Insert Assembly for Rotating Devices, Related Apparatus and Methods - Patent application

Abstract

An insert assembly (10, 10A, 10B, 10C) to be used in a rotary device for thermally treating a fluid is provided. The insert assembly is configured to be mounted in a rotary device including a rotor including a rotor blade arranged in a rotor blade cascade, a plurality of stationary vanes arranged in an essentially annular vane cascade arranged adjacent to the rotor blade cascade to form a stator-rotor-stator arrangement, and a casing in which a duct is formed with at least one inlet and at least one outlet, said casing enclosing the stator-rotor-stator arrangement inside the duct. When positioned inside the duct, each of the insert assemblies (10, 10A, 10B, 10C) forms a guideway for directing a fluid medium flow entering the duct through at least one inlet towards the stator-rotor-stator arrangement and for further directing a fluid medium flow leaving the stator-rotor-stator arrangement towards at least one outlet. By mounting the insert assembly within an apparatus for thermally treating a fluid, the temperature distribution within the apparatus is uniformed and thermal stresses and associated deformations are reduced. Related apparatus and methods are further provided.

Description

[Technical field]

[0001] The present invention relates generally to the field of rotary turbomachines having replaceable, insertable liner components within a pressure casing. In particular, the present invention relates to an insert assembly for a rotating bladed machine, and related devices, methods, and uses. [Background technology]

[0002] In the turbomachinery field, various solutions exist that involve providing a non-sealed liner inside a sealed casing. Such solutions are widely used, for example, in aircraft engine design. An exemplary hydraulic turbocharger, turbine, or pump that includes a modular volute-type insert inside the housing is described in U.S. Patent Application Publication No. 2014 / 0093407 (Calkins et al.). Aircraft engines or other turbomachines typically do not face high temperature differences within the pressure casing and across the individual blade rows.

[0003] Rotating reactor devices including a rotor disk with associated blade cascades, the blade cascades being arranged between rows of stationary vanes arranged on an essentially ring-shaped support and enclosed inside a toroidal casing, are disclosed in U.S. Pat. No. 9,494,038 (Bushuev) and U.S. Pat. No. 9,234,140 (Seppala et al.). The mentioned reactors convert a hydrocarbon feedstock into light olefins via thermal (chemical) cracking. The feedstock-containing process fluid enters the inside of the device through an inlet and passes through the stator and rotor cascades several times, following an essentially helical trajectory, before leaving the reactor. Propagating inside the reactor, the process fluid is heated by at least 500 degrees Celsius (° C.) through the formation of a series of shock waves. Thus, a temperature difference is formed between the inlet section and the discharge section. Depending on the reactor geometry, this difference results in a sharp temperature gradient. This causes thermal stresses and deformations in the reactor casing and in the rotor shaft body. Thermal stresses significantly shorten the life of the reactor and impose additional costs associated with maintenance and repair.

[0004] This problem can be addressed by replacing the entire casing and / or by manufacturing the casing from unique high temperature materials and alloys, however, either of these options are expensive and do not eliminate the problem of thermal gradient formation.

[0005] In addition, the rotating reactor devices described therein tend to suffer from localized coking due to non-uniform velocity profiles resulting from the fact that the velocity of the fluid flow propagating through the reactor decreases in the wall regions. However, conventional decoking methods, such as steam and / or air decoking methods, shorten the life of the device.

[0006] Recently, rotating blade devices may be equipped with a (pre)heater function that can provide significantly more (thermal) energy to high-temperature heat-intensive processes and related installations. Such processes include, for example, non-metallic mineral processing (mostly cement), hydrogen production from natural gas, incineration of used plastics, chemical industry high-temperature thermal processes (e.g. core processes for cracking hydrocarbons into bulk chemicals and converting limestone into cement clinker), iron and steel production (e.g. core processes for melting and forming steel), and the use of the off-gases thus produced as raw materials for bulk chemicals. Most of the above mentioned processes require high and very high temperatures, e.g. temperatures in the range of about 850°C to about 1600°C. In order to effectively withstand high temperature gradients of about 500°C to 1500°C, rotating blade devices still need to be improved.

[0007] In this regard, updates in the field of improving the efficiency of rotating bladed devices employed in the thermal treatment of fluids remain desirable, particularly with a view to addressing challenges associated with the ability of said devices to reliably withstand high temperature stresses when used in associated high and very high temperature industrial applications. Summary of the Invention [Problem to be solved by the invention]

[0008] The object of the present invention is to solve or at least alleviate each of the problems resulting from the limitations and disadvantages of the related art. This object is achieved by various embodiments of an insert assembly for use in a rotating device for thermally treating a fluid, an associated rotating device and a method. Thus, in one aspect of the invention, an insert assembly is provided according to what is defined in independent claim 1. [Means for solving the problem]

[0009] In one embodiment, an insert assembly is provided for use with a rotary apparatus for thermally treating a fluid, the apparatus comprising a rotor, the rotor including a plurality of rotor blades arranged around a rotor hub mounted on a rotor shaft and forming a rotor blade cascade, a plurality of stationary vanes arranged in an essentially annular vane cascade disposed adjacent to the rotor blade cascade to form a stator-rotor-stator arrangement, and a casing, a duct formed therein with at least one inlet and at least one outlet, the casing enclosing the rotor blade cascade and the stationary vane cascade within the duct, the insert assembly being molded and positioned within the duct such that a guideway is formed for directing a fluid medium flow entering the duct through the at least one inlet towards the stator-rotor-stator arrangement and for further directing a fluid medium flow exiting the stator-rotor-stator arrangement towards the at least one outlet, respectively.

[0010] In an embodiment, the insert assembly is molded and positioned within the duct so as to equalize the temperature distribution within the casing and reduce the thermal stresses generated within the casing during propagation of the heat-treated fluid medium through the duct.

[0011] In an embodiment, the insert assembly is configured to direct fluid medium flow entering the duct through the at least one inlet towards a fixed guide vane cascade of the stator-rotor-stator arrangement, and to further direct fluid medium flow exiting the fixed diffuser vane cascade of the stator-rotor-stator arrangement towards the at least one outlet, respectively, the fixed guide vane cascade being disposed upstream of the rotor blades, and the fixed diffuser vane cascade being disposed downstream of the rotor blades.

[0012] In an embodiment, the insert assembly includes a predetermined number of insert units.

[0013] In an embodiment, the insert units are arranged inside the duct of the device adjacent one of the inlet and the outlet, and in an embodiment, the insert units adjacent one of the inlet and the outlet are provided with a shape adjusted to optimize the fluid medium flow propagating through the insert assembly.

[0014] In an embodiment, the insert assembly is configured to attach to any one of the fixed vane cascades.

[0015] In an embodiment, all insert units within the insert assembly are spaced apart from one another.

[0016] In an embodiment, within the insert assembly, the insert units are adjacent to one another inside the duct so as to form a shell liner inside the casing, and in an embodiment, the insert units are adjacent to one another in a non-sealed manner so as to allow an essentially gaseous medium to circulate through gaps remaining along the area where the insert units are adjacent.

[0017] In an embodiment, the shell liner formed within the casing essentially surrounds the stator-rotor-stator arrangement.

[0018] In an embodiment, the shell liner is formed having one or more insert units positioned adjacent to a stationary guide vane cascade and having one or more insert units positioned adjacent to the stationary diffuser vane cascade.

[0019] In an embodiment, the insert assembly at least partially defines a vane-free space formed in a duct between an outlet from the stator-rotor-stator arrangement and an inlet to the stator-rotor-stator arrangement, such that the vane-free space is defined by at least a portion of a duct volume between an inner surface of the insert assembly and an outer surface of a flow shaping device disposed within the casing.

[0020] In an embodiment, within the insert assembly, the insert units are mounted within the casing to allow relative movement of the insert units relative to each other and / or relative to the casing.

[0021] In an embodiment, a number of through holes are arranged on a surface of at least some of the insert units for supplying additional gaseous medium into the duct, the surface of the insert units having a profile shaped to optimize the flow velocity of the fluid medium propagating through the duct.

[0022] In an embodiment, the insert units have a reduced wall thickness relative to the casing, and optionally at least some of the insert units are formed from a material different to that of the casing.

