WO2025188504A1

WO2025188504A1 - Cyclone separators

Info

Publication number: WO2025188504A1
Application number: PCT/US2025/017173
Authority: WO
Inventors: Quan Yuan; Matthew T. Pretz; Yuan Yao; Chi-Wei TSANG; Richard E. Walter; Donald F. Shaw; Albert MEZA
Original assignee: Dow Global Technologies LLC
Current assignee: Dow Global Technologies LLC
Priority date: 2024-03-06
Filing date: 2025-02-25
Publication date: 2025-09-12
Anticipated expiration: 2026-09-06
Also published as: WO2025188504A8

Abstract

A cyclone separator may include an outer shell including a top wall segment, a main body wall segment, and a lower wall segment. The outer shell defines an interior region of the cyclone separator. The cyclone separator may further include an inlet port through the main body wall segment, a gas outlet port through the top wall segment, and a solids outlet port through the lower wall segment. The cyclone separator may further include a vortex finder extending through the gas outlet port into the interior region of the cyclone separator. The vortex finder may include an inner wall and an outer wall. The cyclone separator may further include one or more nozzles positioned in the interior region of the cyclone separator.

Description

CYCLONE SEPARATORS

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application Serial No. 63/561,936 filed March 6, 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. Such gas/solid separations may be performed in cyclone separators. Cyclone separators generally separate particulate solids from gaseous mediums by vortex separation (without the use of filters). Such cyclone separators may be utilized in a wide variety of industrial processes. For example, catalytic formation of light olefins from alkenes may utilized gas/solid separations to separate product gasses from catalysts.

SUMMARY

[0004] In some chemical processes, it may be desirable to cool a processes stream as solids and gasses of the process stream are being 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. However, cooling a process stream that includes the solid particulate will cool the solid particulate, which will then need to be re-heated to reaction temperature, causing undesirable thermal loss. However, as described herein, it has been presently discovered that the process stream may be cooled within a cyclone separator by contacting at least the gasses with a quench fluid, in an interior region of the cyclone separator. Described herein are cyclone separators that are suitable for such use, where a quench stream may be injected into the cyclone separator. In particular, and as described herein, the cyclone separators may include nozzles positioned on the outer wall of the vortex finder in the interior region of the cyclone separator, and may additionally include one or more fluid conduits that run through the vortex finder, between the inner wall and the outer wall of the vortex finder, and to the one or more nozzles. Such a design may allow for injection of the quench fluid in a radial direction, which may decrease a temperature of the gasses while, in some embodiments, not cooling the solid particulate to the same degree. Hence, the gases may be cooled while the solid particulates may, generally, be preserved at a relatively high temperature.

[0005] According to one or more embodiments of the present disclosure, a cyclone separator may comprise an outer shell comprising a top wall segment, a main body wall segment, and a lower wall segment. The outer shell defines an interior region of the cyclone separator. The cyclone separator may further comprise an inlet port through the main body wall segment, a gas outlet port through the top wall segment, and a solids outlet port through the lower wall segment. The cyclone separator may further comprise a vortex finder extending through the gas outlet port into the interior region of the cyclone separator. The vortex finder may comprise an inner wall and an outer wall. The cyclone separator may further comprise one or more nozzles positioned in the interior region of the cyclone separator.

[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 horizontal cross-sectional view of a cyclone separator according to one or more embodiments disclosed herein;

[0010] FIG. 3 schematically depicts a nozzle according to one or more embodiments disclosed herein; [0011] FIG. 4 depicts a cross sectional view of a vortex finder according to one or more embodiments disclosed herein;

[0012] FIG. 5 depicts a schematic view of a nozzle according to one or more embodiments disclosed herein;

[0013] FIG. 6 schematically depicts another vertical cross-sectional view of a cyclone separator according to one or more embodiments disclosed herein; and

[0014] FIG. 7 depicts temperature modeling results of a cyclone separator and a comparative cyclone separator according to Example 1 disclosed herein.

[0015] It should be understood that the drawings are schematic in nature, and do not include every components 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

[0016] One or more non-limiting embodiments of cyclone separators and methods of separating solids from gasses using cyclone separators are described herein. FIG. 1 depicts an embodiment of a cyclone separator. According to one or more embodiments described herein, a cyclone separator 100 may comprise an outer shell 110 defining an interior region 120 of the cyclone separator 100, an inlet port 111, a gas outlet port 112, a solids outlet port 113, and a vortex finder 130. One or more nozzles 140 may be positioned in the interior region 120 of the cyclone separator 100. The one or more nozzles 140 may be positioned, as described in greater detail herein, such that a quench fluid may be passed into the interior region 120 of the cyclone separator. The one or more nozzles 140 may be positioned such that gasses in the interior region 120 of the cyclone separator 100 may be contacted with the quench fluid. The gasses may include reaction products, such as light olefins, and unreacted hydrocarbon feedstock, in one or more embodiments. 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. Additionally, the one or more nozzles 140 may be positioned such that the separation efficiency of the cyclone separator 100 for separating the gasses and solids is not negatively impacted. The solids may include catalyst or any other particulate solid used in a reaction process, for example, a reaction process to produce light olefins.

[0017] 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.

[0018] 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.

[0019] 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.

[0020] 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 main body 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.

[0021] Referring now to FIGS. 1 and 2, 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.

[0022] 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. [0023] In one or more embodiments, the cyclone separator may comprise a solids outlet port 113 through the lower wall segment 116. The solids outlet port 113 may be sized and positioned 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.

