FCC Injection Device Baffles for Pressure Drop Reduction
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Solution Overview
Problem
Existing hydrocarbon charge injection devices face challenges with heavy loads, requiring significant pressure increases and increased atomization gas flow, leading to increased costs and potential negative impacts on reaction yield and equipment manufacturing.
Innovation Solution
An injection device with a hollow tubular body and internal baffles that extend only partially around the periphery, reducing pressure drop and maintaining efficient atomization without increasing atomization gas flow or pump power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a dispersion ring is placed inside the cylindrical body to redirect peripheral axial flow to the inside, then droplet mixture is facilitated, but the internal diameter reduction generates significant pressure loss
Solution Approach 1:
The single dispersion ring is segmented into multiple baffle elements (at least three baffles) distributed around the interior periphery of the contact chamber. This segmentation provides equivalent mixing functionality while distributing the flow resistance across multiple smaller obstacles rather than one large ring, thereby reducing overall pressure loss.
Solution Approach 2:
The baffles are positioned to extend only partially radially from the interior periphery toward the central axis, rather than forming a complete ring. This local quality approach provides mixing action where needed near the periphery while leaving the central flow path open, reducing pressure loss while maintaining droplet mixture stability.
2Productivity
If the flow of atomization gas is increased to atomize heavy loads, then atomization is improved, but treatment cost increases and reaction yield may be negatively impacted
Solution Approach 1:
The injection device uses the kinetic energy of the incoming liquid hydrocarbon load itself to drive the atomization process. The liquid jet impacts the centrally positioned target, generating droplets that are then divided by the peripheral baffles. This self-service mechanism eliminates the need for additional atomization gas flow, maintaining productivity while avoiding the harmful effects of excessive gas injection.
3Stress or pressure
If pump power is increased to achieve desired pressure at injector output for heavy loads, then injection pressure is sufficient, but manufacturing cost increases
Solution Approach 1:
The device changes the operational parameters by using the existing liquid load pressure to drive atomization through target impact rather than requiring additional pressurization. The baffle configuration optimizes the flow path to maintain sufficient injection pressure for heavy loads while minimizing the power required by feeding pumps.
4Productivity
If large amounts of water vapor are injected for atomization, then atomization is enhanced, but effluent separation units must be oversized increasing manufacturing cost
Solution Approach 1:
The system uses the liquid hydrocarbon load itself as the atomization medium through target impact, eliminating the need for additional water vapor injection. This self-service approach enhances atomization productivity while avoiding the need for oversized effluent separation units to handle excess water vapor condensation.
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 solution effectively atomizes heavy loads with reduced pressure drop and energy consumption, minimizing unwanted reactions and manufacturing costs while maintaining efficient fluid mixing.
Implementation Method 1
impact injection devices in which the load is introduced radially into the body and impacts a target located in the center of the body, generating the formation of droplets
Implementation Method 2
A circulating atomization gas axially makes it possible to cause these droplets by dividing them further towards the exit of the body
Implementation Method 3
redirects a portion of the peripheral axial flow of gas and droplets to the inside of the body, which facilitates their mixture when moving up to the exit of the device
Implementation Method 4
This atomization makes it possible to maximize the liquid contact surface (liquid hydrocarbon load) -Solide (catalyst), which promotes heat transfer and thus the vaporization of these hydrocarbons
Implementation Method 5
which promotes heat transfer and thus the vaporization of these hydrocarbons which then react in the gaseous phase
Data Source
Figure 1~2
Figure 2a~2f
Figure 3~6
AI summary
The invention relates to an injection device (10) configured to atomize a liquid into droplets using a gas, comprising a hollow tubular body (12) of longitudinal direction (X). An internal wall (13) defines a first zone referred to as a contact zone (Z1) and a second zone (Z2). The body has: - at least a first and a second inlet opening (14; 16) opening into said first zone (Z1), so as to respectively inject a liquid and an atomizing gas, – at least one outlet orifice (18) situated downstream of the first and second zones, for removing the atomized liquid from the body. The internal wall (13) of the body is provided, between the zones (Z1) (Z2), with at least one chicane (20i) configured so that, in each plane perpendicular to the longitudinal direction of the body containing said chicane, this chicane extends over just part of the periphery of the internal wall (13).