Fouling mitigation in compressor intercoolers by wash oil injection

Abstract

A system and method for decreasing fouling inside an intercooler are provided. An exemplary system includes an intercooler that includes an inlet from a stage in a compressor, a tube bank, and an outlet to a suction drum for a succeeding stage. The system also includes a pair of nozzles disposed on opposite sides of an inlet pipe to the intercooler, and an atomizer mounted in each nozzle, wherein the atomizer injects a wash oil into the inlet of intercooler in a flared spray pattern that extends from each atomizer.

Description

[0001] FOULING MITIGATION IN COMPRESSOR INTERCOOLERS BY WASH OIL INJECTION

[0002] TECHNICAL FIELD

[0003] This disclosure relates to systems and methods for mitigating fouling.

[0004] BACKGROUND ART

[0005] Cracked gas compressors (CGCs) are important unit-operations in ethylene plants that provide the driving force used for conducting back-end separation and purification of the ethylene produced during thermal cracking of hydrocarbon. Each stage or joined stage of the cracked gas compressor increases the temperature of the gas due to the heat of compression. Accordingly, an intercooler is generally placed between stages of the cracked gas compressor to remove this heat. However, the cracked gases can react in the inlet of the intercooler, resulting in fouling.

[0006] Accumulation of the fouling results in a decrease of the available flow area for the cracked gas, and thus reduced throughput, which reduces the throughput and ethylene yield. One method used in the industry to reduce fouling in the intercooler is the injection of wash oil. Wash oil is a hydrocarbon solvent that can dissolve polymeric foulants and prevent the foulants from adhering to treated surfaces.

[0007] SUMMARY OF INVENTION

[0008] An embodiment described herein provides a system for decreasing fouling inside an intercooler. The system includes an intercooler that includes an inlet from a stage in a compressor, a tube bank, and an outlet to a suction drum for a succeeding stage. The system also includes a pair of nozzles disposed on opposite sides of an inlet pipe to the intercooler, and an atomizer mounted in each nozzle, wherein the atomizer injects a wash oil into the inlet of intercooler in a flared spray pattern that extends from each atomizer.

[0009] Another embodiment described in examples herein provides a method for decreasing fouling inside an intercooler. The method includes mounting a pair of nozzles in an inlet line to the intercooler, wherein the pair of nozzles are mounted directly opposite each other on the inlet line. An atomizer is mounted in each of the pair of nozzles. A wash oil is injected into the intercooler in a flared spray pattern that extends from each of the pair of nozzles.

[0010] BRIEF DESCRIPTION OF DRAWINGS

[0011] Figure 1 is a schematic drawing of a compressor system, for example, used for the gas product from a cracker. Figure 2 is a photograph of the tube bank in an intercooler, taken through the inlet line.

[0012] Figure 3 is an illustration of an intercooler, showing the tube bank visible through the inlet flange.

[0013] Figures 4A-4F are drawings of the geometries used for injection of the wash oil into the inlet of the intercooler.

[0014] Figure 5 is a top view of the tube bank 200 directly beneath the inlet pipe cross- sectional area (ID 41”).

[0015] Figures 6A and 6B are drawings of a five-hole atomizer.

[0016] Figure 7 is a contour plot of gas velocity magnitude (m / s) in the feed line.

[0017] Figures 8A and 8B are contour plots of the droplet size distribution for an atomizer with three-holes of 0.118” diameter over the area of the tube bank.

[0018] Figures 9A and 9B are contour plots of the droplet size distribution for an atomizer with five-holes of 0.138” diameter over the area of the tube bank.

[0019] Figure 10 is a close-up view of a single spray atomizer at the center of the inlet pipe, mounted on a feed line that extends across the diameter of the inlet pipe.

[0020] Figures 11A and 1 IB show the particle size distribution for the single spray atomizer placed at the center of inlet pipe.