[0024] 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.

[0025] Referring again to FIG. 1, the cyclone separator 100 may comprise a vortex finder 130. The vortex finder 130 may extend through the gas outlet port 112 into the interior region 120 of the cyclone separator 100. The vortex finder 130 may extend into the interior region 120 of the cyclone separator 100 such that a bottom 133 of the vortex finder 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 one or more embodiments, the vortex finder 130 may comprise an inner wall 131 and an outer wall 132. The vortex finder 130 may be open such that gasses passing through the cyclone separator 100 may pass through the vortex finder 130 and subsequently through the outlet port 112.

[0026] In one or more embodiments, the vortex finder 130 may have a substantially cylindrical shape. In such embodiments, the inner wall 131 and the outer wall 132 of the vortex finder 130 may have a substantially cylindrical shape. In one or more embodiments, the vortex finder 130 may have a frustum shape. In such embodiments, the diameter of the vortex finder 130 at the bottom 133 of the vortex finder may be smaller than the diameter of the vortex finder 130 at the gas outlet port 112. The vortex finder 130 may be positioned such that the central vertical axis 160 passes through the vortex finder 130. In at least some embodiments, the central vertical axis 160 of the cyclone separator 100 may also be the central vertical axis of the vortex finder 130.

[0027] Referring to FIGS. 1 and 2, one or more nozzles 140 may be positioned in the interior region 120 of the cyclone separator 100. In one or more embodiments, the one or more nozzles 140 may be positioned on the outer wall 132 of the vortex finder 130. As described herein, a “nozzle” refers to a pipe or tube that may be used to direct or modify the flow of a fluid. Without intending to be bound by theory, the one or more nozzles 140 may be suitable for injecting a quench fluid into the interior region 120 of the cyclone separator 100.

[0028] Referring now to FIGS. 3 and 5, each nozzle 140 comprises a proximal end 142 connected to the outer wall 132. Each nozzle 140 may further comprise a distal end 144. The distal end 144 of each nozzle 140 is positioned between the outside surface 302 of the outer wall 132 of the vortex finder 130 and a midpoint 502 between the outside surface 302 of the outer wall 132 of the vortex finder 130 and an inner surface 510 of the of the outer shell 110. The distance between the outside surface 302 of the outer wall 132 of the vortex finder 130 and the inner surface 510 of the outer shell 110 is measured in a radial direction for the purposes of determining the location of midpoint 502. In one or more embodiments, the midpoint 502 between the outside surface 302 of the outer wall 132 of the vortex finder 130 and an inner surface 510 of the of the outer shell 110 may be greater than or equal to 6 inches (15.24 cm) from the inner surface 510 of the outer shell 110.

[0029] In one or more embodiments, the distal end 144 of each nozzle 140 is greater than or equal to 2 inches (5.08 cm) from an outside surface 302 of the outer wall 132 of the vortex finder 130. In some embodiments, the distal end 144 of each nozzle 140 is greater than or equal to 4 inches (10.16 cm) from an outside surface 302 of the outer wall 132 of the vortex finder 130. In one or more embodiments, the distal end 144 of each nozzle 140 is greater than or equal to 6 inches (15.24 cm) away from an inner surface 510 of the outer shell 110. In one or more embodiments, the distal end 144 of each nozzle 140 is greater than or equal to 2 inches (5.08 cm) from an outside surface 302 of the outer wall 132 of the vortex finder 130 and greater than or equal to 6 inches (15.24 cm) from an inner surface 510 of the outer shell 110. In one or more embodiments, the distal end 144 of each nozzle 140 is greater than or equal to 4 inches (10.16 cm) from an outside surface 302 of the outer wall 132 of the vortex finder 130 and greater than or equal to 6 inches (15.24 cm) from an inner surface 510 of the outer shell 110.

[0030] Referring to FIGS. 1 and 4, in one or more embodiments, the one or more nozzles 140 may be positioned at or near the bottom 133 of the outer wall 132 of the vortex finder 130. For example, each of the one or more nozzles 140 may be positioned in the lowest 15%, 10%, 5%, or even 1% of the height of the vortex finder 130. In one or more embodiments, the proximal end 142 of each nozzle 140 may be from 0 inches (0 cm) to 12 inches (30.48 cm) above a bottom surface 133 of the outer wall 132 of the vortex finder 130. For example, the proximal end 142 of each nozzle 140 may be above a bottom surface 133 of the outer wall 132 of the vortex finder 130 by from 0 in. (0 cm) to 12 in., from 1 in. (2.54 cm) to 12 in. (30.48 cm), from 2 in. (5.08 cm) to 12 in., from 3 in. (7.62 cm) to 12 in. (30.48 cm), from 4 in. (10.16 cm) to 12 in. (30.48 cm), from 5 in. (12.7 cm) to 12 in. (30.48 cm), from 6 in. (15.24 cm) to 12 in. (30.48 cm), from 7 in. (17.78 cm) to 12 in. (30.48 cm), from 8 in. (20.32 cm) to 12 in. (30.48 cm), from 9 in. (22.86 cm) to 12 in. (30.48 cm), from 10 in. (25.4 cm) to 12 in. (30.48 cm), from 11 in. (27.94 cm) to 12 in. (30.48 cm), from 0 in. (0 cm) to 11 in. (27.94 cm), from 0 in. (0 cm) to 10 in. (25.4 cm), from 0 in. (0 cm) to 9 in. (22.86 cm), from 0 in. (0 cm) to 8 in. (20.32 cm), from 0 in. (0 cm) to 7 in. (17.78 cm), from 0 in. (0 cm) to 6 in. (15.24 cm), from 0 in. (0 cm) to 5 in. (12.7 cm), from 0 in. (0 cm) to 4 in. (10.16 cm), from 0 in. (0 cm) to 3 in. (7.62 cm), from 0 in. (0 cm) to 2 in. (5.08 cm), from 0 in. (0 cm) to 1 in. (2.54 cm), or any range or combination of ranges formed from these endpoints. In some embodiments, the proximal end 142 of each nozzle 140 may be from 0 inches (0 cm) to 4 inches (10.16 cm) above a bottom surface 133 of the outer wall 132 of the vortex finder 130.

