Cyclone separators

Abstract

Cyclone separators may include an outer shell defining an interior region of the cyclone separator, an inlet port, a gas outlet port, a solids outlet port, and a cyclone outlet tube extending through the gas outlet port into the interior region of the cyclone separator. The cyclone outlet tube may have a substantially cylindrical wall and a top wall having an upper surface and an opening. The cyclone separator may include a nozzle extending through the opening of the top wall, wherein the nozzle comprises a wall having an outer surface. The cyclone separator may include a support apparatus having a body that extends from a first edge in direct contact with the outer surface of the wall of the nozzle to a second edge in direct contact with the upper surface of the top wall of the cyclone outlet tube. The first edge may be circular in shape.

Description

CYCLONE SEPARATORSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application Serial No. 63 / 649,529 filed May 20, 2024, the contents of which are incorporated in their entirety herein.TECHNICAL FIELD

[0002] Embodiments described herein generally relate to separation apparatuses and techniques and, more specifically, to methods and systems for separating solids from gasses.BACKGROUND

[0003] Many industrial chemical processes utilize fluidized solid particulates, such as catalysts, that may be separated from the gaseous mediums in which they are fluidized. For example, light olefins may be produced through catalytic processes, such as catalytic dehydrogenation, in which a feed stream is contacted with a fluidized catalyst that facilitates conversion of the feed stream into the light olefins. Gas / solid separations in such processes may be performed in cyclone separators. Cyclone separators generally separate particulate solids from gaseous mediums by vortex separation (without the use of filters).SUMMARY

[0004] In some processes, it may be desirable to cool a process stream after solids and gasses of the process stream are separated. For example, undesired thermal cracking of product gasses in a process stream may be mitigated by cooling the product gasses with a quench fluid. A quench fluid may be injected into the outlet tube of a cyclone separator through a nozzle. However, temperature differences between relatively hot gasses exiting the cyclone separator and relatively cool quench fluid may cause thermal stress on the connection between the nozzle and the outlet tube of the cyclone separator. Embodiments of cyclone separators described herein include a cyclone outlet tube that comprises a top wall, a nozzle extending through an opening in the top wall of the cyclone outlet tube, and a support apparatus that is directly connected to an outer surface of the nozzle and an upper surface of the top wall of the cyclone outlet tube. The support apparatus may temper the thermal gradient between the nozzle and the outlet tube and may allow the nozzle to move relative to the top wall of the cyclone outlet tube to minimize stress caused bythermal expansion and contraction. Additionally, connecting the nozzle to top wall of the cyclone outlet tube by the support apparatus may minimize the impact of erosion on the connection between the nozzle and the cyclone outlet tube, since the support apparatus is positioned away from the area through which the product gasses and quench fluids flow.

[0005] According to one or more embodiments of the present disclosure, a cyclone separator may comprise an outer shell defining an interior region of the cyclone separator, an inlet port, a gas outlet port, a solids outlet port, and a cyclone outlet tube extending through the gas outlet port into the interior region of the cyclone separator. The cyclone outlet tube may comprise a substantially cylindrical wall and a top wall comprising an upper surface and an opening. The cyclone separator may further comprise a nozzle extending through the opening of the top wall, wherein the nozzle comprises a wall having an outer surface and an inner surface. The cyclone separator may further comprise a support apparatus comprising a body that extends from a first edge to a second edge, wherein the first edge is in direct contact with the outer surface of the wall of the nozzle, wherein the second edge is in direct contact with the upper surface of the top wall of the cyclone outlet tube, and wherein the first edge is circular in shape.

[0006] Additional features and advantages of the technology disclosed herein will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the technology as described herein, including the detailed description which follows, the claims, as well as the appended drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The following detailed description of specific embodiments of the present disclosure can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:

[0008] FIG. 1 schematically depicts a vertical cross-sectional view of a cyclone separator according to one or more embodiments disclosed herein;

[0009] FIG. 2 schematically depicts a vertical cross-sectional view of a nozzle in a cyclone outlet tube according to one or more embodiments disclosed herein;

[0010] FIG. 3 schematically depicts a vertical cross-sectional view of a support member according to one or more embodiments disclosed herein;

[0011] FIG. 4 schematically depicts a top view of a cyclone separator according to one or more embodiments disclosed herein;

[0012] FIG. 5 schematically depicts a top view of a cyclone outlet tube according to one or more embodiments disclosed herein; and

[0013] FIG. 6 schematically depicts a vertical cross-sectional view of a first cyclone separator and a second cyclone separator.

[0014] It should be understood that the drawings are schematic in nature, and do not include every component of a cyclone separator commonly employed in the art. It would be known that these components are within the spirit and scope of the present embodiments disclosed. However, operational components, such as those described in the present disclosure, may be added to the embodiments described in this disclosure. Reference will now be made in greater detail to various embodiments, some embodiments of which are illustrated in the accompanying drawings.DETAILED DESCRIPTION

[0015] One or more non-limiting embodiments of cyclone separators are described herein. FIG. 1 depicts an embodiment of a cyclone separator. According to one or more embodiments described herein, a nozzle 140 may be positioned on the top wall 134 of a cyclone outlet tube 130 such that a quench fluid may be passed into the cyclone outlet tube 130 to contact gasses exiting the cyclone separator. In one or more embodiments, the gasses may include reaction products, such as light olefins, and unreacted hydrocarbon feedstock. Contacting the gasses with the quench fluid may reduce the temperature of the gasses and reduce undesired thermal cracking. Undesired thermal cracking may reduce the selectivity of the reaction process for desired products, such as light olefins. The nozzle 140 may be connected to the top wall 134 of the cyclone outlet tube 130 by a support member 150. The support member 150 may reduce thermal stress on the nozzle 140 and the cyclone outlet tube 130 due to differences in temperature between the relatively cold quench fluid passing through the nozzle 140 and the relatively warm gasses exiting the cyclone separator through the cyclone outlet tube 130. Additionally, the nozzle 140 may be positionedsuch that the efficiency of the cyclone separator 100 is not negatively impacted by quench fluid injected through the nozzle 140.