[0023] In an embodiment, within the insert assembly, any one of the insert units is constructed partially or entirely from a material that can bend or flex without breaking. In an embodiment, within the insert assembly, any one of the insert units is constructed from portions of the same or different materials. In an embodiment, within the insert assembly, any one of the insert units is constructed partially or entirely from a ceramic material.

[0024] In an embodiment, the insert assembly is configured to be replaceable.

[0025] In another aspect, there is provided a rotary apparatus for heat treating a fluid as defined in independent claim 22. In an embodiment, the apparatus includes an insert assembly formed according to any one of the above embodiments.

[0026] In an embodiment, the apparatus includes selected vanes within the stationary vane cascade modified to provide attachment points for the insert assembly, In an embodiment, within the apparatus, the insert assembly is provided in the form of a shell liner within the casing, and a duct volume formed between the shell liner and the casing is filled with insulating material.

[0027] In an embodiment, the apparatus is configured as a reactor for the thermally assisted conversion of a feedstock in a fluid medium, optionally for the thermal or thermochemical cracking of a hydrocarbon-containing feedstock.

[0028] In another aspect, a method for reducing thermal stresses and associated deformations in a rotating device during thermal treatment of a fluid is provided according to what is defined in independent claim 27.

[0029] In an embodiment, in the method, conditions for heat treatment of the fluid medium inside the duct of the rotating device are established when a quantity of thermal energy is imparted to the fluid medium flow during its propagation inside the duct between the at least one inlet and the at least one outlet by a series of energy transformations occurring as the fluid medium flow passes successively through a blade / vane array forming a stator-rotor-stator arrangement and a vane-free space, respectively.

[0030] In an embodiment, in the method, the fluid medium flow passes successively through the array of blades / vanes forming the stator-rotor-stator arrangement and through the vane-free spaces, respectively, following an essentially helical flow path.

[0031] In an embodiment, in the method, the heat treatment process involves increasing the temperature of the fluid medium by at least about 400 degrees Celsius (°C).

[0032] In an embodiment, in said method, said thermal treatment process involves thermally assisted conversion of a feedstock in a fluid medium, optionally thermal cracking or thermochemical cracking of a hydrocarbon-containing feedstock. Effect of the Invention

[0033] The utility of the present invention is due to various reasons depending on each specific embodiment. Firstly, the insert assembly proposed here allows a more uniform temperature distribution inside a rotating device for thermally treating fluids, thereby avoiding or at least significantly reducing thermal deformation of the pressure casing and rotor shaft. Rotating devices that benefit most from the present invention operate at relatively high temperatures, for example generally above 500°C, for example up to 900-1300°C, and typically suffer from severe thermal stresses due to the formation of high temperature gradients between the inlet and discharge sections. By having an insert assembly based on the concept of the present invention installed inside the rotating device, the temperature gradients are smoothed and the life of the equipment is increased.

[0034] In addition, by providing an insert assembly (formed to be replaceable), the need to replace the entire pressure casing of the rotating device is eliminated. Typically, the pressure casing is replaced when the device reaches the end of its life or when the conditions of the thermal treatment process require modification. For example, in a thermal conversion process such as steam cracking, a change in residence time (the time required to replace the entire volume of the rotating device in which the thermal conversion process takes place) typically requires replacement of the entire pressure casing / pressure shell. Thus, by providing an insert assembly, the (frequent) system downtime and associated expense associated with replacing the pressure shell can be avoided. In addition, a more uniform temperature distribution in the (thermo)chemical conversion rotating reactor significantly reduces coking, which in turn improves the aerodynamic performance of the rotating blades.

[0035] Furthermore, by providing an insert assembly in the form of a shell liner inside the internal cavity of the rotating equipment, an additional thermal insulation layer can be formed, thus reducing heat loss on an industrial scale. At the same time, it is not necessary to manufacture the entire machine from special heat-resistant alloys. The overall costs associated with manufacturing, maintenance and repairs are reduced, while the part replacement process is greatly facilitated.

[0036] The term "a number of" herein means any positive integer starting from 1, such as 1, 2, or 3. The term "a plurality of" herein means any positive integer starting from 2, such as 2, 3, or 4. The terms "first" and "second", unless expressly stated otherwise, are used herein merely to distinguish one element from another, and do not denote any particular order or importance.

[0037] The term "gasified" is utilized herein to indicate that a substance is converted into a gaseous form by any possible means.

[0038] Various embodiments of the invention become apparent by consideration of the detailed description and accompanying drawings. [Brief description of the drawings]

[0039] [Figure 1] Figure 1A is a vertical cross-sectional view of an exemplary device 100 housing an insert assembly, and Figure 1B is a cross-sectional view taken along lines AA and BB shown in Figure 1A, illustrating a flow diagram of the fluid path through device 100. [Diagram 2] FIG. 2 is an exploded view illustrating an apparatus 100 including an insert assembly 10 according to one embodiment. [Diagram 3] FIG. 3 shows an insert assembly 10 realized according to an embodiment at A, B, and C (10A, 10B, and 10C, respectively). [Figure 4] FIG. 4 shows an exemplary apparatus 100 including an insert assembly according to an embodiment, through the inlet and outlet branches and through the attachment points of the insert assembly. [Diagram 5] FIG. 5 shows the arrangement of the insert assembly 10 according to an embodiment relative to the fixed vane cascade and casing. [Figure 6] FIG. 6 is a schematic diagram illustrating an apparatus 100 including an insert assembly, according to an embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0040] Detailed embodiments of the present invention are now disclosed with reference to the accompanying drawings, in which like reference numerals are used throughout to refer to like parts. 1-Rotor shaft 2-Fixed Guide Vane Cascade 3-rotor blade cascade, 3A-rotor hub / rotor disk 4-Fixed Diffuser Vane Cascade 5-Flow forming device 6-Gas casing, 6A, 6B-Half shells of gas casing 7-Vaneless space 7A—Cavity formed between insert assembly 10 and flow molding device 5 7B—Cavity formed between insert assembly 10 and gas casing 6 8,8A,8B-Entrance (device 100) 9,9A,9B-Exit (device 100) 10-insert assembly 10-1, 10-2, 10-3, 10-4-insert unit or segment 10 in -Insert unit (inlet insert module) mounted adjacent to the fixed guide vane cascade 10 out -Insert unit adjacent to the fixed guide vane cascade (outlet insert module) 11—Flow guide disposed within the insert assembly 12-Local expansion of the gas casing 6 for receiving the insert assembly 13-Attachment points (indicating the locations where the insert assembly can be attached to the stationary component and the gas casing) 14-Areas where the insert unit is adjacent to the modified fixed vane (inlet and outlet areas) 15-Gaps formed along the area where the insert units abut within the insert assembly 16-Clearance to accommodate thermal expansion 17, 17A - fixing pin, 18-Connecting flange 20A, 20B-Bearing block

[0041] 2 and 3 show an embodiment of an insert assembly 10. The insert assembly 10 is configured for use with a rotating bladed device 100 (see FIGS. 1A and 4).

[0042] The insert assembly 10 is positioned within the apparatus 100. When positioned within the apparatus, the insert assembly 10 forms a guideway between the interior of the apparatus and an associated inlet / outlet arrangement through which fluid media streams enter and exit the apparatus, respectively.

[0043] Numerous benefits can be derived from the insert assembly when it is installed in the rotating bladed apparatus 100 realized according to the following description. The apparatus 100 is preferably configured for thermally treating a fluid. In some cases, the apparatus is configured for processing a feedstock in a process fluid through either a thermal or thermochemical treatment process. The thermal treatment process may or may not involve thermal and / or chemical conversion of the feedstock to a desired product. The conversion may include heat and / or chemical decomposition reactions that occur while the feedstock containing the process fluid propagates through the apparatus. In some cases, the apparatus 100 is configured as a reactor for thermochemical cracking of a hydrocarbon-containing feedstock. In some cases, the apparatus 100 is configured for steam cracking the hydrocarbon-containing feedstock to produce lower olefins (ethylene, propylene, etc.).

