Catalytic Cracking Spray Nozzle with Dispersion Ring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing spray nozzle assemblies for fluidized catalytic cracking riser reactors are costly due to complex nozzle bodies made from solid metal stock, requiring laborious machining, and face issues with undesirable stratification of atomized liquid hydrocarbon and steam during travel through the elongated barrel.
Innovation Solution
A spray nozzle assembly with a simpler design featuring a common cylindrical tubular member for both the mixing and barrel zones, utilizing diametrically opposed drilled openings for liquid and steam inlets, and an impingement pin with a recessed surface to enhance atomization, along with an annular dispersion ring to ensure continued intermixing of atomized liquid and steam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a complex nozzle body machined from solid metal stock is used, then the atomization performance is improved, but the manufacturing cost and time increase substantially
Solution Approach 1:
The nozzle body is segmented into modular components: a nozzle body, a separately formed impingement pin, and a dispersion ring. These components are manufactured independently and then assembled together, allowing each part to be optimized and manufactured using simpler, more cost-effective processes rather than requiring complex machining of a solid monolithic structure.
Solution Approach 2:
The impingement pin and dispersion ring are combined into a single integrated component that serves multiple functions: the pin provides the impingement surface for liquid breakdown while the dispersion ring ensures continued mixing in the barrel zone. This merging reduces the number of separate parts and simplifies assembly while maintaining atomization performance.
2Ease of operation
If an elongated barrel is used to transport atomized liquid, then the liquid can be directed through the reactor wall, but undesirable stratification occurs during travel
Solution Approach 1:
The dispersion ring acts as an intermediary element within the barrel zone that promotes continued mixing between the atomized liquid and steam. The ring creates turbulence and ensures uniform distribution of liquid droplets throughout the barrel length, preventing stratification while allowing the elongated barrel to fulfill its transport function through the reactor wall.
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
The design results in a more economical and efficient atomization of liquid hydrocarbons, reducing manufacturing costs and preventing stratification, while maintaining effective operation in catalytic cracking systems.
Implementation Method 1
an impingement pin extends into the chamber and defines a liquid impingement surface on the center line of the mixing chamber in diametrically opposed relation to the liquid inlet against which a pressurized liquid stream impinges and is transversely dispersed
Implementation Method 2
pressurized steam from a gas inlet is directed for further interaction and shearing of the liquid into fine droplets
Implementation Method 3
an annular dispersion ring to ensure continued intermixing of atomized liquid and steam
Data Source
AI summary
A gas assisted spray nozzle assembly having a nozzle body in the form of a hollow tubular member, such as a single cylindrical pipe section, which defines a mixing zone and a downstream barrel extension zone. A liquid inlet and an impingement pin are supported by the tubular member in opposed relation to each other at the mixing zone, and a pressurized gas inlet is provided at an upstream end of the tubular member. An annular dispersion ring is fixedly supported within the tubular member downstream of the impingement pin for defining an annular ledge for directing a peripheral portion of pressurized gas stream and liquid atomized in the mixing zone radially inwardly for facilitating continued intermixing of the liquid and pressurized gas stream as they proceed through the barrel zone for discharge from the spray nozzle.