[0016] Referring now to FIG. 1, a cyclone separator 100 may comprise an outer shell 110. The outer shell 110 may define an interior region 120 of the cyclone separator 100. The outer shell 110 may comprise multiple segments. In one or more embodiments, the outer shell may comprise a top wall segment 114, a main body wall segment 115, and a lower wall segment 116. In one or more embodiments, the main body wall segment 115 may be positioned between the top wall segment 114 and the lower wall segment 116. The outer shell 110 including the top wall segment 114, the main body wall segment 115, and the lower wall segment 116 may have any shape such that the cyclone separator may be suitable for separating solids from gasses.

[0017] In one or more embodiments, the main body wall segment 115 may be generally cylindrical in shape, (i.e., having a substantially circular cross-sectional shape). For example, a diameter of the portion of the interior region 120 of the cyclone separator 100 enclosed by the main body wall segment 115 may be substantially constant over a height of the main body wall segment 115. The main body wall segment 115 may have any suitable height and diameter, and the height and diameter of the main body wall segment 115 may be adjusted such that the cyclone separator is suitably sized to perform a desired separation.

[0018] In one or more embodiments, the top wall segment 114 may be connected to the main body wall segment 115 at the top of the main body wall segment 115. The top wall segment 114 may be sized such that the interior region 120 of the cyclone separator 100 is enclosed at the top of the main body wall segment 115. In one or more embodiments, the top wall segment 114 may have a substantially circular shape, without taking into account any ports or openings in the top wall segment 114. In some embodiments, when accounting for openings or other ports in the top wall segment 114, the top wall segment 114 may have a substantially annular shape. In some embodiments, the top wall segment 114 may be substantially planar. In some embodiments, the top wall segment 114 may have a convex or a concave shape.

[0019] In one or more embodiments, the lower wall segment 116 may be tapered such that a cross-sectional area of the portion of the interior region 120 of the cyclone separator 100 enclosed by the lower wall segment may decrease from a top of the lower wall segment 116 to a bottom of the lower wall segment. The lower wall segment 116 may be connected to the mainbody wall segment 115. In such embodiments, the lower wall segment 116 may have a substantially conical shape, tapering from the cross sectional area of the main body wall segment 115 to a point. In some embodiments the lower wall segment 116 may include an opening or a port at the bottom of the lower wall segment 116, such that the lower wall segment has a substantially frustoconical shape.

[0020] Still referring to FIG. 1, the cyclone separator 100 may comprise an inlet port 111 through the main body wall segment 115. The inlet port 111 may be shaped such that a process stream comprising gasses and entrained solids may be passed to the interior region 120 of the cyclone separator 100. In one or more embodiments, the inlet may be a tangential inlet. In one or more embodiments, the inlet may be an involute inlet. The inlet port 111 may be positioned at or near the top of the main body wall segment 115. For example, a top of the inlet port 111 may be positioned within a top 10%, top 5%, or even top 1% of the main body wall segment 115. In some embodiments, the top of the inlet port may be at the same height as the top of the main body wall segment 115. In one or more embodiments, the inlet port may be shaped such that the process stream passed to the cyclone separator 100 enters the interior region 120 of the cyclone separator 100 in a direction that is substantially tangential to the main body wall segment 115. For example, the inlet port 111 may be positioned such that process stream passed to the cyclone separator 100 enters the interior region 120 of the cyclone separator in a direction that is less than or equal to 30°, 20°, 10°, or even 5° degrees from a direction that is tangential to the main body wall segment 115 at the inlet port 111.

[0021] In one or more embodiments, the cyclone separator may comprise a gas outlet port 112 through the top wall segment 114. The gas outlet port 112 may be sized and positioned so that gasses passing through the cyclone separator 100 may exit the interior region 120 of the cyclone separator 100 through the gas outlet port 112. In one or more embodiments, where a cross- sectional area of the main body wall segment 115 is substantially circular, the gas outlet port 112 may be positioned on a central vertical axis 160 of the cyclone separator 100. In some embodiments, the gas outlet port 112 may be a substantially circular opening in the top wall segment 114.

[0022] In one or more embodiments, the cyclone separator 100 may comprise a solids outlet port 113 through the lower wall segment 116. The solids outlet port 113 may be sized andpositioned so that solids passing through the cyclone separator 100 may exit the interior region 120 of the cyclone separator through the solids outlet port 113. In one or more embodiments, the solids outlet port 113 may be positioned on the central vertical axis 160 of the cyclone separator 100. In some embodiments, both the gas outlet port 112 and the solids outlet port 113 may be positioned on the central vertical axis 160 of the cyclone separator. In one or more embodiments, the solids outlet port 113 may be a substantially circular opening in the lower wall segment 116 such that the lower wall segment 116 tapers from the main body wall segment 115 to the solids outlet port 113.

[0023] In one or more embodiments, a dipleg 117 may be connected to the lower wall segment 116 at the solids outlet port 113. The dipleg 117 may be a pipe, tube, conduit, or any other structure through which the solids may be passed. The dipleg 117 may be sized and positioned such that solids may move through the dipleg 117 away from the interior region 120 of the cyclone separator 100. In one or more embodiments, the dipleg 117 may be a pipe having a cross sectional area that is substantially the same as the cross sectional area of the solids outlet port 113. For example, the dipleg 117 may have a substantially circular cross sectional area in one or more embodiments.