[0031] In one or more embodiments, each nozzle 140 may be positioned at the same height on the outer wall 132 of the vortex finder 130. In one or more embodiments, nozzles 140 may be positioned at different heights. For example, a first group of nozzles 140 may be positioned at a first height and a second group of nozzles 140 may be positioned at a second height on the outer wall 132 of the vortex finder 130.

[0032] Without intending to be bound by theory, positioning the nozzles 140 as described herein may result in the quench fluid contacting the gasses shortly after they enters the cyclone separator 100 through inlet port 111. Generally, gasses enter the inlet port 111 of the cyclone separator 100, flow down in an outer vortex, and subsequently flow up through an inner vortex, through the vortex finder 130, to the gas outlet port 112. If the distal end 144 of each nozzle is too close to the outer wall 132 of the vortex finder, then quench fluid injected into the interior region 120 of the cyclone separator 100 may be pulled directly into the vortex finder 130 and flow up to the gas outlet port 112. This may prevent the quench fluid from cooling the gasses in the outer vortex, which may leave a substantial volume of gasses in the interior region 120 of the cyclone separator unquenched. However, when positioned as described hereinabove, the nozzles may inject quench fluid into the outer vortex, cooling the gasses as they travel down through the outer vortex and subsequently up through the inner vortex to the gas outlet port. This may result in a significant volume of the gasses in the interior region 120 of the cyclone separator being cooled by the quench fluid, which in turn, may reduce undesired thermal cracking in the cyclone separator.

[0033] In one or more embodiments, the one or more nozzles 140 may be positioned below the inlet port 111. A nozzle 140 may be positioned below the inlet port 111 when at least the distal end 144 of the nozzle 140 is below the lowest point of the inlet port 111. In one or more embodiments, each nozzle 140 may be positioned such that the distal end 144 of each nozzle 140 is below the inlet port 111. In one or more embodiments, each nozzle 140 may be positioned such that the entirety of each nozzle 140 is positioned below the lowest point of the inlet port 111.

[0034] Referring now to FIG. 4, in one or more embodiments, each nozzle 140 may extend from the outer wall 132 o f the vortex finder 130 in a dir ection that is from - 15 ° to 15 ° from normal in a vertical direction. For example, as depicted in FIG. 4, axis 162 is normal to central vertical axis 160. Nozzle 140 may extend from the outer wall 132 in a direction such that angle 172 is from -15° to 15° relative to axis 162 in a vertical direction. In one or more embodiments, each nozzle 140 may extend from the outer wall 132 of the vortex finder 130 in a direction from -15° to 15°, from -10° to 15°, from -5° to 15°, from 0° to 15°, from 5° to 15°, from 10° to 15°, from - 15° to 10°, from -15° to 5°, from -15° to 0°, from -15° to -5°, from -15° to -10°, or any range or combination of ranges formed from these endpoints, from normal in a vertical direction.

[0035] Referring now to FIG. 2, in one or more embodiments, each nozzle 140 may extend from the outer wall 132 of the vortex finder 130 in a direction that is from 0° to 90° from normal in a horizontal direction. For example, in FIG. 2 axis 162 is normal to the central vertical axis 160. Nozzle 140 may extend from the outer wall 132 along axis 162 in a direction that is 0° from normal to the central vertical axis in a horizontal direction. In one or more embodiments, the nozzle 140 may extend in a horizontal direction such that angle 170 is from 0° to 90°. The measurement of angle 170 is in the direction in which the process stream introduced into the interior region 120 would flow around the central vertical axis 160. For example, as depicted in FIG. 2, the inlet port 111 is shaped such that process stream introduced into the interior region 120 of the cyclone separator 100 flow in a clockwise direction when viewed from above. Accordingly, angle 170 is measured in a clockwise direction. In embodiments where the inlet port 111 is shaped such that the process stream introduced into the interior region 120 of the cyclone separator 100 flows in a counter-clockwise direction, the angle 170 is measured in a counter-clockwise direction. In one or more embodiments, each nozzle 140 may extend from the outer wall 132 of the vortex finder 130 in a direction that is from 0° to 90°, from 10° to 90°, from 20° to 90°, from 30° to 90°, from 40° to 90°, from 50° to 90°, from 60° to 90°, from 70° to 90°, from 80° to 90°, from 0° to 80°, from 0° to 70°, from 0° to 60°, from 0° to 50°, from 0° to 40°, from 0° to 30°, from 0° to 20°, from 0° to 10°, or any range or combination of ranges formed from these endpoints, from normal in a horizontal direction. In some embodiments, each nozzle 140 may extend from the outer wall 132 of the vortex finder 130 in a direction that is from 0° to 60° from normal in a horizontal direction.