[0021] Figure 12A is a drawing of two opposing nozzles placed perpendicular to the tube bank of the intercooler.

[0022] Figure 12B is a drawing of two opposing nozzles placed parallel to the tube bank of the intercooler.

[0023] Figure 13 is a drawing of the computational geometry used for simulating the effects of droplet size distribution.

[0024] Figures 14A-14C show the initial droplet size distribution for the three droplet sizes.

[0025] Figures 15A-15F show the droplet size distribution of each case over the tube bank.

[0026] Figures 16A-16C show the wash oil droplet distribution over the tube bank.

[0027] Figure 17 is a drawing of the placement of the nozzles above the tube bank.

[0028] Figure 18 is a process flow diagram of a method for decreasing fouling in and intercooler.

[0029] DESCRIPTION OF EMBODIMENTS

[0030] Intercooler fouling is often mitigated through injection of wash oil into the inlet of the intercooler. Wash oil is a blend of hydrocarbons that can prevent fouling by dissolving the fouling material as is formed, coating surfaces to prevent adhesion of fouling, or both. Wash oil often comprises a high percentage of aromatic compounds, such as 90 weight %. The fouling that forms in an intercooler is generally polymeric, such as polymers formed from butadiene, styrene, and ethylene in the cracked gas stream.

[0031] Embodiments described herein provide a method for mitigating fouling by injecting wash oil into the intercooler using spray nozzles. The optimization of the location, orientation, number, and design of atomizers used for the injection was performed using computational fluid dynamics (CFD). Based on the CFD simulation, using two opposing spray nozzles at the wall with a wash oil droplet size not less than 225 pm provides best coverage on the tube bank. Further, the optimum distance of the atomizers to the tube bank is between about 32” to about 40”. Accordingly, the nozzles in which the atomizers are mounted can be located on an inlet pipe at about 8 inches above an inlet flange on the intercooler. Full cone atomizers, such as jet flow regulated (JFR) atomizers, provide acceptable wash oil coverage of the tube bundle below the inlet to the intercooler.

[0032] Figure 1 is a schematic drawing of a compressor system 100, for example, used for the gas product from a cracker (cracked gas) 102. The cracked gas 102 is introduced to a first stage suction drum 104, which separates a liquid stream 106 from a feed stream 108, which is a gaseous stream fed to a compressor train 110. In this example, the compressor train 110 includes 5 compressor stages, labeled 1-5.

[0033] As described herein, a wash oil stream 112 can be added to the feed stream 108 to mitigate fouling from polymerization of materials in the cracked gas. Similarly, the wash oil stream can be added to the feed streams to each of the compressor stages 1-5 116. To control the temperature of the gases in each of the compressor stages 1-5 116, a boiler feed water stream 118 is added.

[0034] From each of the compressor stages 1-5, the compressed gas is fed to a corresponding intercooler 120. In embodiments described herein, a wash oil stream 114 is introduced into the inlet line into each of the intercoolers 120. The cooled compressed gas is then fed from the intercooler 120 to a corresponding flash drum 122. Each flash drum 122 separates a second liquid stream 124 from the cooled compressed gas stream from the corresponding intercooler 120, which then provides a gas feed stream to the next compressor stage 2-5.

[0035] Figure 2 is a photograph of the tube bank 200 in an intercooler, taken through the inlet line. This view is discussed further with respect to Figure 5. The hot gases from the cracked gas compressors create fouling in the intercoolers as well as the compressors. Over time, these fouling materials build up on top of the tube bank at the inlet and cause a high pressure drop across the intercooler and consequently, increased pressure drop across the compression system. One way to manage this accumulation of fouling materials is by injecting wash oil upstream of the intercooler. However, field experience has shown that bulk injection of wash oil immediately upstream of the intercooler without any atomizer, for example, pouring wash oil in as a single stream, is not very effective. It will only coat tubes 202 that are directly underneath the introduction of the wash oil, which allows fouling to form on tubes 204 that are not contacted with wash oil.