[0024] Referring now to FIG. 1 and FIG. 2, the cyclone separator 100 comprises a cyclone outlet tube 130. The cyclone outlet tube 130 may extend through the gas outlet port 112 into the interior region 120 of the cyclone separator 100. In one or more embodiments, the cyclone outlet tube 130 may extend into the interior region 120 of the cyclone separator 100 such that a bottom 133 of the cyclone outlet tube 130 is positioned below the lowest point of the inlet port 111 and above the lowest point of the main body wall segment 115. In some embodiments, a distance from the top wall segment 114 to the bottom 133 of the cyclone outlet tube 130 may be from 0.5 to 2.0, or from 0.8 to 1.3 times a height of the inlet port 111, where the height of the inlet port is the distance from the uppermost point of the inlet port 111 to the lowest point of the inlet port 111. In one or more embodiments, the cyclone outlet tube 130 may comprise a substantially cylindrical wall 132. The substantially cylindrical wall 132 may have an inner surface 232 and an outer surface 234. Referring now to FIG. 4, in one or more embodiments, the substantially cylindrical wall 130 may enclose a space having a circular cross sectional area in a plane normal to the central vertical axis 210 of the cyclone outlet tube 130. As described herein, a “substantially cylindrical wall” refers to a wall enclosing a space having a generally circular cross-sectional area, where thecross sectional area varies by less than 15%, 10%, 5%, or even less than 1% over the height of the substantially cylindrical wall.

[0025] Referring now to FIGs. 2 and 4, the cyclone outlet tube 130 may further comprise a top wall 134. The top wall 134 may comprise an upper surface 136 and a lower surface 137. In one or more embodiments, the lower surface 137 of the top wall 134 may be directly connected to the substantially cylindrical wall 132. It should be understood that components of the system may be “directly connected” at an attachment point, such as a weld. The top wall 134 may be substantially circular in shape. In one or more embodiments, the top wall 134 may close the upper end of the cyclone outlet tube 130. The top wall 134 may comprise an opening 138. The opening 138 may have any suitable shape. For example, in some embodiments, the opening 138 may have a substantially circular shape in a plane normal to the central vertical axis 210 of the cyclone outlet tube 120. In one or more embodiments, the opening 138 may have a center. A distance from the center of the opening 138 of the top wall 134 to the central vertical axis 210 of the cyclone outlet tube 130 may be less than one half of the radius of the smallest circle circumscribing the top wall 134 of the cyclone outlet tube 130 centered on the central vertical axis 210 of the cyclone outlet tube 130. For example, the distance from the center of the opening 138 of the top wall 134 to the central vertical axis 210 of the cyclone outlet tube may be less than 0.5, 0.4, 0.3, 0.2, or even 0.1 times the radius of the smallest circle circumscribing the top wall 134 of the cyclone outlet tube 130 centered on the central vertical axis 210 of the cyclone outlet tube 130. In one or more embodiments, the opening 138 may be positioned on the top wall 134 such that the central vertical axis 210 of the cyclone outlet tube 130 extends through the opening 138. In some embodiments, the opening 138 may be centered on the central vertical axis 210 of the cyclone outlet tube 130.

[0026] Referring again to FIGs. 1 and 2, the cyclone separator 100 may comprise a nozzle 140. The nozzle 140 may extend through the opening 138 of the top wall 134 of the cyclone outlet tube 130. In one or more embodiments, the nozzle 140 may comprise a wall 142 having an outer surface 144 and an inner surface 146.

[0027] In one or more embodiments, the nozzle 140 and the top plate 134 of the cyclone outlet tube 130 are not directly connected. Referring to FIG. 3, in some embodiments, there may be a gap between the outer surface 144 of the wall 142 of the nozzle and the top wall 134 of the cyclone outlet tube 130. Without intending to be bound by theory, when the nozzle 140 is notdirectly connected to the top plate 134 of the cyclone outlet tube 130 stress due to thermal expansion and contraction on the nozzle 140 and the top wall 134 of the cyclone outlet tube 130 may be reduced. For example, relatively cold quench fluid may be passed through the nozzle 140 while relatively warm gasses may be passed through the cyclone outlet tube 130. The difference in temperature may result in thermal stress between the nozzle 140 and the top wall 134 of the cyclone outlet tube. However, when the nozzle 140 and the top wall 134 are not directly connected, the nozzle 140 may slide relative to the top plate 134 in response to thermal expansion and contraction, minimizing stress on the parts.

[0028] A central axis of the nozzle may be oriented within 45° of vertical. For example, the central axis of the nozzle may be within 45°, 40°, 35°, 30°, 25°, 20°, 15°, 10°, or even within 5° of vertical. In one or more embodiments, the central axis of the nozzle 140 may be oriented vertically. In such embodiments, a central axis of the nozzle 140 may be parallel to the central vertical axis 210 of the cyclone outlet tube 130. In some embodiments, the central axis of the nozzle 140 may be the same as the central vertical axis 210 of the cyclone outlet tube 130. Without intending to be bound by theory, when the nozzle is positioned toward the center of the cyclone outlet tube 130 (i.e., when a distance from the center of the opening 138 of the top wall 134 to the central vertical axis 210 of the cyclone outlet tube 130 is less than one half of a radius of the smallest circle circumscribing the top wall 134 of the cyclone outlet tube 130, as described previously), then quench fluid entering the cyclone outlet tube 130 through the nozzle may have a minimal impact on the efficiency of the cyclone separator. Such positioning of the nozzle 140 may facilitate cooling of the vapors exiting the cyclone separator 100 through the cyclone outlet tube 130 without reducing the efficiency of the separation of particulate solids and gasses in the cyclone separator 100.

