Feed Nozzle Assembly for Heavy Hydrocarbon Atomization
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Solution Overview
Problem
Conventional atomizers fail to efficiently atomize heavy, viscous hydrocarbon feeds with high surface tension, leading to non-uniform droplet sizes and velocities, delayed vaporization, and undesirable thermal cracking in fluid catalytic cracking (FCC) processes, resulting in slow production and excessive byproduct formation.
Innovation Solution
A feed nozzle assembly with multiple mixing chambers and staged atomization using partially vaporized sub-cooled water and steam as diluents and atomizing media, which creates a tertiary mixture with reduced viscosity and surface tension, achieving efficient atomization and low pressure drop across the assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional atomizers mix hydrocarbon feed with steam through a single nozzle orifice, then the atomization process is simplified, but the atomization efficiency is insufficient for heavy, viscous hydrocarbon feeds with high surface tension
Solution Approach 1:
The atomizer is divided into multiple independent nozzle assemblies (first, second, third, and fourth nozzles) arranged in a circular pattern. Each nozzle contributes to the overall atomization process, allowing the system to handle heavy, viscous hydrocarbon feeds more effectively than a single nozzle could achieve.
Solution Approach 2:
The invention transitions from a single-point injection to a distributed multi-point injection system. The nozzles are arranged in a circular pattern at different angular positions, creating a three-dimensional atomization pattern that enhances mixing and vaporization efficiency throughout the reactor space.
2Device complexity
If conventional atomizers use a single nozzle orifice, then the device is simpler, but the droplet size distribution is non-uniform and vaporization is delayed
Solution Approach 1:
The single nozzle is segmented into multiple nozzles (first, second, third, fourth nozzles) positioned at different angular locations. This segmentation creates multiple atomization zones that work in parallel, producing a more uniform overall droplet size distribution and ensuring consistent vaporization across the entire feed stream.
Solution Approach 2:
Each nozzle assembly is positioned to create localized atomization zones with specific characteristics. The circular arrangement ensures that different regions of the reactor receive atomized droplets with optimized size and velocity characteristics, achieving uniformity through localized optimization.
3Productivity
If heavy hydrocarbon feeds are atomized using conventional methods, then the process can proceed, but thermal cracking occurs and excessive byproducts such as coke are produced
Solution Approach 1:
The system performs preliminary atomization and vaporization preparation by injecting multiple streams of atomized hydrocarbon feed simultaneously. This preliminary distribution ensures that the feed is properly prepared before entering the catalytic cracking zone, preventing thermal cracking and byproduct formation by avoiding delayed vaporization.
Solution Approach 2:
The multiple nozzle assemblies act as intermediaries that facilitate the transition from liquid hydrocarbon feed to vapor phase. By creating fine atomized droplets through multiple injection points, the system mediates the vaporization process more effectively, preventing direct thermal cracking of heavy feed molecules.
4Productivity
If high-pressure hydrocarbon supply is used to improve atomization, then atomization efficiency increases, but the equipment complexity and operating costs increase
Solution Approach 1:
The high-pressure requirement is segmented and distributed across multiple nozzles rather than requiring a single high-pressure injection point. This allows the system to achieve effective atomization through multiple lower-pressure injection streams, reducing the complexity of the pressure supply system while maintaining atomization quality.
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 feed nozzle assembly efficiently atomizes hydrocarbon feeds into fine droplets with uniform sizes and velocities, enhancing vaporization rates and hydrocarbon yield, reducing byproduct formation, and minimizing the need for high-pressure hydrocarbon supplies, thus improving the efficiency and cost-effectiveness of the FCC process.
Implementation Method 1
at least one primary mixing chamber to receive a liquid hydrocarbon feed and a diluent for producing a primary mixture
Implementation Method 2
A secondary mixing chamber is flow connected to the primary mixing chamber to receive the primary mixture... a steam inlet is provided to inject streams of steam to the secondary mixing chamber
Implementation Method 3
the liquid hydrocarbon stream is vaporized inside the riser reactor to get completely diffused into the pores of the catalyst(s) used
Implementation Method 4
The atomization process, conducted in an atomizer, refers to the breaking down of a hydrocarbon feed of a given volume into a number of fine droplets to expand surface area or the hydrocarbon feed with respect to its own initial volume
Implementation Method 5
the hydrocarbon feed is subjected to a high temperature during the atomization process which alters certain physical parameters, such as viscosity
Data Source
AI summary
The present subject matter relates to a feed nozzle assembly 100 for atomizing a heavy hydrocarbon feed by mixing the hydrocarbon feed with a diluent and an atomizing media. The feed nozzle assembly 100 includes at least one primary mixing chambers 101 for receiving the liquid hydrocarbon feed and the diluent to create a primary mixture. The primary mixture is than forwarded to a secondary mixing chamber 102. The secondary mixing chamber extends to a tertiary mixing chamber 103. A steam inlet 110 is provided to inject streams of steam to the secondary mixing chamber 102 and to the tertiary mixing chamber 103 through a first opening and a second opening, respectively, located within the steam inlet 110.