FCC Cyclones – Fourth Stage & Catalyst Hopper Cyclones

FCC Cyclones – Fourth Stage & Catalyst Hopper Cyclones


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 – Fourth Stage Cyclones

The Cyclone Vessel, which is the common hopper for the cyclone catalyst discharge, is designed to hold the catalyst collected over several days. However, normally the catalyst from the Cyclone Vessel is continuously conveyed to the Fourth Stage Cyclone by a small amount of gas, usually from 1 to 3% of the gases entering the cyclones. During the travel through the un-insulated line and the Fourth Stage Cyclone, a considerable amount of heat is lost from the catalyst and gases.

Additional cooling of the catalyst occurs in the Fines Collection Vessel. The gases from the Fourth Stage Cyclone pass through a critical orifice where the gas pressure is reduced for discharge through the stack. When the Fines Collection Vessel is to be emptied into a closed truck for transport to a land fill, the valve above the vessel is closed, a vent valve is opened to relieve the pressure, and the valve beneath the vessel is opened so that the catalyst may discharge into the truck.

FCC Cyclones – Catalyst Hopper Cyclones

Our Catalyst Hopper Cyclones are easily adaptable to a variety of applications, including loading and/or unloading of Fresh and Spent Catalyst Hoppers, or as auxiliary hoppers for special additives.  These cyclones are typically designed to minimize catalyst lost to atmosphere in the vent from the hopper during loading and/or unloading operations of the hopper.

Emtrol-Buell has blazed a path and leadership role for over 120 years by developing dependable, innovative equipment for refineries. Emtrol-Buell FCC Cyclone systems are meticulously crafted to process heavy petroleum and surpass everything else on the market. We use advanced engineering techniques to provide processing equipment like our Fourth Stage & Catalyst Hopper Cyclones that are capable of running for years and years without maintenance. This attention of detail ensures that we can provide peace of mind and satisfy you with the quality performance of a critical step in the petroleum refining process.

There are many potential problems that can suspend the oil refining process, so it is essential that your facility meets the highest industry protocols and applies advanced systems to prevent issues from arising. You deserve the best industry has to offer. Our brand leads the industry in supplying respected, custom-designed Cyclone systems to refineries and petrochemical plants around the globe.

Emtrol-Buell produces the highest quality FCC Cyclones for all stages of refining, so start to finish your company can employ the highest quality technology. Our customized equipment is perfectly designed for your unique application. We build ideal equipment for any and all facilities. When choosing a company to satisfy your refinery’s needs, choose the company that provides more FCC Cyclone units to refineries and plants than any other. You should be proud of the equipment you use. Choose Emtrol-Buell.

Features & Benefits

  • 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
  • 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

Islandia, NY, USA

Phone: 631-582-9700, ext. 211


Lebanon, PA, USA

Phone: 717-274-7258


United Kingdom

Phone: 44-1480-475071


Scarborough, ON, Canada

Phone: 416-287-6606