[0029] Referring now to FIG. 3, in one or more embodiments, at least a portion of the inner surface 146 of the wall 142 of the nozzle 140 may be coated with a cobalt alloy 310. In one or more embodiments, a bottom surface 145 of the wall 142 of the nozzle 140 may be coated with a cobalt alloy 310. In some embodiments, at least a portion of the inner surface 146 of the wall 142 of the nozzle 140 and at least a portion of a bottom surface 145 of the nozzle 140 are coated with a cobalt alloy 310. The cobalt alloy may be any suitable cobalt alloy. For example, the cobalt alloy may be a Stellite® alloy from Kennametal Inc., such as but not limited, to Stellite 1 or Stellite 6. Without intending to be bound by theory, including a cobalt alloy, such as Stellite, on the innersurface 146 of the wall 142 of the nozzle 140 may reduce erosion on the wall of the nozzle during operation of the cyclone separator 100.

[0030] Still referring to FIG. 3, in one or more embodiments, a lower surface 137 of the top wall 134 may be coated with a refractory material 330. The refractory material 330 is not necessarily limited and may be any suitable refractory material for use in the cyclone outlet tube 130. In some embodiments, the refractory material may be a hex mesh refractory material. In one or more embodiments, the lower surface 137 of the top wall 134 may be coated with a stellite overlay. The stellite overlay may comprise a Stellite® alloy from Kennametal Inc., such as but not limited, to Stellite 1 or Stellite 6. Without intending to be bound by theory, the refractory material or the stellite overlay may insulate the top wall 134 of the cyclone outlet tube 130. In one or more embodiments, a ring 320 may be positioned between the refractory material 330 and the outer surface 144 of the wall 142 of the nozzle. The ring 320 may be directly connected to the lower surface 137 of the top wall 134. The ring 320 may extend around the opening 138 in the top wall 134 of the cyclone outlet tube 130. In one or more embodiments, a bottom surface of the ring may be coated with a cobalt alloy 312. The cobalt alloy may be a Stellite® alloy from Kennametal Inc., such as but not limited, to Stellite 1 or Stellite 6. Without intending to be bound by theory, coating the ring 320 with the cobalt alloy may reduce erosion during operation of the cyclone separator 100.

[0031] Referring again to FIGs. 2 and 3, the cyclone separator 100 may comprise a support apparatus 150. The support apparatus 150 may comprise a body 152 that extends from a first edge 156 to a second edge 158. The first edge 156 may be in direct contact with the outer surface 144 of the wall 142 of the nozzle 140. In one or more embodiments, the first edge 156 is circular in shape. In one or more embodiments, substantially the entirety of the first edge 156 may be in direct contact with the outer surface 144 of the wall 142 of the nozzle 140. The second edge 158 may be in direct contact with the upper surface 136 of the top wall 134 of the cyclone outlet tube 130. The shape of the second edge is not necessarily limited. In one or more embodiments, the second edge 158 may have any shape that surrounds the opening 138 of the top wall 134 of the cyclone outlet tube 130. In some embodiments, the second edge 158 of the support apparatus 150 may have a circular shape. In one or more embodiments, substantially the entirety of the second edge 158 may be in direct contact with the upper surface 136 of the top wall 134 of the cyclone outlet tube 130.

[0032] In one or more embodiments, the body 152 of the support apparatus 150 may be radially symmetrical relative to a central vertical axis of the support apparatus 150. In the embodiment depicted in FIG. 2, the central vertical axis 210 of the cyclone outlet tube 130 is also the central vertical axis of the support apparatus 150. In one or more embodiments, the first edge 156 of the support apparatus 150 may face the central vertical axis of the support apparatus 150. The body 152 of the support apparatus 150 may be curved such that the second edge 158 is normal to the central vertical axis of the support apparatus 150.

[0033] Without intending to be bound by theory, connecting the nozzle 140 to the cyclone outlet tube 130 by the support apparatus 150 may allow the nozzle to slide relative to the cyclone outlet tube 130 due to differences in thermal expansion between the nozzle and the cyclone outlet tube 130. The gaseous effluent exiting the cyclone separator 100 through the cyclone outlet tube 130 may be relatively hot and quench fluid entering the cyclone outlet tube 130 through the nozzle 140 may be relatively cold. Due to the difference in temperature, thermal expansion and contraction of the cyclone outlet tube 130 may be different from the nozzle 140, which could cause stress. Using the support apparatus 150 to connect the nozzle 140 and the cyclone outlet tube 130 may mitigate this stress by providing an intervening structure between the nozzle 140 and the cyclone outlet tube 130.

[0034] In one or more embodiments, the support apparatus 150 may have an inner surface 154 and an outer surface 155. The inner surface 154 may be substantially opposite the outer surface 155. In one or more embodiments, the body 152 of the support apparatus 150 may be shaped such that a distance between the inner surface 154 and the outer surface 155 of the support apparatus 150 is substantially constant from the first edge 156 to the second edge 158 of the support apparatus 150. In one or more embodiments, the inner surface 154 of the support apparatus 150 may face the upper surface 136 of the top wall 134 of the cyclone outlet tube 130 and the outer surface 144 of the wall 142 of the nozzle 140.

[0035] Referring now to FIG. 3, the body of the support apparatus 152 may be shaped such that there is a space between the inner surface 154 of the support apparatus 150, the upper surface 136 of the top wall 134 of the cyclone outlet tube 130, and the outer surface 144 of the wall 142 of the nozzle 140. In one or more embodiments, a refractory material 410 may be positioned between the inner surface 154 of the support apparatus, the upper surface 136 of the top wall 134of the cyclone outlet tube 130, and the outer surface 144 of the wall 142 of the nozzle. The refractory material 410 is not necessarily limited. Without intending to be bound by theory, positioning refractory material between the inner surface 154 of the support apparatus 150, the upper surface 136 of the top wall 134 of the cyclone outlet tube 130, and the outer surface 144 of the wall 142 of the nozzle 140 may insulate quench fluid passing through the nozzle from the relatively hot gasses exiting the cyclone separator 100 through the cyclone outlet tube 130.

