Atomizer Injection Valve for Hydrocracking Reactors
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Solution Overview
Problem
Current hydrocracking systems are limited in effectively mixing hydrogen with high-density hydrocarbons due to inadequate dispersion and contact area, leading to reduced hydrogen interaction and inefficient heat transfer, which hampers the upgrading process.
Innovation Solution
The method involves atomizing high-density hydrocarbon liquids and injecting them into a hydrocracking reactor, optionally mixing hydrogen with the hydrocarbons prior to atomization using swirl devices within an injection valve, and regulating pressure to enhance surface area and reaction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If distillate feed is introduced into the reactor through a line, then the process is simple to implement, but the hydrogen-hydrocarbon interaction is limited due to insufficient surface area
Solution Approach 1:
The distillate feed is broken down into minute particles through atomization, creating a fine spray that dramatically increases the surface area available for hydrogen contact. This segmentation of the liquid feed into droplets enables effective hydrogen interaction while maintaining operational simplicity through the atomization device.
2Ease of operation
If hydrogen bubbles are used for injection, then the process is easy to implement, but the large bubble size limits hydrogen dispersion and contact area
Solution Approach 1:
Instead of using large hydrogen bubbles, the system atomizes the hydrocarbon feed into fine droplets, creating a dispersed spray pattern. This segmentation of the hydrocarbon phase into numerous small particles maximizes the interfacial area with hydrogen, dramatically improving contact efficiency while maintaining ease of injection through the atomization device.
3Device complexity
If light-weight fractions in the hydrocarbon spray remain in liquid phase, then the process is simple, but hydrogen is absorbed unnecessarily reducing availability for heavier fractions
Solution Approach 1:
The atomized hydrocarbon spray is introduced into a hot reactor environment where the light-weight fractions undergo phase transition from liquid to vapor. This vaporization occurs within the reactor, allowing these fractions to be effectively cracked by hydrogen. The phase transition is driven by the reactor temperature and enables efficient hydrogen utilization for cracking reactions.
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 increases the surface area for hydrogen-hydrocarbon interaction, improves heat transfer, and enhances the hydrocracking process by ensuring more efficient cracking of long molecular chains, resulting in better product yields and reduced operating costs.
Implementation Method 1
The method involves atomizing high-density hydrocarbon liquids and injecting them into a hydrocracking reactor
Implementation Method 2
mixing hydrogen with the high-density hydrocarbon liquid prior to atomizing the high-density hydrocarbon liquid
Implementation Method 3
In the absence of bulk liquid disintegration, heat transfer to the hydrocarbons is minimal
Implementation Method 4
High-density hydrocarbons such as heavy oil may be upgraded through hydrocracking by mixing the oil with hydrogen in the presence of a catalyst under high pressure and temperature
Data Source
AI summary
The invention provides a method and apparatus for introducing a high-density hydrocarbon liquid into a hydrocracking reactor. The method comprises atomizing the high-density hydrocarbon liquid and injecting the atomized liquid into the hydrocracking reactor. The method may also comprise mixing hydrogen with the high-density hydrocarbon liquid prior to atomizing the high-density hydrocarbon liquid. The apparatus comprises an injection valve for introducing a high-density hydrocarbon liquid into a hydrocracking reactor comprises an atomizer coupled to receive the high-density hydrocarbon liquid. The atomizer comprises a nozzle configured to atomize the high-density hydrocarbon liquid and inject the high-density hydrocarbon liquid into the hydrocracking reactor. The injection valve may also comprise a mixer coupled to receive hydrogen and the high-density hydrocarbon liquid. The mixer may be configured to mix the hydrogen and high-density hydrocarbon liquid and deliver the mixture to the atomizer.