[0036] Accordingly, embodiments described herein provide injection methods to effectively coat the tube bank 200 through the inlet line. This will provide better coverage of the injected wash oil over the tube and 200 and lower the accumulation of fouling materials at the inlet of the intercoolers. As a result, the intercoolers will have better performance and longer service time between cleanings, resulting in reduced downtime for cleaning. Further, this will result in reduced pressure drop associated with intercooler fouling. The loss of throughput caused by fouling will be minimized increasing the earnings before interest, taxes, depreciation, and amortization (EBIDTA) is impacted. The improved usage of the wash oil will also result in reduced operating expenses (OPEX).

[0037] Figure 3 is an illustration of an intercooler 120, showing the tube bank 200 visible through the inlet flange 302. Nozzles 304 are shown on each side of the inlet flange 302, which can allow for the injection of wash oil. However, adding wash oil through these nozzles are too close to the tube bank 200 for effective coverage. Accordingly, a second set of nozzles are located on the inlet piping that joins to the inlet flange 302 and are used for the injection of the wash oil in embodiments described herein. These nozzles are located about 8 inches above the inlet flange 302 as discussed further with respect to Figures 4A-4D.

[0038] EXAMPLES

[0039] Computational Fluid Dynamic (CFD) Modeling

[0040] The CFD modeling of the wash oil injection into the intercooler 120 was performed using ANSYS Fluent 2022 and 2023. ANSYS Fluent is available from Ansys, Inc., of Canonsburg, Pennsylvania, USA. The simulations were performed using the properties of cracked gas and wash oil as shown in Table 1. Table 2 shows the process conditions. Table 1: Properties of Cracked Gas and Wash Oil

[0041] Table 2: Process Conditions

[0042] Figures 4A-4F are isometric drawings of the geometries used for injection of the wash oil into the inlet of the intercooler 120. Like numbered items are as described with respect to Figures 1 and 3. The geometry used for the simulations were that of a E201 type intercooler. Figure 4A shows the inlet piping 402 leading to the inlet pipe 404 to the intercooler 120. Figure 4B is a close-up drawing of the intercooler 120 shown with the nozzles 406 in the inlet pipe 404 that is coupled to the inlet flange 302 of the intercooler 120. In this embodiment, the nozzles are positioned at a 30° downward angle to the inlet pipe 404. Figure 4C is another close-up drawing of the intercooler 120 shown with the nozzles 406 in the inlet pipe 404 that is coupled to the inlet flange 302 of the intercooler 120. In this embodiment, the nozzles are positioned at a 90° angle to the inlet pipe 404.

[0043] Atomizers are installed in the nozzles to spray the wash oil. Each atomizer can be installed on a quill that is inserted through a double block and bleed valve system. This allows the atomizers to be removed for cleaning when they are fouled.

[0044] This positioning of the nozzles 406 on the inlet pipe 404 are shown in more detail in Figures 4D-4F. Similar to Figure 4C, Figure 4D shows the installation of the nozzles 406 perpendicular to the inlet pipe 404 at a distance 412 of about 8 inches to about 12 inches above the inlet flange 302 of the intercooler 120. Similar to Figure 4B, Figure 4E shows the installation of the nozzles 406 at a 30° angle to the inlet pipe 404, and at a distance of about 8 inches to about 12 inches above the inlet flange 302. The height of the nozzles 406 above the tube bank 200 can be determined by the type of atomizer chosen for installation in the nozzles 406. This is discussed further with respect to Figure 17.

[0045] Figure 4F is a drawing of a configuration in which a nozzle is installed from side to side in the inlet pipe 404. In this embodiment, an atomizer 410 is mounted on the nozzle 408 to spray the wash oil directly in the center of the inlet flange 302 above the tube bank.