[0036] Referring again to FIG. 2, a top surface 147 of the wall 142 of the nozzle 140 is connected to a pipe 160. Referring now to FIGs. 1 and 5, the pipe 160 may comprise a plurality of bends. The bends in the pipe 160 may be sized such that the pipe 160 has sufficient flexibility to withstand movement due to thermal expansion and contraction of the cyclone separator 100. In some embodiments, the pipe 160 may be insulated. In such embodiments, a sleeve of insulation (not shown) may surround the pipe 160. Without intending to be bound by theory, insulating the pipe 160 may keep quench fluid passing through the pipe 160 cool. In some embodiments, the pipe 160 is not insulated.

[0037] In one or more embodiments, a wall thickness of the pipe 160 may be less than a wall thickness of the nozzle 140. As described herein, “wall thickness of the pipe 160” refers to the distance between the inner surface 162 and the outer surface 164 of the pipe 160 on a radius of the pipe 160. The “wall thickness of the nozzle 140” refers to the distance between the inner surface 146 and the outer surface 144 of the wall 142 of the nozzle 140 at a midpoint between the bottom surface 145 and the top surface 147 of the wall 142 of the nozzle 140. As depicted in FIGs. 2 and 3, a top portion of the wall 142 of the nozzle 140 may taper toward the top surface 147 of the wall 142 where the pipe 160 connects to the nozzle 140. In some embodiments a wall thickness of the pipe 160 is less than 50%, 45%, 40%, 35%, 30%, or 25% of the wall thickness of the nozzle 140. Without intending to be bound by theory, reducing the wall thickness of the pipe 160 may increase the flexibility of the pipe 160. This may reduce stress on the pipe due to thermal expansion and contraction of the cyclone separator 100 and the system in which the cyclone separator 100 is used.

[0038] Referring now to FIG. 6, in one or more embodiments, the substantially cylindrical wall 132 of the cyclone outlet port comprises an outlet 170. The outlet may be an opening in the substantially cylindrical wall 132 through which gasses may exit the cyclone separator 100. Theoutlet may have any suitable shape. In one or more embodiments, the outlet 170 may be connected to a crossover duct 680. The crossover duct 680 may be any tube, conduit, duct, or pipe through which the effluent of a cyclone separator 100 may be passed. In one or more embodiments, the crossover duct 680 may be in fluid communication with the inlet 611 of a second cyclone separator 600. The second cyclone separator 600 may comprise an outer shell 610 defining an interior region 620 of the second cyclone separator 600, an inlet port 611, a gas outlet port 612, and a solids outlet port 613, as described hereinabove with respect to the cyclone separator 100. The second cyclone separator 600 may be suitable for removing at least a portion of the solid particles that may be entrained in the effluent passing through the gas outlet port 112 of the cyclone separator 100. Without intending to be bound by theory, positioning the nozzle 140 at the top of the cyclone outlet tube 130 may maximize the time that relatively hot gasses exiting the cyclone separator 100 may be cooled before passing to the second cyclone separator 600. For example, positioning the nozzle 140 at the top of the cyclone outlet tube 130 may allow the quench fluid to contact gasses exiting the cyclone separator 100 through substantially the entirety of the crossover duct 680.

[0039] One or more embodiments of cyclone separators 100 described herein may be used in systems for dehydrogenating alkanes to produce light olefins. The systems for dehydrogenating alkanes may include any suitable system. Examples of systems and methods for dehydrogenating hydrocarbons are described in and International Patent Publication WO 2020 / 046978, entitled “Methods for Dehydrogenating Hydrocarbons,” and International Patent Publication WO 2016 / 160273, entitled “Integrated C3-C4 Hydrocarbon Dehydrogenation Process,” the teachings of each of which are incorporated by reference in their entirety herein. In some embodiments, a system for dehydrogenating alkanes may comprise a reactor section. The reactor section may comprise a reaction vessel, a riser, and one or more cyclone separators 100. In some embodiments, a cyclone separator 100 may be in fluid communication with the riser, such that gaseous fluids and particulate solids may be passed from the reaction vessel, through the riser, to the cyclone separator 100. In some embodiments, the cyclone separator 100 may be directly connected to the riser. In such embodiments, gasses and solids may be passed directly from the riser to the cyclone separator 100 inlet port 111 and the length of any conduits between the riser and the cyclone separator inlet port 111 may be minimized.

[0040] One or more embodiments of cyclone separators 100 described herein may be used in methods for forming light olefins. Embodiments of methods for forming light olefins that include using cyclone separators are now described in more detail.

[0041] In one or more embodiments, a method for forming light olefins may include reacting a hydrocarbon feed in the presence of a dehydrogenation catalyst in a reactor to form a dehydrogenated product. The hydrocarbon feed may comprise one or more of propane, n-butane, iso-butane, ethane, or ethylbenzene. The dehydrogenated product may comprise light olefins. As described herein, light olefins refer to ethylene, propylene, and butene. A stream comprising light olefins may comprise any one of ethylene, propylene, and butene or any combination thereof. It should be understood that the dehydrogenated product may include both reaction products and unreacted components of the hydrocarbon feed.