[0036] It should be understood that in one or more embodiments, each nozzle 140 may extend from the outer wall 132 of the vortex finder 130 at any angle having a vertical component from -15° to 15° relative to normal and a horizontal component from 0° to 90° from normal in a direction in which the process stream introduced into the interior region 120 would flow around the central vertical axis 160. In one or more embodiments, each nozzle 140 may be positioned at the same angle. In some embodiments, nozzles 140 may be positioned at different angles within the bounds described hereinabove.

[0037] Without intending to be bound by theory, when the nozzles 140 are angled as described hereinabove, the flow of quench fluid through each of the one or more nozzles 140 may minimally disrupt the flow of gasses and solids through the cyclone separator 100. For example, injecting the quench fluid into the interior region 120 of the cyclone separator 100 at an angle from 0° to 90° from normal in a horizontal direction in which the process stream is introduced into the cyclone separator 100 may minimize the extent to which the quench fluid disrupts the flow of the gasses and solids. Minimizing the extent to which the quench fluid disrupts the flow of the gasses and solids in the cyclone separator may prevent the quench from reducing the separation efficiency of the cyclone separator.

[0038] In one or more embodiments, the cyclone separator 100 may comprise from 1 to 10 nozzles 140. For example, the cyclone separator may comprise 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 nozzles 140. In some embodiments, the cyclone separator 100 may comprise from 4 to 6 nozzles. In embodiments, the cyclone separator may comprise 4 nozzles. In some embodiments, the cyclone separator may comprise 6 nozzles. Without intending to be bound by theory, the number of nozzles may be selected at least in part based on the size of the cyclone separator 100. For example, when the cyclone separator is relatively small, fewer nozzles may be necessary to distribute the quench fluid into the interior region 120 of the cyclone separator. Likewise, when the cyclone separator is relatively large, more nozzles may be necessary to distribute the quench fluid into the interior region 120 of the cyclone separator.

[0039] In one or more embodiments, the one or more nozzles 140 may be positioned radially on the outer wall 132 of the vortex finder 130 with substantially uniform spacing. For example, referring to FIG. 2, four nozzles 140 are positioned on the outer wall 132 of the vortex finder 130 and the nozzles are positioned radially on the outer wall 132 of the vortex finder 130 such that each nozzle is spaced apart by about 90°. Without intending to be bound by theory, positioning the one or more nozzles 140 on the outer wall 132 of the vortex finder 130 with substantially uniform spacing may improve the uniformity of the distribution of quench fluid within the interior region 120 of the cyclone separator 100.

[0040] In one or more embodiments, one or more fluid conduits 134 may run through the vortex finder 130 between the inner wall 131 and the outer wall 132 and to the one or more nozzles 140. The one or more fluid conduits 134 may be sized such that a quench fluid may pass through the one or more fluid conduits 134 to the one or more nozzles 140. The one or more fluid conduits 134 may have any suitable structure. For example, each of the one or more fluid conduits 134 may comprise a pipe, tube, channel, or any other suitable structure through which a fluid could be passed. [0041] In one or more embodiments, the vortex finder 130 may further comprise one or more inlet ports 150. The one or more inlet ports 150 may each be positioned above the top wall segment 114 of the outer shell 110. In one or more embodiments, the one or more inlet ports 150 may be fluidly connected to the one or more nozzles 140 by the one or more fluid conduits 134. In such embodiments, the one or more inlet ports 150, the one or more nozzles 140, and the one or more fluid conduits 134 may be positioned such that a quench fluid may flow from the one or more inlet ports 150 through the one or more fluid conduits 134 to the one or more nozzles 140. Then the quench fluid may flow through the one or more nozzles 140 into the interior region 120 of the cyclone separator 100.

[0042] In one or more embodiments, the vortex finder comprises an annular space between the inner wall 131 and the outer wall 132. In such embodiments, the annular space may be the fluid conduit 134 running through the vortex finder 130 between the inner wall 131 and the outer wall 132 to the one or more nozzles. In such embodiments, the annular space may fluidly connect each of the one or more inlet ports 150 to each of the one or more nozzles 140. In one or more embodiments, the one or more nozzles 140 may fluidly connect the annular space 134 and the interior region 120 of the cyclone separator 100.

[0043] In one or more embodiments, one or more surfaces of the cyclone separator 100 facing the interior region 120 of the cyclone separator 100 may be lined with refractory material. Without intending to be bound by theory, lining at least portions of the cyclone separator facing the interior region 120 of the cyclone separator 100 with a refractory material may reduce thermal stress on various components of the cyclone separator 100. In one or more embodiments, a surface of the outer shell facing the interior region 120 may be at least partially lined with refractory material. In one or more embodiments, one or more surfaces of the vortex finder 130 may be lined with refractory material. Referring again to FIG. 3, the nozzles 140, the outside surface 302 of the outer wall 132 of the vortex finder 130 and an inner surface 304 of the inner wall 131 of the vortex finder 130 may be lined with refractory material 306.

[0044] 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.

[0045] One or more embodiments of the cyclone separators 100 described herein may be used in methods for separating solids from gasses in a process stream. Methods for separating solids from gasses in a process stream are now described in more detail.

