Biochar models Shell Catalysts & Technologies has developed a specialised model for designing a Shell TSS for biochar service, featur- ing a lower inlet velocity and a capacity approximately 60% of the standard used for designing FCC catalyst separators. This design approach aims to minimise biochar particle attrition. The number of swirl tubes required is estimated based on this reduced capacity. Consequently, the biochar service necessitates more swirl tubes and a larger vessel size than FCC catalyst separation. Performance of the Shell TSS for biochar separation was assessed through both modelling and experimen- tal studies at PSRI. The modelling results estimated that approximately 3.5% of particles greater than 10 µm would remain in the output. In contrast, PSRI experimental stud- ies reported about 7% for particles of the same size range. This variation underscores the importance of refining the models further. Figure 5 illustrates the PSD as estimated by modelling and observed in the PSRI studies. Despite the discrepancy, Shell TSS is expected to achieve even better performance in practice, supported by design parameters such as lower inlet velocities and increased capacity for biochar, helping minimise particle attrition and enhance separation efficiency. Conclusions The Shell TSS effectively addresses the challenges of sepa- rating biochar in pyrolysis and hydropyrolysis, and ash in gas- ification. It offers a significant advantage over conventional systems, such as candle filters, as it can efficiently separate fine particulate matter without the drawbacks of moving parts and a lower risk of plugging, resulting in reduced oper - ational costs and maintenance requirements. As industries strive to reduce their carbon footprint and increase the use of circular and lower-carbon feedstocks, the Shell TSS pro - vides an effective and scalable solution for solids particulate removal in these processes. Kusume Srinivasa Rao is a Senior Technologist in Catalytic Cracking with Shell Catalysts & Technologies, overseeing process design and site support for FCC units across the Americas and EMEA regions. He played a key role in developing a hydropyrolysis and hydrocon - version technology and provided fluidisation support to the develop - ment team. He has approximately 35 years of experience in refineries, including expertise in FCC, distillation and utilities, and holds a BTech in chemical engineering. Ramkumar Ramanathan is a Senior Technologist in Catalytic Cracking with Shell Catalysts & Technologies. He is the global focal point for the Shell TSS and is responsible for the design and commissioning of Shell TSS systems. He provides site support to around 10 FCC units in the Asia-Pacific region. He has 33 years of experience in the pro - cess design, monitoring and troubleshooting of FCC units and holds a BTech in chemical engineering. Todd Foshee is the Fluidisation Technology team lead and FCC Licensing Technology Manager at Shell Catalysts & Technologies. He heads a team specialising in fluidisation technologies, including FCC, and is responsible for technical support, design and licensing efforts. He has 30 years of experience in the hydrocarbon process industry, covering process design, site support, operations and licensing and holds both BS and MS degrees in chemical engineering.
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