[0042] In one or more embodiments, a dehydrogenation reaction may utilize gallium and / or platinum catalyst as a dehydrogenation catalyst. In such embodiments, the dehydrogenation catalyst may comprise a gallium and / or platinum catalyst. For example, if the reaction is a dehydrogenation reaction, then the dehydrogenation catalyst may comprise gallium and / or platinum catalyst. As described herein, a gallium and / or platinum catalyst comprises gallium, platinum, or both. The gallium and / or platinum catalyst may be carried by an alumina or alumina silica support, and may optionally comprise potassium. Such gallium and / or platinum catalysts are disclosed in U.S. Pat. No. 8,669,406, which is incorporated herein by reference in its entirety. However, it should be understood that other suitable catalysts may be utilized to perform the dehydrogenation reaction.

[0043] Generally, the dehydrogenated product has a temperature near that of or equal to the temperature in the reactor. The temperature may depend upon the reaction and utilized catalyst system. In one or more embodiments, dehydrogenated product has a temperature of at least 550 °C (such as at least 575 °C, at least 600 °C, at least 625 °C, at least 650 °C, at least 675 °C, at least 700 °C, or even at least 725 °C). For example, when propane is dehydrogenated, the temperature of the dehydrogenated product may be approximately 620 °C (such as from 600 °C to 640 °C). When ethylbenzene is dehydrogenated, the temperature of the dehydrogenated product may be approximately 595 °C (such as from 575 °C to 615 °C). When ethane is dehydrogenated, the temperature of the dehydrogenated product may be approximately 750 °C (such as from 730 °Cto 770 °C). When butane is dehydrogenated, the temperature of the dehydrogenated product may be approximately 600 °C (such as from 580 °C to 620 °C).

[0044] In one or more embodiments, at least a portion of the dehydrogenation catalyst may be separated from the dehydrogenated product in a cyclone separator 100. The cyclone separator 100 may be any embodiment of the cyclone separators 100 described hereinabove. In one or more embodiments, a major portion of the dehydrogenated product may be passed through the cyclone outlet tube 130. As used herein, a “major portion” of a process stream refers to at least 75% of the process stream. For example, in one or more embodiments, at least 75%, at least 80%, at least 85%, at least 90%, or at least 95% of the dehydrogenated product may be passed through the cyclone outlet tube 130. In one or more embodiments, a major portion of the dehydrogenation catalyst may be passed through the solids outlet port 113. For example, at least 75%, at least 80%, at least 85%, at least 90%, or at least 95% of the dehydrogenation catalyst may be passed through the solids outlet port 113.

[0045] In one or more embodiments, a quench fluid may be passed through the nozzle 140. The quench fluid may be passed to the nozzle 140 through pipe 160. In one or more embodiments, the quench fluid may be a gas. The quench fluid passed through the nozzle 140 may be combined with the dehydrogenated product exiting the cyclone separator 100 through the cyclone outlet tube 130.

[0046] The quench fluid may have a temperature that is less than a temperature of the dehydrogenated product. In one or more embodiments, the quench fluid may have a temperature of less than 150 °C. For example, the quench fluid may have a temperature of less than 150 °C, less than 125 °C, less than 100 °C, less than 75 °C, or even less than 50 °C. In one or more embodiments, the temperature of the quench stream may be at least 200 °C less than the temperature of the dehydrogenated product (such as at least 250 °C less, at least 300 °C less, at least 350 °C less, at least 400 °C less, at least 450 °C less, or even at least 500 °C less than the temperature of the dehydrogenated product).

[0047] In one or more embodiments, combining the quench fluid with the dehydrogenated product may cool the dehydrogenated product by at least 10 °C to form a quenched product. For example, a temperature of the quenched product may be at least 10 °C, 15 °C, 20 °C, 25 °C, 30 °C, 35 °C, 40 °C, 45 °C, 50 °C, 60 °C, 70 °C, 80 °C, 90 °C, 100 °C, 110 °C, 120 °C, 130 °C, 140°C, or even 150 °C less than a temperature of the dehydrogenated product. Without intending to be bound by theory, the rate of thermal cracking of one or more of propane, n-butane, ethane, or ethylbenzene, and reaction products thereof, may be reduced in the quenched product as compared with the dehydrogenated product. For example, the rate of thermal cracking of these components in the quenched product, due at least in part to the reduction in temperature, may be less than 90%, less than 85%, less than 80%, less than 75%, less than 70%, less than 65%, less than 60%, less than 55%, less than 50%, less than 45%, less than 40%, less than 35%, less than 30%, less than 25%, less than 20%, less than 15%, less than 10%, or even less than 5% of that in the dehydrogenated product.

[0048] In some embodiments, the quenched product may be passed to a second cyclone separator 600. The second cyclone separator 600 may further separate any remaining solids, such as dehydrogenation catalyst, in the quenched product. Referring again to FIG. 6, in one or more embodiments, the quenched product may be passed through the outlet 170 of the cyclone outlet tube 130, through the crossover duct 680, an into the second cyclone separator 600 through the inlet port 611 of the second cyclone separator. Quenched product may exit the second cyclone separator 600 through the gas outlet port 612, and separated solids may exit the second cyclone separator 600 through the solids outlet port 613.

[0049] In one or more embodiments, the quenched product may be cooled to form a cooled product. The quenched product may be further cooled by any suitable means. For example, the quenched product may be cooled in a heat exchanger or in a liquid quenching system. The temperature of the cooled product may be about the same as the temperature of the quench stream, described previously. In one or more embodiments, a portion of the cooled product is used as at least a portion of the quench stream. In some embodiments, a portion of the cooled product is the quench stream. It should be understood that the chemical contents of the quench stream may be similar or identical to those of the dehydrogenation product (i.e., no further reactions outside of some residual thermal cracking have taken place since the reactor). The quenching of the dehydrogenation product by contacting with the quench stream may substantially reduce the rate of thermal cracking. The dehydrogenation product may be at a temperature, before quenching, where thermal cracking occurs and such thermal cracking may reduce selectivity of the desired reaction products.

