Atomized Resid Nozzle for Fouling-Resistant Thermal Cracking
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Solution Overview
Problem
Existing methods for converting petroleum resid fluids, such as resid steam cracking, face challenges like fouling and agglomeration due to high viscosity and mixed-phase feed issues, which hinder efficient conversion of heavy oils into valuable products.
Innovation Solution
An apparatus and method involving the generation of an atomized resid fluid stream, delivered to heated cracking particles at temperatures ranging from 700° C. to 1200° C., using a multi-phase fluid application device and pyrolysis reactor to facilitate thermal cracking, reducing fouling and agglomeration through precise control of fluid and particle interactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If resid steam cracking uses nozzles with small inlet ports to generate resid vapor, then cracking efficiency is improved, but inlet ports quickly foul due to mixed-phase resid cracking feed
Solution Approach 1:
The nozzle inlet is segmented into multiple smaller ports rather than a single large opening. This segmentation increases the surface area for vaporization while reducing the likelihood of complete blockage, as fouling can occur at individual ports while others remain functional. The multiple small ports collectively maintain cracking efficiency while improving reliability against fouling.
Solution Approach 2:
Different regions of the nozzle are given different properties - the inlet ports are designed with specific geometries and distributions optimized for vapor generation, while other regions handle different phases of the resid feed. This local differentiation allows efficient cracking vapor generation while managing fouling tendencies in specific zones separately.
2Quantity of substance
If heavy resid feed has high viscosity, then it contains more valuable heavy hydrocarbons, but it slows fluidized flow and causes solids agglomeration
Solution Approach 1:
The heavy resid feed undergoes phase transition from liquid to vapor through controlled vaporization in the nozzle. This phase change reduces the viscosity and agglomeration tendency of the heavy hydrocarbons, allowing them to flow freely in fluidized state while maintaining their valuable heavy hydrocarbon content. The vaporization process converts the problematic high-viscosity liquid into a manageable vapor phase.
Solution Approach 2:
The system uses fluid dynamics and pressure control to manage the flow of high-viscosity resid feed. By controlling pressure gradients and fluid velocity profiles, the system maintains adequate flow rates of heavy hydrocarbons while preventing solids agglomeration through proper fluidization conditions.
3Productivity
If resid feed is heated to high temperature for cracking, then conversion efficiency is improved, but fouling and agglomeration increase
Solution Approach 1:
The resid feed is pre-vaporized and pre-heated in controlled stages before reaching the high-temperature cracking zone. This preliminary action prepares the feed by reducing its viscosity and preventing premature agglomeration, allowing subsequent high-temperature cracking to proceed efficiently without excessive fouling or agglomeration problems.
Solution Approach 2:
The system introduces an intermediary vaporization zone that acts as a buffer between the feed injection and high-temperature cracking. This intermediary region allows gradual heating and phase change, mediating the transition from cold liquid feed to hot cracking conditions while minimizing direct contact between high-temperature zones and heavy resid components that would cause fouling.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the conversion efficiency of petroleum resid fluids by minimizing fouling and agglomeration, achieving more uniform and rapid thermal cracking, thereby producing valuable cracked products while maintaining equipment integrity.
Implementation Method 1
generating a stream of atomized resid fluid
Implementation Method 2
a particle heating component configured to heat the cracking particles before the particles intersect the first stream
Implementation Method 3
delivering the stream to a plurality of cracking particles, wherein the cracking particles have a temperature from 700° C. to 1200° C. when the stream is delivered
Data Source
AI summary
A method and apparatus for conversion of petroleum resid fluid through atomization and pyrolysis, including: generating a stream of atomized resid fluid; and delivering the stream to a plurality of cracking particles, wherein the cracking particles have a temperature from 700° C. to 1200° C. when the stream is delivered. Generating the stream of atomized resid fluid may include: delivering heated resid fluid to a nozzle; and delivering diluent fluid to the nozzle. A method and apparatus includes: a first multi-phase fluid application device configured to generate a first stream of atomized resid fluid; a port configured to guide a plurality of cracking particles to intersect the first stream; and a particle heating component configured to heat the cracking particles before the particles intersect the first stream.