[0046] In one or more embodiments, methods for separating solids from gasses in a process stream may comprise passing a process stream into the interior region 120 of a cyclone separator 100. The cyclone separator 100 may comprise an outer shell 110 defining the interior region 120 of the cyclone separator 100, an inlet port 111, a gas outlet port 112, and a solids outlet port 113, as previously described. The method may include separating the solids from the gasses, such that the solids pass through the solids outlet port 113, and the gasses pass through the gas outlet port 112. In one or more embodiments, a majority of the gasses passed to the cyclone separator 100 through the inlet port 111 may exit the cyclone separator through the gas outlet port 112 and a majority of the solids passed to the cyclone separator 100 may exit the cyclone separator through the solids outlet port 113.

[0047] Embodiments of the methods described herein may further comprise, in the interior region, contacting at least the gasses with a quench fluid to decrease a temperature of the gasses by greater than or equal to 10 °C relative to a temperature of the process stream. For example, a temperature of the gasses exiting the cyclone separator through the gas outlet port 112 may be decreased by greater than or equal to 10 °C, 20 °C, 30 °C, 40 °C, 50 °C, 60 °C, 70 °C, 80 °C, 90 °C, 100 °C, 120 °C, 130 °C, 140 °C, or even 150 °C, relative to the temperature of the process stream at the inlet port 111. Without intending to be bound by theory, reducing the temperature of the gasses within the cyclone separator 100 may reduce undesired thermal cracking within the cyclone separator 100.

[0048] Referring now to FIG. 6, the interior region 120 of the cyclone separator 100 comprises a concentrated solids zone 610, an outer vortex 620, and an inner vortex 630. It should be noted that the depiction of the concentrated solids zone 610, the outer vortex 620, and the inner vortex 630 in FIG. 6 are schematic in nature and for general illustrative purposes. The dimensions of and boundaries between these zones may differ based on the structure of the cyclone separator 100 and the operating conditions of the cyclone separator 100.

[0049] In one or more embodiments, the concentrated solids zone 610 is positioned between the outer shell 110 and the outer vortex 620. In one or more embodiments, the concentrated solids zone 610 may comprise at least 90 wt.% of the solids in the interior region 120 of the cyclone separator 100. For example, the concentrated solids zone 610 may comprise at least 90 wt.%, 91 wt.%, 92 wt.%, 93 wt.%, 94 wt.%, 95 wt.%, 96 wt.%, 97 wt.%, 98 wt.%, or even at least 99 wt.% of the solids in the interior region 120 of the cyclone separator 100. In one or more embodiments, solids may move down through the concentrated solids zone 610 from the inlet port 111 to the solids outlet port 113.

[0050] In one or more embodiments, the outer vortex 620 may be positioned between the concentrated solids zone 610 and the inner vortex 630. The inner vortex 630 may be positioned such that the central vertical axis 160 of the cyclone separator 100 passes through the inner vortex 630. In one or more embodiments, at least a portion of the gasses move down through the outer vortex 620 and then up through the inner vortex 630 to the gas outlet port 112. In one or more embodiments, the vortex finder 130 may at least partially separate the outer vortex 620 from the inner vortex 630. At least a portion of the inner vortex 630 may be positioned within the vortex finder 130 between the bottom 133 of the vortex finder 130 and the gas outlet port 112. Without intending to be bound by theory, the vortex finder 130 may stabilize the inner vortex 630.

[0051] In one or more embodiments, contacting the gasses with the quench fluid occurs in the outer vortex 620. For example, the quench fluid may be injected into the outer vortex 620 through the one or more nozzles 140 to contact the gasses within the cyclone separator 100. In one or more embodiments, contacting the gasses with the quench fluid occurs in both the outer vortex 620 and the inner vortex 630. As previously described, quench fluid may be injected into the outer vortex 620 through the one or more nozzles 140. At least a portion of the quench fluid and the gasses may move down through the outer vortex 620 and then up through the inner vortex 630 to the gas outlet port 112.

[0052] The quench fluid may be injected into the interior region 120 of the cyclone separator at any suitable conditions. In one or more embodiments, a velocity of the quench fluid entering the interior region 120 of the cyclone separator 100 may be less than a velocity of the gasses in the outer vortex 620. In one or more embodiments, a dynamic head of the quench fluid entering the interior region 120 of the cyclone separator may be greater than or equal to twice the dynamic head of the gasses in the outer vortex. Without intending to be bound by theory, the velocity and dynamic head of the quench fluid entering the interior region 120 of the cyclone separator should be low enough that the flow of gasses through the outer vortex 620 is not disrupted, which may reduce the separation efficiency of the cyclone. However, the velocity and dynamic head of the quench fluid entering the interior region 120 of the cyclone may be great enough to provide contact between the quench fluid and a major portion of the gasses within the interior region 120 of the cyclone separator. Additionally, the dynamic head of the quench fluid should be great enough that the quench fluid passes from the nozzle to the outer vortex 620. If the dynamic head of the quench fluid is too low, then quench fluid may pass from the nozzle to the inner vortex 630 and be passed out of the cyclone separator 100 through the gas outlet port 112, bypassing, and not quenching, a significant volume of gas within the interior region 120 of the cyclone separator 100.

[0053] In one or more embodiments, the quench fluid may be any suitable fluid. In some embodiments, the quench fluid may comprise hydrocarbons. For example, the quench fluid may comprise one or more of ethylene, propylene, or a butene isomer. In some embodiments, the quench fluid may comprise saturated steam.