[0050] In a first aspect of the present disclosure, a cyclone separator comprises an outer shell defining an interior region of the cyclone separator, an inlet port, a gas outlet port, a solids outlet port, and a cyclone outlet tube extending through the gas outlet port into the interior region of the cyclone separator. The cyclone outlet tube comprises a substantially cylindrical wall and a top wall comprising an upper surface and an opening. The cyclone separator further comprises a nozzle extending through the opening of the top wall, wherein the nozzle comprises a wall having an outer surface and an inner surface. The cyclone separator further comprises a support apparatus comprising a body that extends from a first edge to a second edge, wherein the first edge is in direct contact with the outer surface of the wall of the nozzle, wherein the second edge is in direct contact with the upper surface of the top wall of the cyclone outlet tube, and wherein the first edge is circular in shape.

[0051] A second aspect of the present disclosure may include the first aspect, wherein the body of the support apparatus is radially symmetrical relative to a central vertical axis of the support apparatus, and wherein the first edge surrounds the central vertical axis of the support apparatus.

[0052] A third aspect of the present disclosure may include the first aspect or the second aspect, wherein the nozzle and the top plate of the cyclone outlet tube are not directly connected.

[0053] A fourth aspect of the present disclosure may include any one of the first to third aspects, wherein a distance from a center of the opening of the top wall to a central vertical axis of the cyclone outlet tube is less than one half of a radius of the smallest circle circumscribing the top wall of the cyclone outlet tube centered on the central vertical axis of the cyclone outlet tube.

[0054] A fifth aspect of the present disclosure may include any one of the first to third aspects, wherein a central vertical axis of the cyclone outlet tube extends through the opening of the top wall.

[0055] A sixth aspect of the present disclosure may include the fourth aspect or the fifth aspect, wherein a central axis of the nozzle is parallel to the central vertical axis of the cyclone outlet tube.

[0056] A seventh aspect of the present disclosure may include any one of the first to sixth aspects, wherein an inner surface of the body of the support apparatus faces the upper surface of the top wall of the cyclone outlet tube and the outer surface of the wall of the nozzle.

[0057] An eighth aspect of the present disclosure may include the seventh aspect, wherein a refractory material is positioned between the inner surface of the support apparatus, the upper surface of the top wall of the cyclone outlet tube and the outer surface of the nozzle.

[0058] A ninth aspect of the present disclosure may include any one of the first to eighth aspects, wherein at least a portion of the inner surface of the wall of the nozzle and at least a portion of a bottom surface of the wall of the nozzle are coated with a cobalt alloy.

[0059] A tenth aspect of the present disclosure may include any one of the first to ninth aspects, wherein a top surface of the wall of the nozzle is connected to a pipe comprising a plurality of bends.

[0060] An eleventh aspect of the present disclosure may include any one of the first to tenth aspects, wherein the substantially cylindrical wall of the outlet tube comprises an outlet connected to a crossover duct, and wherein the crossover duct is in fluid communication with an inlet of a second cyclone separator.

[0061] In a twelfth aspect of the present disclosure, a method for forming light olefins comprises reacting a hydrocarbon feed in the presence of a dehydrogenation catalyst in a reactor to form a dehydrogenated product and separating at least a portion of the dehydrogenation catalyst from the dehydrogenated product in the cyclone separator. The cyclone separator comprises an outer shell defining an interior region of the cyclone separator, an inlet port, a gas outlet port, a solids outlet port, and a cyclone outlet tube extending through the gas outlet port into the interior region of the cyclone separator. The cyclone outlet tube comprises a substantially cylindrical wall and a top wall comprising an upper surface and an opening. The cyclone separator further comprises a nozzle extending through the opening of the top wall, wherein the nozzle comprises a wall having an outer surface and an inner surface. The cyclone separator further comprises a support apparatus comprising a body that extends from a first edge to a second edge, wherein the first edge is in direct contact with the outer surface of the wall of the nozzle, wherein the second edge is in direct contact with the upper surface of the top wall of the cyclone outlet tube, andwherein the first edge is circular in shape. The method further comprises passing a major portion of the dehydrogenated product through the cyclone outlet tube, passing a major portion of the dehydrogenation catalyst though the solids outlet port, passing a quench fluid through the nozzle, and combining the quench fluid with the dehydrogenated product to cool the dehydrogenated product by at least 10 °C to form a quenched product.

[0062] A thirteenth aspect of the present disclosure may include the twelfth aspect, further comprising cooling the quenched product to form a cooled product, wherein a portion of the cooled product is used as at least a portion of the quench fluid.

[0063] A fourteenth aspect of the present disclosure may include the twelfth aspect or the thirteenth aspect, wherein the quench fluid is a gas.

[0064] A fifteenth aspect of the present disclosure may include any one of the twelfth to fourteenth aspects, wherein a temperature of the quench fluid is at least 300 °C less than a temperature of the dehydrogenated product.

[0065] ft is noted that one or more of the following claims utilize the term “wherein” as a transitional phrase. For the purposes of defining the present technology, it is noted that this term is introduced in the claims as an open-ended transitional phrase that is used to introduce a recitation of a series of characteristics of the structure and should be interpreted in like manner as the more commonly used open-ended preamble term “comprising.”

[0066] ft should be understood that where a first component is described as “comprising” a second component, it is contemplated that, in some embodiments, the first component “consists of’ or “consists essentially of’ that second component. Additionally, the term “consisting essentially of’ is used in this disclosure to refer to quantitative values that do not materially affect the basic and novel characteristic(s) of the disclosure.