[0044] The apparatus 100 can be configured to achieve fluid medium flow between an inlet and an outlet along a flow path established according to an essentially helical trajectory formed inside an essentially toroidal casing. The fluid flow passes successively through a row of stationary guide vanes, rotor blades, and stationary diffuser vanes. This type of device is discussed in detail in U.S. Pat. No. 9,494,038 to Bushuev and U.S. Pat. No. 9,234,140 to Seppala et al., which are incorporated herein by reference. Alternatively, the apparatus 100 may take the form outlined in U.S. Pat. No. 10,744,480 to Xu and Rosic and U.S. Pat. No. 7,232,937 to Bushuev.

[0045] An exemplary apparatus 100 configured to receive the insert assembly 10 is shown in FIG. 1A. The apparatus 100 includes a rotor system, hereafter rotor. The rotor includes a rotor shaft 1 positioned along a horizontal (longitudinal) axis XX′ and a rotor unit including at least one rotor blade row. The rotor blades are arranged around a rotor disk or rotor hub 3A mounted on the rotor shaft. A plurality of rotor blades (also called working blades) arranged in at least one blade row establish a rotor blade assembly or rotor blade cascade 3.

[0046] The device utilizes a drive engine. In a preferred embodiment, the device utilizes an electric motor as the drive engine. Additionally or alternatively, the device may be directly driven, for example, by a gas or steam turbine, or by any other suitable drive engine device. For purposes of this disclosure, any suitable type of electric motor (i.e., a device capable of transferring energy from a power source to a mechanical load) may be utilized. Suitable couplings between the motor drive shaft and the rotor shaft, as well as various appliances, such as power converters, controllers, and the like, are not described herein. Bearing assemblies with associated shaft end seals are shown at 20A, 20B (see right images of Figures 2 and 4).

[0047] The device 100 further comprises a stationary component. The stationary component is formed by a plurality of stationary (stator) vanes arranged in a row. The stationary vane rows form a stationary vane cascade. In an embodiment, on either side of the working blade row (working blade cascade 3), a stationary vane cascade 2, 4 is provided as an essentially annular assembly. Upstream of the rotor blade cascade 3, a first stationary vane cascade 2 is arranged, and downstream of the rotor blade cascade, a second stationary vane cascade 4 is arranged.

[0048] The term "cascade" (crown of blades / vanes) means a collection of (working) blades or (stationary) vanes mounted around the periphery of a rotor disk / rotor hub or on a ring-like support or casing, respectively.

[0049] The terms "upstream" and "downstream" refer to the spatial and / or functional arrangement of a structural part or component relative to a given part or component, here at least one rotor blade row / cascade, as viewed in the direction of fluid flow essentially throughout the apparatus (e.g., along axis XX' as shown in FIG. 1A).

[0050] The cascade arranged upstream of at least one row of rotor blades comprises a plurality of stationary guide vanes, which may be formed as stationary nozzle guide vanes (NGVs). In an embodiment, these vanes form a first stationary vane cascade 2, also called the stationary guide vane cascade. The cascade arranged downstream of at least one row of rotor blades comprises a plurality of stationary diffuser vanes, which form a second stationary vane cascade 4, also called the stationary diffuser cascade.

[0051] The fixed vane cascades 2, 4 arranged adjacent to the rotor blade row 3 form a stator-rotor-stator arrangement 2, 3, 4. In the stator-rotor-stator arrangement, the rotor blade cascade 3 is positioned between the fixed guide vane cascade 2 and the fixed diffuser vane cascade 4.

[0052] The device 100 comprises a casing 6 (also called a gas casing or a pressure casing), within which an internal passage is established in the form of a duct between at least one inlet 8 and at least one outlet 9. The casing 6 is hermetically (gas-tightly) sealed.

[0053] In this disclosure, the gas casing 6 is generally referred to as the equipment casing, although the equipment structure 100 may also be enclosed within a separate outer housing (not shown).

[0054] 1A shows a device with two inlets 8A, 8B and two outlets 9A, 9B. Other configurations may be envisaged where appropriate. The inlets and outlets include associated orifices or ports in the casing 6 and a number of branches, sleeves or manifolds associated with each said orifice or port.

[0055] In the configuration of FIG. 1A, the casing 6 is formed to substantially completely surround the rotor disk on which the working blades 3 are assembled and the fixed vane cascades 2,4 adjacent to the rotor blades and which together form the stator-rotor-stator arrangement 2,3,4. The casing 6 has a substantially toroidal shape ("doughnut" shape) in three-dimensional form, whereby the rotor system (1,3A,3) with the associated bearing assembly can be seen as filling an aperture that defines an opening in the central part of the essentially toroidal shape. The toroidal structure thus forms a gas-tight gas casing. In its meridian section, the gas casing 6 is essentially ring-shaped.

[0056] Arranged inside the gas casing 6 is a flow shaping device (flow guide device) 5. The flow shaping device 5 can be formed as an internal fixed ring-like structure, allowing for the establishment of an essentially annular duct inside the casing 6. The device 5 is fixed within the gas casing 6 by suitable fasteners (not shown). In some embodiments, the flow shaping device 5 is an annular, essentially hollow structure, such as a hoop.

[0057] The interior volume of the apparatus 100 is defined as the space established between the gas casing 6 (the outer "donut") and the internal flow shaping device 5 (the inner "donut").

[0058] A substantially annular passage / duct is thus formed between the inner surface of the gas casing 6 and the outer surface of the flow shaping device 5. This duct therefore has a ring-shaped meridian section. The flow shaping device 5 may adjoin the tips of the rotor blades (between which gaps are formed to allow unhindered rotation of the rotor) and also adjacent to the periphery of the stator vanes, if these are mounted on bearing blocks (not shown) which form the bearing system of the rotor.

[0059] Alternatively, the stator cascade may be assembled on the flow shaping device 5 in a manner adjacent to the rotor blades 3. The stator vanes may thus be mounted on the flow shaping device and / or coupled thereto by auxiliary devices such as rings, brackets, and the like (not shown). The above-mentioned features are discussed in more detail in the above-referenced patent documents by Bushuev (U.S. Pat. No. 9,494,038) and Seppala et al. (U.S. Pat. No. 9,234,140).

[0060] In the gas casing 6 (in its duct), the cascades 2, 3, 4 are adjacent to each other such that a vane-free space 7 is formed between the outlet from the stator-rotor-stator arrangement (i.e. the outlet from the diffuser cascade 4) and the inlet into said arrangement (i.e. the inlet into the fixed (nozzle) guide vane cascade 2). The vane-free space is formed between the inner surface of the gas casing 6 and the outer surface of the flow shaping device 5.

[0061] Within the apparatus 100, a continuous row of stationary guide vanes 2, rotor blades 3, and stationary diffuser vanes 4 (together forming a stator-rotor-stator arrangement) establishes an energy transfer section, also referred to as the base section or working section (hereafter section).

[0062] The function of the base section is to impart mechanical energy to the fluid and convert the mechanical energy into thermal energy. The section is thus configured to mediate a complete energy conversion and energy transfer cycle. The fluid medium is heated as it flows through at least one section formed by successive rows 2, 3, and 4 (stator-rotor-stator arrangements 2, 3, 4) and vane-free space 7.

[0063] During the energy conversion / energy transfer cycle, the fixed guide blade row 2 arranged upstream of the rotor blades 3 prepares the required flow conditions at the inlet of the rotating blade row (cascade). Within the rotor blade row, the mechanical energy of the shaft and the rotating blades is transferred to the fluid flow. In at least a part of each rotor blade row 3, the fluid medium flow can reach supersonic flow conditions.

[0064] A row of stationary blades (diffuser 4) located downstream of the rotor blades 3 converts the mechanical energy of the fluid medium into its thermal energy. The fluid flow leaves the rotor blades 3 and enters the diffuser 4 at supersonic speed. When the flow upstream of the diffuser is at supersonic speed, the kinetic energy of the fluid flow is converted into the internal energy of the fluid through a system of multiple impacts and viscous mixing and dissipation. The flow dissipates its kinetic energy into the internal energy of the fluid flow propagating through the device, thus providing a thermal energy content to the fluid. As a result of the increase in the internal energy of the fluid, the fluid temperature increases. In some embodiments, the increase in temperature promotes the thermal or thermochemical decomposition of the feedstock species and its conversion into the desired product. In the device 100 configured for thermal and / or chemical conversion of the feedstock, the majority of the chemical reactions that initiate the conversion of the feedstock into the target product occur in the vane-free space.

