Extending the performance of large industrial cyclones in a high-load environment is an important goal for many reactors systems. Soultia operates such cyclones in its acrylonitrile reactors, and have extensive operating data on wall wear and performance. Simulations made with the commercial engineering software Barracuda have been compared to wear details (photographs) in several regions of the cyclone, inlet, backwall, vortex tube. Trade studies have lead to design decisions that will improve cyclone lifetime, and aid with particle (catalyst) attrition.