[0046] Figure 5 is a top view of the tube bank 200 directly beneath the inlet pipe cross- sectional area (ID 41”). Like numbered items are as described with respect to Figures 1 and 2. This corresponds to the picture of Figure 2 and illustrates the area that the wash oil needs to cover.

[0047] Example 1 is a computational fluid dynamic (CFD) simulation of a single spray nozzle placed on the inlet flange perpendicular to the tube bank 200. For this example, two in-house atomizer designs were evaluated, a three-hole atomizer of 0. 118” diameter and a five-hole atomizer of 0. 138” diameter. Figures 6A and 6B are drawings of the five-hole atomizer. In the model the atomizers were installed in nozzle which was located on the inlet pipe wall at about 8” above the inlet flange 302 and about 14” above the tube bank to spray wash oil perpendicular to the cracked gas flow direction.

[0048] Figure 7 is a contour plot of gas velocity magnitude (m / s) in the feed line. As can be seen in the contour plot, the gas velocity entering the inlet pipe may not be balanced, e.g., with higher velocities in some regions. Thus, the distribution of droplets in the spray pattern may be important for ensuring coverage of the tube bank to prevent fouling.

[0049] Figures 8A and 8B are contour plots of the droplet size distribution for an atomizer with three-holes of 0.118” diameter over the area of the tube bank 200. Like numbered items are as described with respect to Figure 2. However, most of the area of the tube bank 200 (Figure 5) was not covered by the wash oil, indicating that the wash oil injection is ineffective.

[0050] Figures 9A and 9B are contour plots of the droplet size distribution an atomizer with five-holes of 0. 138” diameter over the area of the tube bank 200. Like numbered items are as described with respect to Figure 2. Similar performance to that of the three-hole atomizer was observed for the five-hole nozzle with 0.138” diameter.

[0051] Example 2: CFD Simulation of a Single Spray Atomizer Placed at the Center of Inlet Pipe

[0052] Figure 10 is a close-up view of a single spray atomizer 410 at the center of the inlet pipe 404, mounted on a nozzle 408 that extends across the diameter of the inlet pipe 404. Like numbered items are as described with respect to Figures 1, 3, and 4. In this embodiment, a full cone atomizer, such as a JFR atomizer, with spray angle of 90° and mean droplet diameter in the range of 225mm was evaluated. The location of the nozzle is 32” above the tube bank.

[0053] Figures 11A and 1 IB show the particle size distribution for the single spray atomizer 410 placed at the center of inlet pipe 404. Like numbered items are as described with respect to Figure 2. Two orientations of the atomizer were studied, parallel to the cracked gas flow direction (downward), as shown in Figure 12A and with the atomizer rotated clockwise at 30° to the cracked gas flow direction, as shown in Figure 12B. The clockwise rotation of the nozzle direction 30° to the cracked gas flow direction seems to provide better coverage of the tube bank 200 by the wash oil compared to the first orientation.

[0054] However, as described herein, locating the single spray atomizer 410 in the center of the inlet pipe 404 requires a feed line 408 that goes across the inlet pipe 404 to provide the wash oil to the atomizer 410 can cause operational difficulties. For example, fouling material may accumulate on the nozzle 408, which may interfere with the operation of the atomizer 410. Further, fouling formed on the outside of the feed line 408 may make it difficult to remove for inspection or repair.

[0055] Example 3: CFD Simulation of Two Opposing Spray Nozzles

[0056] For this example, two nozzle arrangements were studied, including two opposing spray nozzles 406 placed 60° to the inlet pipe wall, as described with respect to Figure 4E, and two opposing spray nozzles 406 placed 90° to the inlet pipe wall, as described with respect to Figure 4D. As discussed herein, a quill with an atomizer mounted at the end is inserted into each nozzle 406. For the two opposing spray nozzles placed 90° to the inlet pipe wall, two tangential orientations as shown in Figures 12A and 12B were considered.