[0065] Figure 1B is a cross-sectional view taken along lines AA and BB shown in Figure 1A. The cross-sectional area taken along line AA is located at the inlet to the (nozzle) guide vane cascade 2, while the cross-sectional area taken along line BB is located at the exit from the diffuser cascade 4. Overall, cross-sections AA and BB show events occurring at the inlet to or exit from the stator-rotor-stator arrangement.

[0066] The inlet to a blade / vane cascade is generally defined by the leading edge of the associated blade / vane, whereas the outlet from the cascade is defined by the trailing edge of said blade / vane. The inlet and outlet are defined in the direction of fluid flow.

[0067] The locations where the fluid flow enters and exits the interior (duct) of the device 100 are shown on the images showing cross sections AA and BB. In addition, the fluid flow lines passing through the stator-rotor-stator arrangement 2, 3, 4, which follow a generally helical path, are shown as separate numbered sector areas or sectors by Roman numerals i-vii. A flow diagram showing the flow line path through the device is shown on the right. Figure 1B shows the flow lines traveling between the first inlet 8A and the first outlet 9A. The flow lines traveling between the second inlet 8B and the second outlet 9B are not shown.

[0068] During operation, a fluid media stream, e.g., a feedstock-containing process fluid, enters the apparatus through inlet 8 (8A) and arrives at the fixed guide vane cascade 2. Some of the fixed vanes located in the inlet region can be modified to allow coupling of the vanes (2) with an insert assembly (see FIG. 2 and reference number 14).

[0069] The fluid flow propagates through the stator-rotor-stator arrangement 2, 3, 4. This means in practice that the flow propagates successively through the fixed guide vanes 2, through the rotor blades 3 and through the fixed diffuser vanes 4, after which the flow exits the diffuser cascade at sector (i) of the cascade (cross section BB) and flows "upwards" through the vaneless space 7. After it leaves the fixed diffuser vane cascade 4, the flow enters the vaneless space.

[0070] Each time the process fluid propagates through the stator-rotor-stator cascade, the temperature of the process fluid increases, optionally promoting chemical reactions in vane-free spaces located downstream of the cascade, viewed in the direction of fluid flow.

[0071] After passing through the vaneless space 7, the fluid flow arrives at sector (i) (cross section AA) of the nozzle guide vane cascade 2, and the above process is repeated; that is, the fluid flow proceeds through the cascades 2, 3, 4, exits at sector (ii) (cross section BB) of the diffuser cascade 4, and continues through the vaneless space 7, following a generally helical path, towards sector (ii) (cross section AA) of the guide vane cascade 2. Thus, in the configuration shown in FIG. 1B, the fluid flow establishes eight segments by propagating through the cascades eight times. Configurations with fewer or more segments can be utilized. After one final (here the eighth) propagation through the stator-rotor-stator cascade, the fluid flow exits the cascade and proceeds from the device to outlet 9 (9A).

[0072] Some of the fixed vanes located in the outlet region (diffuser cascade 4) can also be modified similarly as fixed guide vanes 2, allowing coupling of the vanes with the insert assembly (see FIG. 2 and reference number 14).

[0073] In the apparatus 100 shown diagrammatically in FIG. 1A, configured to achieve a substantially helical fluid flow (FIG. 1B), the regions where the fluid flow enters the apparatus (8A, 8B) and the regions where the fluid flow exits the apparatus (9A, 9B) are essentially located in close proximity to one another. Because the input (feed) stream has a significantly lower temperature than the output (product) stream, such a difference results in the formation of high temperature gradient zones in the regions where the "cold" stream entering the apparatus and the "hot" stream exiting the apparatus are located in close proximity to one another (see FIG. 1B, "High Temperature Gradient Zones"). These are the most common locations where high thermal stresses within the gas casing 6 occur.

[0074] The definitions of "cold" and "hot" in this context are relative and are used, broadly speaking, to distinguish the temperature of the fluid stream (e.g., feedstock-containing fluid stream) entering the apparatus (t inlet) from the temperature of the fluid stream (e.g., product stream) exiting the apparatus (t outlet). In some embodiments, the fluid stream temperature at the inlet may be in the range of 300-700°C and is classified as "cold", whereas the temperature at the outlet may reach up to 800-1300°C (or higher) and is classified as "hot". For example, a typical temperature profile in a steam cracking process carried out in the rotary apparatus 100 shown in FIG. 1A is in the range of about 500-700°C at the inlet and about 800-1000°C at the outlet.

[0075] Overall, thermal stresses tend to occur when the heat treatment process carried out in the apparatus 100 involves increasing the temperature of the fluid medium by at least about 400° C. (delta t / Δt≧400° C.). Thus, having a temperature gradient (the difference between the fluid stream temperature at the inlet and the fluid stream temperature at the outlet, commonly expressed as delta t (Δt)) in the range of about 400-1000° C. induces thermal stresses and associated deformations in the pressure casing and rotor shaft body. However, the delta t values ​​mentioned above typically induce thermal stresses when accompanied by relatively high starting temperatures (t inlet≧approximately 300° C.). It should be noted that the values ​​presented herein are not intended to be limiting, but rather, these values ​​are intended to provide the skilled reader with a better understanding of the problems that may be solved by the present invention in the context of the relevant technical background.

[0076] The invention is based on the observation that an insert, specially configured in a predefined manner in the casing 6, stabilizes / uniformizes the temperature distribution inside the casing (in the duct) and reduces the thermal stresses that arise in the casing during the propagation of the fluid medium to be heat treated through the duct. The insert can be provided as a modular solution comprising a predefined number of individual insert units that are further assembled into a module. In the present disclosure, the insert units and / or modules are collectively referred to as an insert assembly 10.

[0077] The insert assembly 10 is positioned within a duct formed between an inner surface of the gas casing 6 and an outer surface of the flow shaping device 5 (see FIG. 1A). The insert assembly is disposed within the vaneless space 7. The insert assembly can be seen as being positioned within the vaneless space 7. The insert assembly is molded and positioned within the duct such that guideways are formed which direct the fluid medium flow entering the duct through at least one inlet 8 towards the stator-rotor-stator arrangements 2, 3, 4, respectively, and further direct the fluid medium flow exiting the stator-rotor-stator arrangements towards at least one outlet 9.

[0078] The insert assemblies can each be configured to guide the fluid media flow entering the duct through at least one inlet 8 towards the fixed guide vane cascade 2 of the stator-rotor-stator arrangement, and to further direct the fluid media flow exiting the fixed diffuser vane cascade 4 of the stator-rotor-stator arrangement towards at least one outlet 9.

[0079] In some embodiments, the insert assembly includes a number of separate insert units arranged inside the duct adjacent either the inlet 8 or the outlet 9. The insert assembly may be disposed in the duct between the inner surface of the casing 6 and the stationary vanes (vane cascade). In some cases, the insert assembly is positioned between the inlet / outlet of the device and the associated stationary vane cascade. The insert assembly may be formed to attach to the stationary vane cascade 2, 4. The insert assembly may be bonded to the stationary vanes and / or the casing 6. The insert assembly may be further formed to connect the inlet 8 to the stationary guide vane cascade 2 and / or the outlet 9 (e.g., a branch thereof) to the stationary diffuser vane cascade 4, respectively.

[0080] In order for the insert assembly to guide the fluid flow in the above manner, the insert unit adjacent to either the inlet or the outlet is provided with a shape adjusted to optimize the fluid medium flow propagating through the insert assembly. The insert unit further comprises a flow guide 11, e.g. an internal passage / channel (FIG. 2). The entire insert assembly, and in particular the internal passage, can take any suitable form or shape to form a flow channel configured to guide the fluid medium to and from the device 100 in the most beneficial manner from a gas dynamics point of view. The insert assembly can thus be considered as an intermediate component provided to optimize the fluid flow entering the device 100 (and the fixed guide vane cascade 2) through the inlet 8 and the fluid flow exiting the device 100 (and the fixed diffuser vane cascade 4) as it leaves the device through the outlet 9.

[0081] It may be advantageous to increase the dimensions of the casing 6 to accommodate the insert assembly. However, the insert assembly may also be sized to fit into an existing device 100. The casing 6 may be locally expanded in area 12 to receive the insert assembly (FIG. 2).