[0067] For the purposes of describing and defining the present disclosure it is noted that the terms “about” or “approximately” are utilized in this disclosure to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. The terms “about” and / or “approximately” are also utilized in this disclosure to represent the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue.

[0068] It should be understood that any two quantitative values assigned to a property may constitute a range of that property, and all combinations of ranges formed from all stated quantitative values of a given property are contemplated in this disclosure.

[0069] Generally, “inlet ports” and “outlet ports” of any system unit described herein refer to openings, holes, channels, apertures, gaps, or other like mechanical features in the system unit. For example, inlet ports allow for the entrance of materials to the particular system unit and outlet ports allow for the exit of materials from the particular system unit. Generally, an outlet port or inlet port will define the area of a system unit to which a pipe, conduit, tube, hose, material transport line, or like mechanical feature is attached, or to a portion of the system unit to which another system unit is directly attached. While inlet ports and outlet ports may sometimes be described herein functionally in operation, they may have similar or identical physical characteristics, and their respective functions in an operational system should not be construed as limiting on their physical structures.

[0070] The subject matter of the present disclosure has been described in detail and by reference to specific embodiments. It should be understood that any detailed description of a component or feature of an embodiment does not necessarily imply that the component or feature is essential to the particular embodiment or to any other embodiment. Further, it should be apparent to those skilled in the art that various modifications and variations can be made to the described embodiments without departing from the spirit and scope of the claimed subject matter.

Claims

CLAIMS1. A cyclone separator comprising: an outer shell defining an interior region of the cyclone separator; an inlet port; a gas outlet port; a solids outlet port; a cyclone outlet tube extending through the gas outlet port into the interior region of the cyclone separator, wherein the cyclone outlet tube comprises a substantially cylindrical wall and a top wall comprising an upper surface and an opening; a nozzle extending through the opening of the top wall, wherein the nozzle comprises a wall having an outer surface and an inner surface; and a support apparatus comprising a body that extends from a first edge to a second edge, wherein the first edge is in direct contact with the outer surface of the wall of the nozzle, wherein the second edge is in direct contact with the upper surface of the top wall of the cyclone outlet tube, and wherein the first edge is circular in shape.

2. The cyclone separator of claim 1, wherein the body of the support apparatus is radially symmetrical relative to a central vertical axis of the support apparatus, and wherein the first edge surrounds the central vertical axis of the support apparatus.

3. The cyclone separator of claim 1 or claim 2, wherein the nozzle and the top plate of the cyclone outlet tube are not directly connected.

4. The cyclone separator of any one of claims 1 to 3, wherein a distance from a center of the opening of the top wall to a central vertical axis of the cyclone outlet tube is less than one half of a radius of the smallest circle circumscribing the top wall of the cyclone outlet tube centered on the central vertical axis of the cyclone outlet tube.

5. The cyclone separator of any one of claims 1 to 3, wherein a central vertical axis of the cyclone outlet tube extends through the opening of the top wall.

6. The cyclone separator of any one of claim 4 or claim 5, wherein a central axis of the nozzle is parallel to the central vertical axis of the cyclone outlet tube.

7. The cyclone separator of any one of claims 1 to 6, wherein an inner surface of the body of the support apparatus faces the upper surface of the top wall of the cyclone outlet tube and the outer surface of the wall of the nozzle.

8. The cyclone separator of claim 7, wherein a refractory material is positioned between the inner surface of the support apparatus, the upper surface of the top wall of the cyclone outlet tube and the outer surface of the nozzle.

9. The cyclone separator of any one of claims 1 to 8, wherein at least a portion of the inner surface of the wall of the nozzle and at least a portion of a bottom surface of the wall of the nozzle are coated with a cobalt alloy.

10. The cyclone separator of any one of claims 1 to 9, wherein a top surface of the wall of the nozzle is connected to a pipe comprising a plurality of bends.

11. The cyclone separator of any one of claims 1 to 10, wherein the substantially cylindrical wall of the outlet tube comprises an outlet connected to a crossover duct, and wherein the crossover duct is in fluid communication with an inlet of a second cyclone separator.

12. A method for forming light olefins, the method comprising: reacting a hydrocarbon feed in the presence of a dehydrogenation catalyst in a reactor to form a dehydrogenated product; separating at least a portion of the dehydrogenation catalyst from the dehydrogenated product in the cyclone separator, wherein the cyclone separator comprises: an outer shell defining an interior region of the cyclone separator; an inlet port; a gas outlet port; a solids outlet port;a cyclone outlet tube extending through the gas outlet port into the interior region of the cyclone separator, wherein the cyclone outlet tube comprises a substantially cylindrical wall and a top wall comprising an upper surface and an opening; a nozzle extending through the opening of the top wall, wherein the nozzle comprises a wall having an outer surface and an inner surface; and a support apparatus comprising a body that extends from a first edge to a second edge, wherein the first edge is in direct contact with the outer surface of the wall of the nozzle, wherein the second edge is in direct contact with the upper surface of the top wall of the cyclone outlet tube, and wherein the first edge is circular in shape; passing a major portion of the dehydrogenated product through the cyclone outlet tube; passing a major portion of the dehydrogenation catalyst though the solids outlet port; passing a quench fluid through the nozzle; and combining the quench fluid with the dehydrogenated product to cool the dehydrogenated product by at least 10 °C to form a quenched product.

13. The method of claim 12, further comprising cooling the quenched product to form a cooled product, wherein a portion of the cooled product is used as at least a portion of the quench fluid.

14. The method of claim 12 or claim 13, wherein the quench fluid is a gas.

15. The method of any one of claims 12 to 14, wherein a temperature of the quench fluid is at least 300 °C less than a temperature of the dehydrogenated product.

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