145},"minimark",[54,69,74,87,91,113,117,124,128],[55,56,57,58,62,63,68],"p",{},"A ",[59,60,61],"strong",{},"third-stage separator (TSS)"," is the high-efficiency cyclone vessel installed downstream of the ",[64,65,67],"a",{"href":66},"\u002Fglossary\u002Ffcc-regenerator","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.",[70,71,73],"h2",{"id":72},"construction","Construction",[55,75,76,77,81,82,86],{},"A TSS typically contains 50–150 small high-efficiency ",[64,78,80],{"href":79},"\u002Fglossary\u002Fcyclone-separator","cyclone separators"," in parallel inside a common vessel. Each cyclone has its own ",[64,83,85],{"href":84},"\u002Fglossary\u002Fcyclone-dipleg","dipleg"," that drains into a common collection hopper.",[70,88,90],{"id":89},"failure-modes","Failure modes",[92,93,94,101,107],"ul",{},[95,96,97,100],"li",{},[59,98,99],{},"Individual cyclone pluggage"," — fines bridge in a single dipleg, that cyclone bypasses gas to neighbours",[95,102,103,106],{},[59,104,105],{},"Common hopper bridging"," — the collection hopper plugs, backing up all the diplegs above",[95,108,109,112],{},[59,110,111],{},"Cyclone erosion"," — the high catalyst-fines velocity wears cyclone walls",[70,114,116],{"id":115},"sonic-horn-duty","Sonic-horn duty",[55,118,119,123],{},[64,120,122],{"href":121},"\u002Fglossary\u002Fsonic-horn","Sonic horns"," 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.",[70,125,127],{"id":126},"related-terms","Related terms",[92,129,130,134,140],{},[95,131,132],{},[64,133,67],{"href":66},[95,135,136],{},[64,137,139],{"href":138},"\u002Fglossary\u002Ffluid-catalytic-cracking","Fluid catalytic cracking (FCC)",[95,141,142],{},[64,143,144],{"href":79},"Cyclone separator",{"title":146,"searchDepth":147,"depth":147,"links":148},"",2,[149,150,151,152],{"id":72,"depth":147,"text":73},{"id":89,"depth":147,"text":90},{"id":115,"depth":147,"text":116},{"id":126,"depth":147,"text":127},"steel-refining","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.","md",{},true,"\u002Fglossary\u002Fthird-stage-separator",[160,161,162],"fcc-regenerator","fluid-catalytic-cracking","cyclone-separator",{"title":164,"description":165},"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.",[167],{"title":168,"url":169},"Wikipedia — Fluid catalytic cracking","https:\u002F\u002Fen.wikipedia.org\u002Fwiki\u002FFluid_catalytic_cracking","glossary\u002Fthird-stage-separator","Third-stage separator","yToxyEBVBQDrPPM3N30Kt7IP32yOq9Lkr-84ytzrJOE",[174,264,368],{"id":175,"title":67,"aliases":176,"body":179,"category":153,"description":253,"extension":155,"meta":254,"navigation":157,"path":66,"relatedTerms":255,"seo":257,"sources":260,"stem":262,"term":67,"__hash__":263},"glossary\u002Fglossary\u002Ffcc-regenerator.md",[177,178],"FCCU regenerator","catalyst regenerator (FCC)",{"type":52,"value":180,"toc":248},[181,195,199,225,227,232,234],[55,182,183,184,186,187,190,191,194],{},"The ",[59,185,67],{}," burns coke deposits off spent ",[64,188,189],{"href":138},"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 ",[64,192,193],{"href":158},"third-stage"," external) before going to either a CO boiler or a power-recovery expander.",[70,196,198],{"id":197},"fouling-concerns","Fouling concerns",[92,200,201,207,213,219],{},[95,202,203,206],{},[59,204,205],{},"Catalyst fines accumulation"," in the regenerator cyclone hoppers",[95,208,209,212],{},[59,210,211],{},"Refractory-debris accretion"," in flue-gas paths after major outages",[95,214,215,218],{},[59,216,217],{},"Pluggage"," in the third-stage separator's dipleg",[95,220,221,224],{},[59,222,223],{},"Dust hopper bridging"," below catalyst recovery equipment",[70,226,116],{"id":115},[55,228,229,231],{},[64,230,122],{"href":121}," 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.",[70,233,127],{"id":126},[92,235,236,240,244],{},[95,237,238],{},[64,239,139],{"href":138},[95,241,242],{},[64,243,47],{"href":158},[95,245,246],{},[64,247,144],{"href":79},{"title":146,"searchDepth":147,"depth":147,"links":249},[250,251,252],{"id":197,"depth":147,"text":198},{"id":115,"depth":147,"text":116},{"id":126,"depth":147,"text":127},"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.",{},[161,256,162],"third-stage-separator",{"title":258,"description":259},"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.",[261],{"title":168,"url":169},"glossary\u002Ffcc-regenerator","DpReoa4qbfh8C45PkBcJ174yiPEs8Rat2sKozgNoBCM",{"id":265,"title":139,"aliases":266,"body":269,"category":153,"description":356,"extension":155,"meta":357,"navigation":157,"path":138,"relatedTerms":358,"seo":360,"sources":363,"stem":365,"term":366,"__hash__":367},"glossary\u002Fglossary\u002Ffluid-catalytic-cracking.md",[189,267,268],"fluid