[0082] Reference is now made to Figure 2, which shows an exploded view of an apparatus 100 including an insert assembly 10, according to one embodiment. The insert assembly shown in Figure 2 includes a number of insert units or segments arranged within a duct adjacent an inlet 8 and an outlet 9. When the apparatus 100 is assembled, a duct is formed between the inner surfaces of the casing components (half shells) 6A, 6B and the outer surface of the flow molding device 5.

[0083] The insert unit mounted adjacent to the fixed guide vane cascade 2 is an inlet insert unit or segment (10 in ), and the insert unit adjacent to the fixed diffuser vane cascade 4 is called the outlet insert unit or segment (10 out) Two or more inlet insert units may be considered an inlet insert module, and two or more outlet insert units may be considered an outlet insert module.

[0084] The inlet insert unit contains internal passages / channels 11 for directing the fluid medium flow from the inlet 8 (or associated branch pipe or other device) towards the fixed guide vane cascade 2, and the outlet insert unit contains internal passages / channels for directing the fluid flow from the fixed diffuser vane cascade 4 towards the outlet 8 (or associated branch pipe or other device).

[0085] The insert unit 10 is attached to the casing 6 (its inner surface) at a number of attachment sites by any suitable attachment appliance, such as connectors, placeholders, support plates, and the like (not shown). Possible attachment points are shown at 13 in Figures 2 and 3.

[0086] The insert unit 10 may be attached to the stationary vane cascade through a predetermined number of stationary vanes that have been modified accordingly (see dashed circle A in FIG. 2 and the enlarged portion showing the modified stationary vanes at location 14). Such an attachment mode may be employed to couple the insert unit to the stationary guide vane cascade 2 and the stationary diffuser vane cascade 4, respectively. The selected stationary vanes that have been modified to be attached to the insert unit are preferably located in the vane cascade regions adjacent to the outlet 8 and / or outlet 9 of the apparatus.

[0087] Reference is now made to FIG. 3, which shows insert assemblies 10 according to embodiments A, B and C (10A, 10B and 10C, respectively). In all configurations 10A, 10B and 10C, the insert units mounted adjacent to the fixed guide vane cascade 2 are the inlet insert unit (10 inThe insert unit is called the outlet insert unit (10) and is attached to abut the fixed diffuser vane cascade 4. out )

[0088] View A (FIG. 3) shows the same insert assembly, designated 10A, as shown in FIG. 2. The insert units, designated 10-1 and 10-2 (FIG. 3, A), are spaced apart from one another. In view 10A, the insert assembly is formed to have a number of separate, discontinuous insert units. View A is a partial view showing insert units 10-1 and 10-2 positioned side-by-side in a casing half shell (see FIG. 2, 6A and 6B). Thus, insert units 10-1 and 10-2 together form inlet insert module 10. in or outlet insert module 10 out may be formed.

[0089] View B shows an alternative configuration for the insert assembly at 10B. View B is a partial view showing an individual insert unit formed as a half shell. The insert unit generally follows the shape of the casing half shell. When the insert assembly 10B is assembled into the apparatus 100, two insert units shown in view B of FIG. 3 are adjacent to each other to form a shell liner inside the casing 6. In the apparatus 100, the shell liner 10B is located in a duct between the gas casing 6 and the flow shaping device 5.

[0090] In an embodiment, the insert assembly 10B, referred to as a shell liner, is formed with two or more insert units. In some cases, the insert assembly 10B can be formed with a predetermined number of insert modules. The insert assembly 10B shown in FIG. 3 is thus formed with two insert units. Each insert unit is positioned adjacent to an associated fixed guide vane cascade (2, 4). In an embodiment, the insert assembly 10B may be formed with one or more insert units positioned adjacent to the fixed guide vane cascade 2 and one or more insert units positioned adjacent to the fixed diffuser vane cascade 4.

[0091] To construct a shell liner, identical insert units (e.g., insert units as shown in view B of FIG. 3) may be adjacent the inlets 8, 8A, 8B and outlets 9, 9A, 9B. For example, the inlet insert unit / module (10) may be identical in terms of the shape of the internal passages / channels. in ) to the outlet insert unit / module (10 out ) to distinguish it from the inlet insert unit / module (10 in ) customization is not excluded.

[0092] Thus, in all configurations (10A, 10B, 10C), all of the insert units / modules that make up the insert assembly may be identical, or the inlet insert units / modules may differ from the outlet insert units / modules in terms of their dimensions and / or shape.

[0093] Furthermore, in insert assembly 10 (10A, 10B, 10C), the insert units positioned on opposite sides of apparatus 100 (i.e., the fixed guide vane cascade side and the fixed diffuser vane cascade side) may be identical or different at least in terms of the number of insert units, their structure, and additional appliances such as auxiliary apertures (e.g., fluid passages), coatings, catalysts, and the like. In some cases, the insert units positioned on opposite sides of apparatus 100 essentially facing each other adopt a mirror image arrangement.

[0094] The insert assembly 10 and all units (segments) and / or modules forming said assembly are preferably made interchangeable.

[0095] Referring back to the configurations 10, 10C of FIG. 3, the insert assembly embodied as 10C is a shell liner similar to that embodied as 10B, however, in 10C, the shell liner is formed with more insert units. In 10C, the shell liner includes two or more insert units positioned adjacent to the stationary guide vane cascade 2 and two or more insert units positioned adjacent to the stationary diffuser vane cascade 4. In the presented configuration, the insert assembly 10, 10C includes four insert units, 10-1, 10-2, 10-3, 10-4, on the inlet side, thereby forming an inlet insert module (10 in ) and including an equal number of insert units (not shown) on the outlet side to form an outlet insert module (10 out). Whether the insert assembly is comprised of multiple insert segments in the manner shown in 10C, all or selected segments (e.g., 10-1, 10-2) may be configured to guide flow to and from the associated fixed vane cascade. View C illustrates an insert assembly in which insert segments 10-1, 10-2 include flow guides 11, while segments 10-3 and 10-4 do not.

[0096] Similarly, configuration 10C may be configured to include, for example, two or three insert units (segments) adjacent to a fixed guide vane cascade 2, thereby forming an inlet insert module 10. in and includes the same or different number of insert units adjacent to the diffuser vane cascade 4, thereby forming an outlet insert module 10 out Any suitable form is contemplated.

[0097] In the configurations 10B and 10C, the insert module 10 in and 10 out are adjacent to each other inside the duct and form a (modular) shell liner inside the casing 6 .

[0098] The shell liner form of the insert assembly (10B, 10C) is further visualized diagrammatically in Figure 6, which shows an apparatus 100 in vertical cross section with a gas casing 6 constituting an outermost pressure shell (outer "donut"), an intermediate layer formed by the shell liner / insert assembly 10, and an innermost flow shaping device 5 (inner "donut").

[0099] In the case of insert assemblies provided in shell liner configuration (10B, 10C), all insert units and insert modules (10-1, 10-2, 10-3, 10-4 and 10-5, respectively) are arranged in a manner that allows the essentially gaseous medium to circulate through gaps 15 along the area where the insert units are adjacent (see FIG. 3, view C). in ,10 out 10C) are adjacent to each other in a non-sealed manner. Gaps 15 are thus formed between individual insert units (e.g., 10C) and / or between insert modules 10. in ,10 out When the insert modules 10 are adjacent to each other to form an insert assembly 10 (10B, 10C) and essentially surround the stationary cascade and the rotor cascade, in ,10 out exists between.

[0100] Thus, in the shell liner configuration, the insert assemblies 10, 10B, 10C essentially surround the stator-rotor-stator arrangements 2, 3, 4.

[0101] Providing gaps 15 between the insert units allows relative movement of the insert units within the insert assembly 10 relative to one another in order to compensate for thermal expansion. Additionally or alternatively, the insert units can be made movable relative to the gas casing 6.

[0102] Overall, in configurations 10B and 10C, the gas casing 6 and insert assembly 10 can be seen as a dual shell structure of the device 100. In this dual shell structure, the gas casing 6 forms the outer shell (pressure shell) while the insert assembly 10 forms the inner shell. The casing 6 provides a hermetically sealed, gas tight shell while the insert assembly forms a non-hermetic inner shell liner. This inner shell liner allows fluid, e.g., gas, to circulate between the individual components (insert units) of which the shell liner is comprised.

