Gas-Assisted Spray Nozzle for Hydroprocessing Effluent Cooling
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Solution Overview
Problem
Existing systems for injecting fluids into gas streams, particularly those using light gases like hydrogen, face issues with large droplet sizes leading to reduced heat and mass transfer, non-homogeneous distribution, and increased risk of corrosion and clogging in hydrotreating and hydrocracking processes.
Innovation Solution
The development of spray nozzles that utilize light gases, such as hydrogen, to produce micron-sized droplets through high-shear mixing, optimizing gas velocity and pressure to achieve efficient atomization and distribution, thereby enhancing mass and heat transfer while preventing downstream clogging and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spray nozzles produce millimeter-sized droplets using conventional injection methods, then the system is simple to operate, but heat and mass transfer is reduced and droplet coalescence occurs leading to maldistribution
Solution Approach 1:
The spray nozzle divides the liquid stream into numerous small droplets through specialized internal geometry and atomization mechanisms, transforming a single large liquid flow into many fine particles for improved heat and mass transfer
Solution Approach 2:
The patent introduces a gas injection port that injects gas into the liquid stream as an intermediary substance to facilitate atomization and prevent droplet coalescence, improving distribution homogeneity
2Reliability
If large droplet sizes are used in wash water injection, then the injection system is simpler, but gravity settling increases leading to droplet coalescence and heat exchanger tube plugging
Solution Approach 1:
The nozzle segments the liquid into fine droplets that resist gravity settling and coalescence, preventing heat exchanger tube plugging while maintaining operational reliability
Solution Approach 2:
The spray nozzle creates dynamic atomization patterns that adapt to flow conditions, maintaining droplet dispersion and preventing settling even under varying operational conditions
3Reliability
If conventional spray nozzles are used with light gases like hydrogen, then the system can utilize available processing gas, but effective atomization of liquid into fine particles is difficult due to low gas density
Solution Approach 1:
The nozzle design changes critical parameters including gas injection pressure, liquid-to-gas ratio, and internal flow geometry to optimize atomization performance when using low-density gases like hydrogen
Solution Approach 2:
The patent introduces a gas injection port that adds a third dimension to the atomization process by injecting gas perpendicular to or at an angle to the liquid stream, creating effective mixing and fine droplet formation even with light gases
4Object-affected harmful factors
If wash water injection rate is increased to improve distribution, then more water remains unvaporized for corrosion prevention, but droplet maldistribution and clogging risks increase
Solution Approach 1:
The nozzle segments liquid into fine droplets that distribute uniformly throughout the effluent stream, preventing localized accumulation and clogging while maintaining corrosion protection
Solution Approach 2:
The system optimizes the liquid-to-gas ratio and injection pressure parameters to achieve the minimum effective water injection rate that provides corrosion protection without causing maldistribution or clogging
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 reduces the risk of corrosion and clogging, improves heat and mass transfer, and ensures homogeneous distribution of atomized liquids, enhancing the reliability of effluent cooling in hydroprocessing systems.
Implementation Method 1
Because the nozzles create high shear between liquid and gas phases adjustment in gas velocity may be made to account for less mass flow with lighter hydrogen or recycle gas
Implementation Method 2
The nozzle body has a liquid inlet, a gas inlet, and an atomized liquid discharge outlet. The atomizing gas inlet communicates with a pressurized gas source.
Data Source
AI summary
A hydroprocessing system having a processing vessel that discharges a high temperature effluent that must be cooled prior to collection in a reflux drum. One or more gas assisted spray nozzle are provided that utilize light atomizing gas having a density of 8-15 times less than air, such as hydrogen, which preferably is the processing or recycle gas of the system. The spray nozzles are designed for the efficient atomization and direction of cooling water into a micron sized droplet distribution utilizing the light atomizing gas for affecting higher mass and heat transfer from the effluent. The spray nozzles each include a unique atomizing gas and cooling liquid passageway systems, a downstream impingement post, and a plurality of discharge orifices which sequentially breakdown the liquid into micron sized droplets as low as 500 microns and less.