catalytic cracker","cat cracker",{"type":52,"value":270,"toc":351},[271,280,284,320,324,330,332],[55,272,273,275,276,279],{},[59,274,139],{}," 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 ",[64,277,278],{"href":66},"regenerator",".",[70,281,283],{"id":282},"cleaning-targets-in-the-fcc-complex","Cleaning targets in the FCC complex",[92,285,286,292,301,308,314],{},[95,287,288,291],{},[59,289,290],{},"Riser-reactor cyclones"," — separate spent catalyst from hydrocarbon vapour",[95,293,294,300],{},[59,295,296,299],{},[64,297,298],{"href":66},"Regenerator"," primary and secondary cyclones"," — separate regenerated catalyst from flue gas",[95,302,303,307],{},[59,304,305],{},[64,306,47],{"href":158}," — recovers catalyst fines from flue gas",[95,309,310,313],{},[59,311,312],{},"CO boiler"," — burns regenerator flue-gas CO for energy recovery",[95,315,316,319],{},[59,317,318],{},"Catalyst fines hopper"," — fine catalyst recovered from the gas-cleaning train",[70,321,323],{"id":322},"sonic-horn-fit","Sonic-horn fit",[55,325,326,327,329],{},"Refinery FCC units are demanding applications: high temperature, abrasive catalyst, continuous 24\u002F7 operation, very high economic stakes per outage hour. ",[64,328,122],{"href":121}," 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.",[70,331,127],{"id":126},[92,333,334,338,342,346],{},[95,335,336],{},[64,337,67],{"href":66},[95,339,340],{},[64,341,47],{"href":158},[95,343,344],{},[64,345,144],{"href":79},[95,347,348],{},[64,349,350],{"href":121},"Sonic horn",{"title":146,"searchDepth":147,"depth":147,"links":352},[353,354,355],{"id":282,"depth":147,"text":283},{"id":322,"depth":147,"text":323},{"id":126,"depth":147,"text":127},"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.",{},[160,256,162,359],"sonic-horn",{"title":361,"description":362},"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.",[364],{"title":168,"url":169},"glossary\u002Ffluid-catalytic-cracking","Fluid catalytic cracking","diPDdTnBdIwbDyqAnpcyroreLKX4t7Klq-iKud3gfHU",{"id":369,"title":144,"aliases":370,"body":374,"category":488,"description":489,"extension":155,"meta":490,"navigation":157,"path":79,"relatedTerms":491,"seo":496,"sources":499,"stem":503,"term":144,"__hash__":504},"glossary\u002Fglossary\u002Fcyclone-separator.md",[371,372,373],"cyclone","cyclones","gas cyclone",{"type":52,"value":375,"toc":482},[376,385,389,421,425,445,449,454,456],[55,377,57,378,381,382,384],{},[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 ",[64,383,85],{"href":84}," below.",[70,386,388],{"id":387},"where-cyclones-are-used","Where cyclones are used",[92,390,391,398,405,418],{},[95,392,393,397],{},[64,394,396],{"href":395},"\u002Fglossary\u002Fcfb-boiler","CFB boiler"," primary separators — large-diameter, high-temperature",[95,399,400,404],{},[64,401,403],{"href":402},"\u002Fglossary\u002Fpreheater-cyclone","Cement preheater cyclones"," — multi-stage gas-to-meal heat exchange",[95,406,407,408,412,413,417],{},"Pre-cleaners ahead of ",[64,409,411],{"href":410},"\u002Fglossary\u002Fbaghouse","baghouses"," and ",[64,414,416],{"href":415},"\u002Fglossary\u002Felectrostatic-precipitator","ESPs"," — knock out coarse dust to reduce downstream load",[95,419,420],{},"Process gas separation in chemical and refining duty",[70,422,424],{"id":423},"cyclone-fouling","Cyclone fouling",[92,426,427,433,439],{},[95,428,429,432],{},[59,430,431],{},"Wall build-up"," — dust accretes on the wall and gradually narrows the gas path; flow re-organises and efficiency drops",[95,434,435,438],{},[59,436,437],{},"Dipleg pluggage"," — separated material backs up in the dipleg, eventually re-entraining",[95,440,441,444],{},[59,442,443],{},"Vortex finder fouling"," — alters internal swirl pattern",[70,446,448],{"id":447},"cleaning","Cleaning",[55,450,451,453],{},[64,452,122],{"href":121}," 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.",[70,455,127],{"id":126},[92,457,458,464,469,473,478],{},[95,459,460],{},[64,461,463],{"href":462},"\u002Fglossary\u002Fmulti-cyclone-multiclone","Multi-cyclone \u002F multiclone",[95,465,466],{},[64,467,468],{"href":84},"Cyclone dipleg",[95,470,471],{},[64,472,396],{"href":395},[95,474,475],{},[64,476,477],{"href":402},"Preheater cyclone",[95,479,480],{},[64,481,350],{"href":121},{"title":146,"searchDepth":147,"depth":147,"links":483},[484,485,486,487],{"id":387,"depth":147,"text":388},{"id":423,"depth":147,"text":424},{"id":447,"depth":147,"text":448},{"id":126,"depth":147,"text":127},"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.",{},[492,493,494,495,359],"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",1782613757642]