[0103] By having a shell liner 10 (10B, 10C) mounted inside the duct, the vane-free space 7 formed between the fixed cascades 2, 4 is divided into cavities 7A and 7B, with cavity 7A being formed with a portion of the duct volume between the inner surface of the insert assembly 10 (facing the flow-shaping device 5) and the outer surface of the flow-shaping device, and cavity 7B being formed with a portion of the duct volume between the outer surface of the insert assembly (facing the gas casing 6) and the inner surface of the gas casing (see Figures 4 and 6).

[0104] In one particular configuration, the insert assembly mounted inside the duct of the apparatus 100 at least partially defines a vaneless space 7 formed in the duct between the outlet from the stator-rotor-stator arrangement 2,3,4 (aka the outlet from the fixed diffuser vane cascade 4) and the inlet to the stator-rotor-stator arrangement 2,3,4 (aka the inlet to the fixed guide vane cascade 2). Thus, the vaneless space 7 may be defined by at least a portion of the duct volume between the inner surface of the insert assembly 10 and the outer surface of the flow shaping device 5 disposed inside the casing. For example, in the shell liner configuration (10B, 10C), the vaneless space 7 is defined with the duct volume forming a cavity 7A (FIGS. 4 and 6). Where the insert assembly is comprised of a predetermined number of separate, discontinuous insert units, for example of form 10A, the vane-free space 7 is essentially defined with the duct volume between the flow shaping device 5 and the gas casing 6, and the insert units participate in forming said vane-free space, with some design-specific variation.

[0105] FIG. 4 shows a cross-section of an apparatus 100 including an insert assembly 10 and illustrates the formation of a flow guide 11 by the insert unit. At the inlet and outlet, (respectively, 10 in and 10out The flow guides 11 formed as internal passages or channels within the insert units / modules (shown as 11 ) are respectively designated by the reference numerals 11 in and 11 out As shown in the figure.

[0106] 4 shows a cavity 7B formed between the gas casing 6 (its inner surface) and the insert assembly 10. An additional fluid medium, the same as or different from the fluid medium flow propagating through the duct undergoing heat treatment, may be introduced into the cavity 7B. The additional fluid medium is preferably a gaseous medium, such as a diluent gas (steam, inert gas, etc.), a reactive chemical-containing gas, and / or other gases, for mediating cooling of the main flow (the fluid medium flow undergoing heat treatment in the device 100) or additional heating. The reactive chemicals (reactants) may include any one of the following: combustion gases, such as hydrogen gas, hydrocarbons, oxygen, air, other gases, and / or any other suitable reactive compounds, optionally a catalyst.

[0107] In some cases, the insert assembly 10 (10A, 10B, 10C) includes a number of through holes (not shown) arranged on the surface of at least some of the insert units. Through these holes, and through gaps 15 formed in the joining areas of the insert units, the additional gaseous medium mentioned above may be fed into the ducts of the device 100. The through holes may also take several forms to allow circulation of the gaseous medium between the cavities 7A, 7B formed in the ducts.

[0108] Through holes and / or other similar appliances (not shown) allow for a more uniform supply of the fluid medium into the apparatus and improve the uniformity of the temperature distribution inside the gas casing 6. The additional gaseous medium can be supplied at a pressure slightly higher than the pressure inside the gas casing (e.g., 0.1 atm to 10 atm higher), so that part of the supplied gas enters the process and another part is discharged from the apparatus 100 through apertures formed in the gas casing 6 (not shown). Such an arrangement allows the total amount of gaseous medium entering the process to be reduced.

[0109] Additionally or alternatively, cavity 7B may contain an insulating material, for example a thermally insulating material.

[0110] Reference is now made to Figure 5 which shows the arrangement of insert assembly 10 (here embodied as 10A) relative to a fixed vane cascade and casing (see half shells 6A, 6B). The fixed vane cascade shown in Figure 5 is shown as a fixed guide vane cascade 2, however the same arrangement is fully applicable to a fixed diffuser vane cascade (not shown).

[0111] In some cases, it is advantageous to realize selected parts of the fixed vane cascade, specifically the parts located in the high temperature gradient zone (see FIG. 1B), removable from the main cascade. In FIG. 5, the removable cascade part is indicated by reference number 2A, whereas the remainder of the cascade (called the "main cascade") is indicated by reference number 2. A clearance 16 is provided between the removable part 2A and the remainder of the cascade 2 to accommodate thermal expansion. In addition, the fastening of the removable cascade part 2A to the remainder of the cascade is arranged so that said removable part 2A can move relative to the main part of the fixed vane cascade 2 during thermal expansion. For example, the removable part 2A may include an elongated aperture at the attachment site of the pin 17. The pin fixes the removable part 2A on the cascade 2. Together with the clearance 16, the elongated aperture accommodates thermal expansion of the removable part 2A.

[0112] Reference numeral 17A denotes a fixing pin installed with minimal clearance.

[0113] The configuration with a removable fixed cascade part 2A allows a reduction in manufacturing costs, since the fixed cascade 2, 4 other than the removable part (2A) can be manufactured from less heat-resistant and therefore less expensive materials.

[0114] A similar fastening arrangement may be employed to hold the insert units together in a manner that allows relative movement of the insert units with respect to one another.

[0115] The insert assembly 10, and any of its constituent parts, may be provided with a surface (inner and / or outer surface) that includes a profile arranged to optimize the flow rate of the fluid medium propagating through the duct. The profile may be, for example, of the corrugated type arranged in an essentially helical pattern, or in any other suitable shape.

[0116] The insert assembly can be manufactured with a smaller wall thickness relative to the gas casing 6. By having thinner walls, the insert unit is thus significantly less rigid than the gas casing. Additionally or alternatively, the insert assembly can also be manufactured from a material different from the casing. The insert material can be selected from a group of metals that withstand higher temperatures, are inert in chemical reactions and / or reduce coking (or at least do not increase coking).

[0117] In a preferred form, the insert assembly and any one of the insert units are constructed partially or entirely from a material that can flex or bend without breaking (i.e., is not rigid), which can be accomplished by fabricating them from a relatively thin sheet of metal or metal alloy.

[0118] In some other configurations, the insert assembly, and at least some of the insert units contained within the insert assembly, may be constructed partially or entirely from a material having low flexibility, such as a ceramic material or any other suitable refractory material.

[0119] The use of ceramics or other refractories to manufacture at least portions of the insert assembly can increase the service life of the apparatus 100. Ceramic materials are inert, have good (thermal) insulating and thermal shock resistant properties, and can be prefabricated or cast into the desired / required shape. Exemplary ceramic materials include composites where aluminum (Al2O3), silica (SiO2), silicon carbide, zircon, etc. are mixed with various binders to provide a suitable rheological consistency for forming.

[0120] In some configurations, the insert units within the insert assembly 10 can be constructed from the same or different materials. For example, the insert units connectable to the inlets and outlets of the device 100 (insert segments 10-1, 10-2 with flow guides 11, see 10C in FIG. 3) can be formed from a first material, and the insert units not directly connectable to the inlets / outlets (10-3 and 10-4 without flow guides 11, see 10C in FIG. 3) can be formed from a second material different from the first material. In configurations such as 10C, the insert units adjacent to and / or connected to the inlets and outlets can be constructed completely or partially from a material with higher heat resistance compared to the other segments.

[0121] In the insert assembly 10 (10A, 10B, 10C), any one of the insert units can be comprised of portions formed from the same or different materials.

[0122] Reference is made to FIG. 6, which shows an insert assembly 10 provided as an internal shell liner inside a gas casing 6. The insert units / insert modules adjacent to the inlet and outlet branches (8 and 9, respectively) have end extensions which project into the branches 8 and 9. The shell liner with end extensions is shown in dashed lines. The insert assembly may thus extend into either the inlet or outlet branch to a predetermined length in the form of a tubesheet lining. By means of its end extensions, the insert assembly may extend up to and / or through the connecting flange 18 into the inlet / outlet pipe.

[0123] In the arrangement shown in Figure 6, the entire assembly 10 may be formed from the same material, such as a metal, metal alloy, ceramic, or other refractory material. Alternatively, the shell liner may be formed from a first material and the end extensions may be formed from a second material different from the first material. For example, the end extensions may be formed from ceramic or other refractory material for better thermal insulation, while the shell liner with the flow guide channels etc. may be formed from a metal. An end extension formed from a ceramic may employ a ferrule configuration, for example.