[0054] In one or more embodiments, the quench fluid has a temperature of less than or equal to 250 °C. For example, the quench fluid may have a temperature of less than or equal to 250 °C, 225 °C, 200 °C, 175 °C, 150 °C, 125 °C, or even 100 °C. Contacting the quench fluid with the one or more gasses may reduce the temperature of the gasses in the cyclone separator 100. In one or more embodiments, the temperature of the gasses exiting the cyclone separator 100 at the gas outlet port 112 may be less than the temperature of the process stream. For example, the temperature of the gasses exiting the cyclone separator through the gas outlet port 112 may be 10 °C, 20 °C, 30 °C, 40 °C, 50 °C, 60 °C, 70 °C, 80 °C, 90 °C, 100 °C, 120 °C, 130 °C, 140 °C, or even 150 °C less than the temperature of the process stream entering the cyclone separator through inlet port 111.

[0055] Without intending to be bound by theory, contacting the quench fluid with gasses in the cyclone separator may reduce the rate of thermal cracking of one or more gasses within the cyclone separator. For example, the rate of thermal cracking of one or more of ethane, propane, butane, or styrene may be reduced by contacting the gasses with the quench fluid. In one or more embodiments, contacting the gasses with the quench fluid reduces a rate of thermal cracking of the gasses by greater than or equal to 20%. For example, contacting the gasses with the quench fluid may reduce the rate of thermal cracking of one or more gasses by greater than or equal to 20%, 30%, 40%, 50%, 60%, 70%, 80%, or even 90%.

[0056] In one or more embodiments, contacting the at least the gasses with the quench fluid decreases the average temperature of the solids by less than 1 °C relative to a temperature of the process stream. For example, contacting the gasses with the quench fluid may decrease the average temperature of the solids by less than 1 °C, 0.75 °C, 0.5 °C, or even 0.25 °C relative to a temperature of the process stream. The average temperature of the solids may be measured at the solids outlet port 113 and the temperature of the process stream may be measured at the inlet port 111. Without intending to be bound by theory, the quench fluid may be injected into the outer vortex 620, in which a minimal amount of solids is entrained. In some embodiments, less than 0.1 vol.% of the outer vortex is entrained solids. By injecting the quench fluid into the outer vortex 620 a minimal amount of quench fluid may contact the solids in the concentrated solids zone 610. For example, in one or more embodiments, less than 5 wt.% of the quench fluid may be passed to the concentrated solids zone 610. Accordingly, the temperature of the solids in the concentrated solids zone 610 may not be significantly reduced by the quench fluid (for example, the temperature of the solids may decrease by less than 1 °C relative to the temperature of the process stream). A minimal reduction in temperature of the solids may be beneficial in embodiments where the solids are a catalyst that may be regenerated. Minimizing the temperature reduction of catalyst in the cyclone separator may minimize the heat necessary to regenerate the catalyst. [0057] In one or more embodiments, the process stream may have a temperature of greater than or equal to 550 °C. For example, the process stream may have a temperature of greater than or equal to 550 °C, 575 °C, 600 °C, 625 °C, 650 °C, 675 °C, 700 °C, or even greater than or equal to 725 °C. As previously described, the process stream may comprise gasses. In one or more embodiments, the process stream may comprise one or more of ethylene, propylene, styrene, and butene.

[0058] One or more embodiments of methods for separating solids from gasses in a process stream described herein may further comprise contacting a hydrocarbon feed stream with the solids in a reactor. The hydrocarbon feed stream may comprise one or more of ethane, propane, n-butane, iso-butane, or ethylbenzene. Contacting the hydrocarbon feed stream with the solids may react the hydrocarbon feed stream to form the process stream. The process stream may include reaction products and unreacted feed chemicals. The reaction products may comprise one or more of ethylene, propylene, styrene, and butene.

[0059] The solids may be used as catalysts or oxygen carriers in various reactions, such as dehydrogenation reactions, that may be used to from the process stream. Examples of suitable catalysts and oxygen carries are described in more detail in previously referenced 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.”

[0060] In some embodiments, the solids may exhibit properties known in the industry as

“Geldart A” or “Geldart B” properties. Particles may be classified as “Group A” or “Group B” according to D. Geldart, Gas Fluidization Technology, John Wiley & Sons (New York, 1986), 34- 37; and D. Geldart, “Types of Gas Fluidization,” Powder Technol. 7 (1973) 285-292, which are incorporated herein by reference in their entireties.

[0061] Group A is understood by those skilled in the art as representing an aeratable powder, having a bubble-free range of fluidization; a high bed expansion; a slow and linear deaeration rate; bubble properties that may include a predominance of splitting/recoalescing bubbles, with a maximum bubble size and large wake; high levels of solids mixing and gas backmixing, assuming equal U-Umf (U is the velocity of the carrier gas, and Umf is the minimum fluidization velocity, typically though not necessarily measured in meters per second, m/s, i.e., there is excess gas velocity); axisymmetric slug properties; and no spouting, except in very shallow beds. The properties listed tend to improve as the mean particle size decreases, assuming equal cfp; or as the <45 micrometers (pm) proportion is increased; or as pressure, temperature, viscosity, and density of the gas increase. In general, the particles may exhibit a small mean particle size and/or low particle density (<1.4 grams per cubic centimeter, g/cm3), fluidize easily, with smooth fluidization at low gas velocities, and may exhibit controlled bubbling with small bubbles at higher gas velocities.