[0057] Figure 12A is a drawing of two opposing spray nozzles 406 placed perpendicular to the tube bank of the intercooler, and parallel to the nozzle 304 on the inlet flange 302. Figure 12B is a drawing of two opposing nozzles 406 placed parallel to the tube bank of the intercooler, and perpendicular to the nozzle 304 on the inlet flange 302. These orientations were selected based on the non-uniform gas velocity profile shown in Figure 7.

[0058] A number of parameters were used to determine effectiveness of the wash oil injection. For example, the fraction of wash oil impacting the tube bank 200 directly beneath the inlet pipe cross-sectional area as described with respect to Figure 5. In this analysis, the wetted surface of the tube bank 200 is defined as the sum of areas with wash oil concentration greater than 5% of average concentration on the tube bank directly beneath cross-sectional area of the inlet pipe 404. The uniformity index is determined from the variation of a specified field variable (concentration) over a surface. When uniform index is 1, it indicates highest uniformity. The uniformity index can be weighted by area or mass. The area-weighted uniformity index captures the variation of the quantity, for example, the species concentration, while the mass-weighted uniformity index captures the variation of the flux (for example, the species flux). Generally, uniformity index above 0.95 is considered uniformly distributed.

[0059] The area-weighted uniformity index (ga) of a specified field variable is calculated using the following equation: a population standard deviation ya= 1 - = 1 - — - p population mean

[0060] Mathematically, this is expressed by to the following equation: where i is the facet index of a surface with n facets, and a is the average value of the field variable over the surface, represented as:

[0061] Table 3 shows the CFD results of all the cases that were simulated using full cone nozzles with 90° spray angle.

[0062] Among the spray nozzles considered in this study, a centrally located full cone spray nozzle in the inlet pipe provides the best wash oil spray coverage and distribution. However, as described herein, a spray nozzle centrally located in the inlet pipe requires the nozzle to the placed across the inlet pipe. This might create operational difficulties due to fouling. Accordingly, this design option was not considered further. Thus, a design option that was better have the wall spray nozzle placed 90° vertical to the inlet pipe, place above and perpendicular to the tube bank, as shown in Figure 12A. Table 3 : Results of Simulation for Different Scenarios

[0063] Example 4: CFD Simulation of Effects of Droplet Size

[0064] For this example, three droplet sizes were tested, 120mm, 150mm, and 225mm. Configuration with two opposing full cone spray nozzles placed 90° to the inlet pipe wall was used, as shown in Figure 13.

[0065] Figures 14A-14C show the initial droplet size distribution for the three droplet sizes. Figures 15A-15F show the droplet size distribution of each of the cases of Figures 14A-14C over the tube bank 200. Based on the results, the full cone spray nozzle with mean droplet size of 225 pm shows better performance.

[0066] Example 5: CFD Simulation of Impact of Atomizer Design

[0067] The impact of atomizer design on the wetting of the tube bank 200 was investigated using the configuration described with respect to Figure 13. Three commercially available atomizer designs were simulated, all with a mean droplet diameter of 225 pm. These included a full cone atomizer, a hollow cone atomizer, and a full cone atomizer inclined at an angle of 30° from horizontal. Figures 16A-16C show wash oil droplet distribution over the tube bank 200. For the hollow cone atomizer design, the wash oil droplet concentration at the center of the tube bank 200 is low compared to the full cone atomizer and JFR atomizer. In addition, the tube bank 200 was not fully covered by the wash oil droplets for the hollow cone atomizer. The JFR atomizer provides acceptable coverage similar to the full cone spray nozzle with mean droplet diameter of 225 pm and provides the bast coverage.