[0124] Any combination of suitable materials is contemplated.

[0125] In one aspect, a rotary machine 100 for heat treating a fluid is provided, the machine comprising a rotor, the rotor including a plurality of rotor blades arranged around a rotor hub 3A mounted on a rotor shaft 1 and forming a rotor blade cascade 3, a plurality of stationary vanes arranged in an essentially annular vane cascade 2,4 arranged adjacent to the rotor blade cascade so as to form a stator-rotor-stator arrangement 2,3,4, a casing 6 in which a duct is formed with at least one inlet 8 and at least one outlet 9, the casing enclosing the rotor blade cascade and the stationary vane cascade within the duct, an insert assembly 10,10A,10B,10C, in which the insert assemblies are molded and positioned inside the duct to respectively form guideways for directing the fluid medium flow entering the duct through the at least one inlet 8 towards the stator-rotor-stator arrangement and for further directing the fluid medium flow leaving the stator-rotor-stator arrangement towards the at least one outlet 9. The insert assemblies then homogenize the temperature distribution inside the casing and reduce thermal stresses generated in the casing during the propagation of the heat-treated fluid medium through the duct.

[0126] The device advantageously includes an insert assembly 10, 10A, 10B, 10C according to any of the configurations outlined above.

[0127] In a further aspect, there is provided a method for reducing thermal stresses and associated deformations in a rotating device during thermal processing of a fluid, said method comprising at least the steps of: (a) - a rotor, said rotor comprising a plurality of rotor blades arranged around a rotor hub 3A mounted on a rotor shaft 1 and forming a rotor blade cascade 3; a plurality of fixed vanes arranged in an essentially annular vane cascade 2,4 arranged adjacent to said rotor blade cascade so as to form a stator-rotor-stator arrangement 2,3,4; a casing 6 in which a duct is formed with at least one inlet 8 and at least one outlet 9, said casing enclosing said rotor blade cascade and said fixed vane cascade in said duct; obtaining a rotating device 100 including (b) disposing said insert assemblies 10, 10A, 10B, 10C inside said duct so as to form guide paths for directing the fluid medium flow entering said duct through said at least one inlet 8 towards said stator-rotor-stator arrangement and for further directing the fluid medium flow exiting said stator-rotor-stator arrangement towards said at least one outlet 9, respectively; (c) propagating the fluid medium through a duct between the at least one inlet and at least one outlet to thermally treat the fluid medium; Including, the insert assembly homogenizes the temperature distribution inside the casing and reduces thermal stresses generated in the casing during propagation of the heat-treated fluid medium through the ducts; A method is provided.

[0128] In an embodiment, the heat treatment process involves increasing the temperature of the fluid medium by at least about 400 degrees Celsius (°C).

[0129] Thus, the apparatus 100 may be provided with a (pre)heater function. The thermal treatment process may thus be the direct heating of various fluids, such as process gas, inert gas, air, or any other gas, or the indirect heating of fluids (liquid, steam, gas, steam / liquid mixture, etc.). The heated fluid generated in the rotating apparatus may be used to heat any one of gas, steam, liquid, and solid materials. The rotating apparatus may replace or be combined with several types of furnaces, heaters, kilns, gasifiers, and reactor devices that are traditionally fired or heated with solid, liquid, or gaseous fossil fuels, or in some cases bio-based fuels.

[0130] The thermal treatment process may involve the thermally assisted conversion of a feedstock in a fluid medium, optionally thermal or thermochemical cracking of the hydrocarbon-containing feedstock. The cracking process involves a fluidized hydrocarbon-containing feedstock (i.e., a fluidized organic feed material that contains primarily carbon and hydrogen). In some cases, the thermal treatment process is steam cracking of the hydrocarbon-containing feedstock in a fluid medium.

[0131] As it propagates through the device 100, the fluid medium passes through the cascades 2, 3 and 4 several times, and during each pass the temperature of the fluid medium is raised to a predetermined value (more precisely, the temperature increase occurs when the fluid medium stream leaves the rotor blades and passes through the diffuser and vaneless space 7). The amount of thermal energy added to the medium is sufficient to initiate chemical decomposition reactions, such as reactions that break the chemical bonds between long carbon-hydrogen (CH) chains. Thus, the high molecular weight compounds present in the fluid stream are effectively reduced in size.

[0132] Additionally or alternatively, the thermally assisted conversion of the feedstock may involve processing oxygen-containing feed materials, such as oxygen-containing hydrocarbon derivatives. In some configurations, the apparatus 100 may be configured to process cellulosic feedstocks. In some additional or alternative configurations, the apparatus 100 may be configured to process (waste) animal fat-based feedstocks and / or (waste) vegetable oil-based feedstocks. The animal fat-based and vegetable oil-based feedstocks may include hydrodeoxygenation (removal of oxygen from oxygen-containing compounds), resulting in the breakdown of (tri)glyceride structures and resulting in mostly linear alkanes. In further additional or alternative configurations, the apparatus 100 may be configured to process by-products of the wood pulp industry, such as tall oil, or any derivatives thereof. The definition of "tall oil" refers to a by-product of the commonly known Kraft process, used primarily in pulping softwoods in wood pulp production.

[0133] In the process, a hydrocarbon-containing feed is provided that includes, by way of example, any one of the following: medium-weight hydrocarbons, such as naphtha and gas oil, and light hydrocarbons, such as ethane, propane, and butane. Propane, and heavier fractions can also be utilized.

[0134] In some cases, the hydrocarbon-containing feed is a gasified pretreated biomass material. The biomass-based feed is a pretreated cellulosic-derived, or specifically lignocellulosic-derived, biomass that is fed into the apparatus in a substantially gaseous form.

[0135] The hydrocarbon-containing feed can further be provided as any one of pre-treated glyceride-based materials, such as (waste or residual) vegetable oils, and / or animal fats, or pre-treated plastic waste or residues. Pre-treatment of said (tri)glyceride-based feedstock may involve different processes, such as pyrolysis or deoxygenation, as described above. A wide variety of plastic wastes, including PVC, PE, PP, PS materials and mixtures thereof, can be utilized in the process of recovery of pyrolysis oil or gas, which can be further used as a feedstock for producing new plastics and / or refined into fuel oil (diesel equivalent).

[0136] Thus, in selected embodiments, the apparatus 100 can be configured to perform at least one procedure selected from the group consisting of processing a hydrocarbon feedstock, preferably containing a medium-weight and a light-weight hydrocarbon fraction, processing a gasified carbohydrate-containing feed material, processing a gasified glyceride- and / or fatty acid-containing feed material, and processing a gasified cellulosic biomass material. Thus, the apparatus 100 can be configured to process an oxygen-containing feedstock, for example derived from a bio-based feedstock. Possible fields of application include refining biomass-based or biomass-derived materials to produce renewable fuels, in processes such as the direct catalytic hydrogenation of vegetable oils or animal fats to the corresponding alkanes, or the catalytic dehydrogenation of gaseous hydrocarbons, for example as one of the steps of the Fischer-Tropsch process. In addition, the apparatus can be configured for the valorization (enhancement or purification of gaseous materials) of bio-based pyrolysis gases or syngas.

[0137] In the case of utilizing feedstocks based on biomass, glycerides, and / or polymeric materials, the apparatus 100 may be further configured for catalytic processes. This is accomplished by a number of catalytic surfaces (not shown) formed by catalytic coatings on the blades or inner walls in contact with the process fluid. In some cases, the apparatus may include a number of catalytic modules defined by a ceramic or metal substrate or support carrier with an active (catalytic) coating, optionally realized as a monolithic honeycomb structure.

[0138] As is obvious to a person skilled in the art, with the development of technology, the basic idea of ​​the invention can be implemented in various ways. The invention and its embodiments in general can vary within the scope of the appended claims.