[0062] Group B is understood by those skilled in the art as representing a “sand-like” powder that starts bubbling at Umf; that exhibits moderate bed expansion; a fast deaeration; no limits on bubble size; moderate levels of solids mixing and gas backmixing, assuming equal U- Umf; both axisymmetric and asymmetric slugs; and spouting in only shallow beds. These properties tend to improve as mean particle size decreases, but particle size distribution and, with some uncertainty, pressure, temperature, viscosity, or density of gas seem to do little to improve them. In general, most of the particles having a particle size (cfp) of 40 pm <cfp <500 pm when the density (pp) is 1.4 <pp <4 g/cm3, and preferably 60 pm <cfp <500 pm when the density (pp) is 4 g/cm3 and 250 pm <cfp <100 pm when the density (pp) is 1 g/cm3.

[0063] In one or more embodiments, the process stream may be passed directly from the reactor to the interior region 120 of the cyclone separator 100. As previously described, a reactor for dehydrogenating alkanes may comprise a reaction vessel and a riser. The cyclone separator may be fluidly connected to the riser such that the process stream may be passed directly from the riser to the interior region 120 of the cyclone separator 100. The process stream may be passed directly from the reactor to the cyclone separator 100 where the process stream is passed through no intervening system components outside of pipes or conduits connecting the reactor and the cyclone separator 100. Without intending to be bound by theory, passing the process stream directly from the reactor to the cyclone separator 100 may reduce undesired side reactions that may occur while the reaction products are in contact with the catalyst.

EXAMPLES

[0064] Various embodiments of the cyclone separators described herein will be further clarified in the following Examples. The Examples are illustrative in nature, and should not be understood to limit the subject matter of the present disclosure. [0065] Example 1

[0066] The gas/solid flow through a cyclone separator was simulated using a computational fluid dynamics model developed in OpenFOAM®. The cyclone separator may have the structure depicted in FIG. 1. The main body wall segment 115 of the cyclone separator 100 was cylindrical in shape and had an inner diameter of 69.3 inches and a height of 103.6 inches. The lower wall segment 116 had a frustoconical shape and tapered from an inner diameter of 69.3 inches to a diameter of 17.5 inches. The inlet 111 had a width of 17.5 inches and a height of 46.3 inches. The inner wall 131 of the vortex finder had a cylindrical shape with an inner diameter of 29.5 inches. The distance from the bottom 133 of the vortex finder 130 to top wall segment 114 was 57.8 inches. The cyclone separator 100 had four nozzles 140. Each nozzle 140 was positioned 2 inches above the bottom 133 of the vortex finder 130. Each nozzle extended 4 inches from the outer wall 132 of the vortex finder 130 in a direction normal to the outer wall 132 of the vortex finder 130.

[0067] The flow of product gasses and catalyst from a dehydrogenation process through the cyclone separator 100 was modeled. The flow rate of the product gas entering the cyclone separator was 17,347.4 kg/hr. The flow rate of the catalyst entering the cyclone separator 100 was 394,025.3 kg/hr. The temperature of the product gas and the catalyst entering the cyclone separator 100 was 620 °C. A quench stream was introduced into the interior region 120 of the cyclone separator through the nozzles 140 at a flow rate of 771.5 kg/hr. The quench stream had a temperature of 50 °C. The velocity of the quench fluid exiting each nozzle 140 was 25 m/s. The temperature of the vapor (product gas and quench fluid) in the interior region 120 of the cyclone separator 100 was reduced to 600 °C, lowering the rate of thermal cracking that occurs within the cyclone separator 100. Tess than 5% of the quench fluid was entrained with the catalyst near the outer shell 110 of the cyclone separator 100. Since the quench fluid was primarily in contact with the product gas within the cyclone separator 100, the impact of the quench fluid on the temperature of the catalyst was minimal.

[0068] A comparative cyclone separator was also modeled. The comparative cyclone separator had the same dimensions as previously described cyclone separator 100 with the exception that nozzles 140 were omitted from the comparative cyclone separator. Instead, a quench fluid was injected downstream of the gas outlet port of the comparative cyclone separator. The flow of product gas and catalyst through the comparative cyclone separator was modeled using the same catalyst and product gas flows described previously. The temperature profde of comparative cyclone separator 600 and cyclone separator 100 are depicted in FIG. 7. As shown in FIG. 7, substantially the entire interior region of the comparative cyclone separator 600 was at a temperature of 620 °C. In contrast, the vapors in the interior region 120 of the cyclone separator 100 were reduced to a temperature of about 600 °C by injecting the quench fluid into the interior region 120 of the cyclone separator 100. This reduction in temperature may reduce the rate of thermal cracking that may occur within the cyclone separator 100 relative to the comparative cyclone separator 600.

[0069] The modeled separation efficiency between the catalyst and vapor (product gas and quench fluid) of the cyclone separator 100 was 99.97%. Fikewise, the modeled separation efficiency of the comparative cyclone separator 600 was 99.97%. Accordingly, injecting the quench fluid into the interior region 120 of the cyclone separator 100 did not negatively impact the separation efficiency of the cyclone separator 100 relative to the comparative cyclone separator 600 in which no quench fluid was injected into the interior region.

[0070] In a first aspect of the present disclosure, a cyclone separator comprises an outer shell comprising a top wall segment, a main body wall segment, and a lower wall segment. The outer shell defines an interior region of the cyclone separator. The cyclone separator further comprises an inlet port through the main body wall segment, a gas outlet port through the top wall segment, and a solids outlet port through the lower wall segment. The cyclone separator further comprises a vortex finder extending through the gas outlet port into the interior region of the cyclone separator. The vortex finder comprises an inner wall and an outer wall. The cyclone separator further comprises one or more nozzles positioned in the interior region of the cyclone separator.

