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Separator Systems | Cyclone Separator Systems


FCC Cyclones – Third Stage Separator Systems

Fluid Catalytic Cracking Units (FCC Cyclones) are the principal technologies that enable the critical process within heavy oil refining of converting the heavy oils into more valuable gasoline and lighter products. More than half of the refinery's heavy petroleum is processed through the FCC Cyclones, and the FCC Cyclones are also an important source of butene and pentene olefins used in refinery processes.

Our Emtrol-Buell brand has supplied more FCC Cyclones to refineries and petrochemical plants worldwide than any other supplier, so our experience in this area is unequaled. Our FCC Cyclones are designed to enhance separation efficiency, accommodate increased catalyst loading, and are tailored to meet the application needs of refineries and petrochemical plants.

 We custom-engineer the following products at the highest quality:

  • FCC Cyclones - Patented Beam Hanger Support System
  • FCC Cyclones - Reactor
  • FCC Cyclones - Regenerator
  • FCC Cyclones - Third Stage Separator Systems
  • FCC Cyclones - Fourth Stage & Catalyst Hopper Cyclones


FCC Cyclones - Third Stage Separator Systems

Third Stage Separator Systems include cyclones, a containment vessel, an underflow system, catalyst storage and evacuation.

Unlike traditional third stage units designed to eliminate particles >10 micron diameter and high inlet and outlet velocities, characterized by a large number of small cyclone, Emtrol-Buell brand Third Stage Separate Systems are designed to collect as much catalyst as possible while limiting system erosion and catalyst attrition.

We utilize a pressure vessel to contain fewer, larger diameter, high efficiency cyclones sized to maintain inlet velocity (with refractory lined cyclones, erosion on cyclone surface is reduced to an acceptable level).

Unlike other systems, our technologies do not require underflow for proper operation, as solids can be discharged directed through a valve. From the final collection hopper, the fines can be off-loaded to a truck or disposal container.



  • Low Total Cost of Ownership
  • Maximum performance and efficiency
  • High reliability
  • Enhanced to increase separation efficiency
  • Premium quality material construction to withstand severe operating conditions



  • Enhanced aspect ratio of the cyclone inlet
  • New crossover duct design
  • Minimized use of edge bars in the refractory linings
  • Standard or complex designs
  • Dust hopper and lined dipleg stub designs that enhance catalyst discharge while decreasing erosion effects



Third Stage Separator Systems | FCC Cyclone Separator Systems
Separator Systems | Cyclone Separator Systems