[0068] Figure 17 is a drawing of the placement of the nozzles 406 above the tube bank 200. The height (H) 1704 of the nozzles 406 above the tube bank 200 is selected based on the geometrical and operational parameters of the atomizers 1702. This follows the equation:

[0069] In this equation, and the corresponding figure, a is the angle between a horizontal line across the inlet pipe 404 and the center of the spray from the atomizers 1702. The term 0 represents the total angular with of the spray from the atomizers 1702. The gas flow velocity in the inlet pipe 404 is represented by Vg. The diameter of the inlet pipe 404 is D. The terminal velocity of the droplets of the wash oil is Ut. If the height 1704 of the nozzles 406 has already been determined, the height of the nozzles can be used to select the atomizers 1702, or example, choosing a and 0 of the atomizers 1702 to maximize coverage of the tube bank 200.

[0070] Figure 18 is a process flow diagram of a method 1800 for decreasing fouling in an intercooler. The method begins at block 1802 with mounting a pair of nozzles in an inlet line to the intercooler, wherein the pair of nozzles are melted directly opposite each other on the inlet line. As described herein, the inlet line is a line upstream of the intercooler that is coupled to a flange on the intercooler.

[0071] At block 1804, and atomizer is mounted in each of the pair of nozzles. As described herein, in some embodiments, the atomizer is mounted at the end of a quill or lance which is inserted into the inlet line through a double block and bleed valve mounted to the nozzle. This allows the quill with the atomizer to be removed from the inlet line, for example, for cleaning, while the compressor and intercooler system remains in operation.

[0072] At block 1806, a wash oil is injected into the intercooler in a flared spray pattern that extends from each of the atomizers. The flared spray pattern can be a solid cone spray pattern, a hollow cone spray pattern, or a spray pattern generated by a jet flow regulated (JFR) atomizer. As described herein, the JFR atomizer placed on each side of the inlet line, perpendicular to the tube bank, provides the greatest coverage of the tube bank without causing further fouling problems.

[0073] Embodiments

[0074] An embodiment described herein provides a system for decreasing fouling inside an intercooler. The system includes an intercooler that includes an inlet from a stage in a compressor, a tube bank, and an outlet to a suction drum for a succeeding stage. The system also includes a pair of nozzles disposed on opposite sides of an inlet pipe to the intercooler, and an atomizer mounted in each nozzle, wherein the atomizer injects a wash oil into the inlet of intercooler in a flared spray pattern that extends from each atomizer.

[0075] In an aspect, combinable with any other aspect, each nozzle includes a valve system that allows the atomizer to be retracted while the intercooler is operational. In an aspect, and the valve system includes a double block and bleed system. In an aspect, each atomizer is mounted on a retractable line. In an aspect, each atomizer is mounted on the retractable line to spray at an angle of between about 30° and about 60° below horizontal. In an aspect, each atomizer is mounted on the retractable line to spray at an angle of about 45° below horizontal.

[0076] In an aspect, combinable with any other aspect, at least one of the atomizers includes a full cone spray nozzle.

[0077] In an aspect, combinable with any other aspect, at least one of the atomizers includes a hollow cone spray nozzle.

[0078] In an aspect, combinable with any other aspect, at least one of the atomizers includes a full cone spray nozzle that is inclined 30° to the horizontal.

[0079] In an aspect, combinable with any other aspect, a droplet size from each atomizer is between about 120 pm and 250 pm. In an aspect, a droplet size from each atomizer is about 225 pm.

[0080] In an aspect, combinable with any other aspect, the pair of nozzles are mounted in the inlet line to the intercooler at between about 6 inches and about 12 inches above and inlet flange on the intercooler.

[0081] In an aspect, combinable with any other aspect, the pair of nozzles are mounted in the inlet line to the intercooler at about 8 inches above an inlet flange on the intercooler.

[0082] Another embodiment described in examples herein provides a method for decreasing fouling inside an intercooler. The method includes mounting a pair of nozzles in an inlet line to the intercooler, wherein the pair of nozzles are mounted directly opposite each other on the inlet line. An atomizer is mounted in each of the pair of nozzles. A wash oil is injected into the intercooler in a flared spray pattern that extends from each of the pair of nozzles.