Claims

1. 1. An insert assembly (10, 10A, 10B, 10C) to be used in a rotary device for heat treating a fluid, said device comprising: a rotor comprising a plurality of rotor blades arranged around a rotor hub (3A) mounted on a rotor shaft (1) and forming a rotor blade cascade (3); a plurality of fixed vanes arranged in an essentially annular vane cascade (2,4) arranged adjacent to said rotor blade cascade so as to form a stator-rotor-stator arrangement (2,3,4); and a casing (6) in which a duct is formed with at least one inlet (8) and at least one outlet (9), the casing enclosing the rotor blade cascade (3) and the fixed vane cascade (2, 4) inside the duct; said insert assembly being molded and positioned within said duct such that one or more guide paths are formed which respectively direct the fluid medium flow entering said duct through said at least one inlet (8) towards said stator-rotor-stator arrangement and further direct the fluid medium flow exiting said stator-rotor-stator arrangement towards said at least one outlet (9); Insert assembly.

2. 2. The insert assembly of claim 1, wherein the insert assembly is molded and positioned within the duct so as to equalize the temperature distribution within the casing and reduce thermal stresses generated within the casing during propagation of a heat-treated fluid medium through the duct.

3. each insert assembly is configured to direct a fluid medium flow entering the duct through the at least one inlet (8) towards a fixed guide vane cascade (2) of the stator-rotor-stator arrangement, and to further direct a fluid medium flow exiting a fixed diffuser vane cascade (4) of the stator-rotor-stator arrangement towards the at least one outlet (9), the fixed guide vane cascade (2) being located upstream of the rotor blades, and the fixed diffuser vane cascade (4) being located downstream of the rotor blades; 3. An insert assembly according to claim 1 or 2.

4. 3. The insert assembly of claim 1 or 2, comprising a predetermined number of insert units.

5. 3. An insert assembly according to claim 1 or 2, wherein the insert unit is arranged inside the duct so as to be adjacent to either the inlet (8) or the outlet (9).

6. 3. An insert assembly as described in claim 1 or 2, wherein the insert units adjacent to either the inlet or the outlet are provided with a shape adjusted to optimize fluid medium flow propagating through the insert assembly.

7. 3. An insert assembly according to claim 1 or 2, configured to be attached to any one of said fixed vane cascades (2, 4).

8. 3. The insert assembly according to claim 1 or 2, wherein all the insert units are spaced apart from one another.

9. 3. An insert assembly according to claim 1 or 2, wherein the insert units are adjacent to each other inside the duct so as to form a shell liner inside the casing (6).

10. 10. The insert assembly of claim 9, wherein the insert units are non-sealingly adjacent to one another to allow an essentially gaseous medium to circulate through gaps remaining along the areas where the insert units are adjacent.

11. 10. The insert assembly of claim 9, wherein the shell liner formed inside the casing (6) essentially surrounds the stator-rotor-stator arrangement (2, 3, 4).

12. 10. The insert assembly of claim 9, wherein the shell liner is formed with one or more insert units positioned adjacent a stationary guide vane cascade (2) and one or more insert units positioned adjacent the stationary diffuser vane cascade (4).

13. 10. The insert assembly of claim 9, wherein the insert assembly at least partially defines a vane-free space (7) formed in a duct between an outlet from the stator-rotor-stator arrangement (2, 3, 4) and an inlet to the stator-rotor-stator arrangement, whereby the vane-free space (7) is defined by at least a portion of a duct volume between an inner surface of the insert assembly and an outer surface of a flow-shaping device (5) disposed inside the casing.

14. 3. An insert assembly according to claim 1 or 2, wherein the insert units are mounted within the casing (6) in a manner that allows movement of the insert units relative to each other and / or relative to the casing.

15. 3. The insert assembly according to claim 1, wherein a predetermined number of through holes are arranged on the surface of at least some of the insert units for supplying additional gaseous medium into the duct.

16. 3. An insert assembly according to claim 1 or 2, wherein the surface of the insert unit has a profile formed to optimize the flow velocity of a fluid medium propagating through the duct.

17. 3. An insert assembly according to claim 1 or 2, wherein the insert units have a small wall thickness relative to the casing (6), and optionally at least some of the insert units are made from a material different from that of the casing (6).

18. 3. The insert assembly of claim 1 or 2, wherein any one of the insert units is constructed partially or entirely from a material that can be flexed or bent without breaking.

19. 3. The insert assembly of claim 1 or 2, wherein any one of the insert units is constructed partially or entirely from a ceramic material.

20. 3. An insert assembly according to claim 1 or 2, wherein any one of said insert units is made up of parts made of the same or different materials.

21. 3. The insert assembly of claim 1 or 2, which is configured to be replaceable.

22. A rotary device (100) for thermally treating a fluid, comprising: a rotor comprising a plurality of rotor blades arranged around a rotor hub (3A) mounted on a rotor shaft (1) and forming a rotor blade cascade (3); a plurality of fixed vanes arranged in an essentially annular vane cascade (2,4) arranged adjacent to said rotor blade cascade so as to form a stator-rotor-stator arrangement (2,3,4); a casing (6) in which a duct is formed with at least one inlet (8) and at least one outlet (9), the casing enclosing the rotor blade cascade (3) and the fixed vane cascade (2, 4) inside the duct; and - insert assembly (10, 10A, 10B, 10C), wherein the insert assemblies are molded and positioned within the duct to define one or more guide paths that respectively direct the fluid medium flow entering the duct through the at least one inlet (8) towards the stator-rotor-stator arrangement and further direct the fluid medium flow exiting the stator-rotor-stator arrangement towards the at least one outlet (9). Rotating equipment for heat treating fluids.

23. The device of claim 22, comprising an insert assembly as described in claim 1.

24. 23. The apparatus of claim 22, including selected vanes within said stationary vane cascade (2, 4) modified to form attachment points for said insert assemblies.

25. 23. The device according to claim 22, wherein the insert assembly is provided in the form of a shell liner inside the casing (6), and a duct volume formed between the shell liner and the casing is filled with insulating material.

26. 26. Apparatus according to any one of claims 22 to 25, wherein the apparatus is configured as a reactor for the thermally assisted conversion of a feedstock in a fluid medium, optionally as a reactor for the thermal or thermochemical cracking of a hydrocarbon-containing feedstock.

27. 1. A method for reducing thermal stresses and associated deformations in a rotating device during thermal processing of a fluid, the method comprising: (a) Obtaining a rotating device (100) comprising: a rotor comprising a plurality of rotor blades arranged around a rotor hub (3A) mounted on a rotor shaft (1) and forming a rotor blade cascade (3); a plurality of fixed vanes arranged in an essentially annular vane cascade (2,4) arranged adjacent to said rotor blade cascade so as to form a stator-rotor-stator arrangement (2,3,4); and a casing (6) in which a duct is formed with at least one inlet (8) and at least one outlet (9), the casing enclosing the rotor blade cascade (3) and the fixed vane cascade (2, 4) inside the duct; (b) disposing said insert assemblies (10, 10A, 10B, 10C) inside said duct so as to form one or more guide paths for respectively directing a fluid medium flow entering said duct through said at least one inlet (8) towards said stator-rotor-stator arrangement and for further directing a fluid medium flow exiting said stator-rotor-stator arrangement towards said at least one outlet (9); and (c) propagating the fluid medium stream through a duct between the at least one inlet and at least one outlet to thermally treat the fluid medium; the insert assembly homogenizes the temperature distribution inside the casing and reduces the thermal stresses generated in the casing during the propagation of the fluid medium to be heat treated through the ducts; A method for reducing thermal stresses and associated deformations in rotating equipment during thermal processing of fluids.

28. 28. The method of claim 27, wherein conditions for heat treatment of the fluid medium inside the duct are established when an amount of thermal energy is imparted to the fluid medium flow during its propagation inside the duct between the at least one inlet (8) and the at least one outlet (9) by a series of energy transformations that occur when the fluid medium flow passes successively through a blade / vane array forming a stator-rotor-stator arrangement and a vane-free space (7), respectively.

29. 29. A method according to claim 27 or 28, wherein the fluid medium flow follows an essentially helical flow path passing successively through the array of blades / vanes forming the stator-rotor-stator arrangement and through the vane-free space (7), respectively.

30. 29. The method of claim 27 or 28, wherein the heat treatment process involves increasing the temperature of the fluid medium by at least about 400 degrees Celsius (°C).

31. 29. The method of claim 27 or 28, wherein the process of thermal treatment involves thermally assisted conversion of a feedstock in a fluid medium, optionally thermal cracking or thermochemical cracking of a hydrocarbon-containing feedstock.

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