[0071] A second aspect of the present disclosure may include the first aspect, wherein the one or more nozzles are positioned on the outer wall of the vortex finder, and wherein one or more fluid conduits run through the vortex finder, between the inner wall and the outer wall, and to the one or more nozzles.

[0072] A third aspect of the present disclosure may include the first aspect or the second aspect, wherein the vortex finder comprises an annular space between the inner wall and the outer wall. [0073] A fourth aspect of the present disclosure may include the third aspect, wherein the one or more nozzles fluidly connect the annular space and the interior region of the cyclone separator.

[0074] A fifth aspect of the present disclosure may include any one of the first through fourth aspects, wherein the one or more nozzles are positioned below the inlet port.

[0075] A sixth aspect of the present disclosure may include any one of the first through fifth aspects, wherein the one or more nozzles are positioned at or near the bottom of the outer wall of the vortex finder.

[0076] A seventh aspect of the present disclosure may include any one of the first through sixth aspects, wherein the cyclone separator comprises from 1 to 10 nozzles.

[0077] An eighth aspect of the present disclosure may include any one of the first through seventh aspects, wherein each nozzle extends from the outer wall of the vortex finder in a direction that is from -15° to 15° from normal in a vertical direction.

[0078] A ninth aspect of the present disclosure may include any one of the first through eighth aspects, wherein each nozzle extends from the outer wall of the vortex finder in a direction that is from 0° to 90° from normal in a horizontal direction.

[0079] A tenth aspect of the present disclosure may include any one of the first through ninth aspects, wherein each nozzle comprises a proximal end connected to the outer wall of the vortex finder and a distal end.

[0080] An eleventh aspect of the present disclosure may include the tenth aspect, wherein the distal end of each nozzle is positioned between the outside surface of the outer wall of the vortex finder and a midpoint between the outside surface of the outer wall of the vortex finder and an inner surface of the outer shell.

[0081] A twelfth aspect of the present disclosure may include the tenth or eleventh aspect, wherein the proximal end of each nozzle is from 0 inches to 12 inches above a bottom surface of the outer wall of the vortex finder. [0082] A thirteenth aspect of the present disclosure may include any one of the tenth through twelfth aspects, wherein the distal end of each nozzle is greater than or equal to 2 inches from an outside surface of the outer wall of the vortex finder.

[0083] A fourteenth aspect of the present disclosure may include any one of the tenth through thirteenth aspects, wherein the distal end of each nozzle is greater than or equal to 6 inches away from an inner surface of the outer shell.

[0084] A fifteenth aspect of the present disclosure may include any one of the first through fourteenth aspects, wherein the gas outlet port and the solids outlet port are positioned on a central vertical axis of the cyclone separator.

[0085] 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.”

[0086] It 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.

[0087] 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.

[0088] 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. [0089] The subject mater 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

1. A cyclone separator comprising: an outer shell comprising a top wall segment, a main body wall segment, and a lower wall segment, wherein the outer shell defines an interior region of the cyclone separator; an inlet port through the main body wall segment; a gas outlet port through the top wall segment; a solids outlet port through the lower wall segment; a vortex finder extending through the gas outlet port into the interior region of the cyclone separator, the vortex finder comprising an inner wall and an outer wall; and one or more nozzles positioned in the interior region of the cyclone separator.

2. The cyclone separator of claim 1, wherein the one or more nozzles are positioned on the outer wall of the vortex finder, and wherein one or more fluid conduits run through the vortex finder, between the inner wall and the outer wall, and to the one or more nozzles.

3. The cyclone separator of claim 1 or claim 2, wherein the vortex finder comprises an annular space between the inner wall and the outer wall.

4. The cyclone separator of claim 3, wherein the one or more nozzles fluidly connect the annular space and the interior region of the cyclone separator.

5. The cyclone separator of any one of claims 1 to 4, wherein the one or more nozzles are positioned below the inlet port.

6. The cyclone separator of any one of claims 1 to 5, wherein the one or more nozzles are positioned at or near the bottom of the outer wall of the vortex finder.

7. The cyclone separator of any one of claims 1 to 6, wherein the cyclone separator comprises from 1 to 10 nozzles.

8. The cyclone separator of any one of claims 1 to 7, wherein each nozzle extends from the outer wall of the vortex finder in a direction that is from -15° to 15° from normal in a vertical direction.

9. The cyclone separator of any one of claims 1 to 8, wherein each nozzle extends from the outer wall of the vortex finder in a direction that is from 0° to 90° from normal in a horizontal direction.

10. The cyclone separator of any one of claims 1 to 9, wherein each nozzle comprises a proximal end connected to the outer wall of the vortex finder and a distal end.

11. The cyclone separator of claim 10, wherein the distal end of each nozzle is positioned between the outside surface of the outer wall of the vortex finder and a midpoint between the outside surface of the outer wall of the vortex finder and an inner surface of the outer shell.

12. The cyclone separator of claim 10 or 11, wherein the proximal end of each nozzle is from 0 inches to 12 inches above a bottom surface of the outer wall of the vortex finder.

13. The cyclone separator of any one of claims 10 to 12, wherein the distal end of each nozzle is greater than or equal to 2 inches from an outside surface of the outer wall of the vortex finder.

14. The cyclone separator of any one of claims 10 to 13, wherein the distal end of each nozzle is greater than or equal to 6 inches away from an inner surface of the outer shell.

15. The cyclone separator of any one of claims 1 to 14, wherein the gas outlet port and the solids outlet port are positioned on a central vertical axis of the cyclone separator.