[0083] In an aspect, the method includes selecting an atomizer with a full cone spray pattern. In an aspect, the method includes selecting an atomizer with a hollow cone spray patern.

[0084] In an aspect, the method includes selecting an atomizer with a lobed spray patern.

[0085] In an aspect, combinable with any other aspect, the flared spray patern is directed towards the intercooler at an angle of about 30° to about 60° below horizontal.

[0086] In an aspect, the flared spray patern is directed towards the intercooler at an angle of about 45° below horizontal.

[0087] In an aspect, combinable with any other aspect, the method includes mounting the pair of nozzles at between about 6 inches and about 12 inches above an inlet flange on the intercooler. In an aspect, the method includes mounting the pair of nozzles at about 8 inches above an inlet flange on the intercooler.

[0088] Other implementations are also within the scope of the following claims.

[0089] INDUSTRIAL APPLICABILITY

[0090] Compressor systems including intercoolers are unit-operations in commercial ethylene plants. This disclosure provides a system and method for mitigating fouling inside a compressor intercooler.

Claims

CLAIMS1. A system for decreasing fouling inside an intercooler, comprising: an intercooler comprising: an inlet from a stage in a compressor; a tube bank; and an outlet to a suction drum for a succeeding stage; a pair of nozzles disposed on opposite sides of an inlet pipe to the intercooler; and an atomizer mounted in each nozzle, wherein the atomizer injects a wash oil into the inlet of intercooler in a flared spray pattern that extends from each atomizer.

2. The system of claim 1, wherein each nozzle comprises a valve system that allows the atomizer to be retracted while the intercooler is operational.

3. The system of claim 2, wherein the valve system comprises a double block and bleed system.

4. The system of claim 2, wherein each atomizer is mounted on a retractable line.

5. The system of claim 4, wherein each atomizer is mounted on the retractable line to spray at an angle of between about 30° and about 60° below horizontal.

6. The system of claim 4, wherein each atomizer is mounted on the retractable line to spray at an angle of about 45° below horizontal.

7. The system of claim 1, wherein at least one of the atomizers comprises a full cone spray nozzle.

8. The system of claim 1, wherein at least one of the atomizers comprises a hollow cone spray nozzle.

9. The system of claim 1, wherein at least one of the atomizers comprises a full cone spray nozzle that is inclined 30° to the horizontal.

10. The system of claim 1, wherein a droplet size from each atomizer is between about 120 pm and 250 pm.

11. The system of claim 1, wherein a droplet size from each atomizer is about 225 pm.

12. The system of claim 1, wherein the pair of nozzles are mounted in the inlet line to the intercooler at between about 6 inches and about 12 inches above and inlet flange on the intercooler.

13. The system of claim 1, wherein the pair of nozzles are mounted in the inlet line to the intercooler at about 8 inches above an inlet flange on the intercooler.

14. A method for decreasing fouling inside an intercooler, comprising:mounting a pair of nozzles in an inlet line to the intercooler, wherein the pair of nozzles are mounted directly opposite each other on the inlet line; mounting an atomizer in each of the pair of nozzles; and injecting a wash oil into the intercooler in a flared spray pattern that extends from each of the pair of nozzles.

15. The method of claim 14, comprising selecting an atomizer with a full cone spray pattern.

16. The method of claim 14, comprising selecting an atomizer with a hollow cone spray pattern.

17. The method of claim 14, comprising selecting an atomizer with a lobed spray pattern.

18. The method of claim 14, comprising directing the flared spray pattern towards the intercooler at an angle of about 30° to about 60° below horizontal.

19. The method of claim 14, comprising directing the flared spray pattern towards the intercooler at an angle of about 45° below horizontal.

20. The method of claim 14, comprising mounting the pair of nozzles at between about 6 inches and about 12 inches above an inlet flange on the intercooler.

21. The method of claim 14, comprising mounting the pair of nozzles at about 8 inches above an inlet flange on the intercooler.

Images