Hydrocarbon Atomizer with Opposing Cyclonic Mixing and Impingement
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Solution Overview
Problem
Conventional atomizers fail to efficiently atomize heavy hydrocarbon feedstocks with high viscosity and surface tension, leading to non-uniform droplet formation, delayed vaporization, and increased production of undesirable byproducts like coke and gas in the Fluid Catalytic Cracking (FCC) process due to phase stratification and nozzle plugging.
Innovation Solution
An atomizer assembly that thoroughly mixes hydrocarbon feedstock with diluent mixed steam in opposing cyclonic and anti-cyclonic motions to reduce viscosity and surface tension, forming a stable emulsion which is then shattered at an impingement section to produce uniform droplets, minimizing pressure requirements and enhancing atomization efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional atomizers are used to atomize heavy hydrocarbon feedstock, then the atomization process is simple, but the droplet formation is non-uniform and vaporization is delayed
Solution Approach 1:
The atomizer is divided into multiple functional sections: a mixing section with multiple nozzles for injecting hydrocarbon and steam separately, and a disruption section with perpendicular nozzles. This segmentation allows each section to perform its specific function optimally, resulting in uniform droplet formation through controlled mixing and disruption.
Solution Approach 2:
The hydrocarbon feedstock and steam are pre-mixed in the mixing section before reaching the disruption section. This preliminary mixing action ensures that the components are properly combined and ready for uniform atomization, preventing non-uniform droplet formation that would occur with direct atomization.
2Reliability
If heavy hydrocarbon feedstock with high viscosity and surface tension is atomized conventionally, then the feedstock can be processed, but nozzle plugging occurs and equipment lifespan is reduced
Solution Approach 1:
Steam is introduced as an intermediary substance that mixes with the heavy hydrocarbon feedstock in the mixing section. This steam-hydrocarbon mixture reduces the viscosity and surface tension of the feedstock, preventing it from plugging the nozzles and extending equipment lifespan while maintaining reliable operation.
Solution Approach 2:
The physical parameters of the hydrocarbon feedstock are changed by mixing with steam, which alters the viscosity and surface tension properties. This parameter change prevents nozzle plugging by making the feedstock less prone to adhesion and clogging, thereby improving reliability and extending equipment lifespan.
3Speed
If the surface area per unit volume of hydrocarbon feedstock is increased through atomization, then vaporization speed increases, but the complexity of achieving uniform droplets increases
Solution Approach 1:
The atomization process is segmented into mixing and disruption phases. The mixing section creates a preliminary homogeneous mixture, while the disruption section with perpendicular nozzles breaks this mixture into uniform droplets. This segmentation achieves both high surface area for fast vaporization and uniform droplet distribution.
Solution Approach 2:
The mixing of steam with hydrocarbon changes the physical parameters of the feedstock, reducing viscosity and surface tension. This enables the formation of uniform droplets with high surface area to volume ratio, achieving fast vaporization speed while maintaining droplet uniformity that would be difficult to achieve with conventional single-stage atomization.
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 achieves efficient atomization of hydrocarbon feedstocks with varied viscosities and surface tensions, resulting in uniform droplet formation, faster vaporization, and improved heat absorption in the FCC reactor, reducing byproduct formation and extending equipment lifespan by preventing nozzle plugging.
Implementation Method 1
The inner conduit receives hydrocarbon feedstock through a first inlet positioned tangentially to the inner conduit. The inner conduit receives diluent mixed steam through a second inlet positioned tangentially to the inner conduit, opposite to the direction of the first inlet. The hydrocarbon feedstock and the diluent mixed steam are mixed together in the inner conduit in opposing cyclonic and anti-cyclonic motions to reduce viscosity and surface tension of the hydrocarbon feedstock and form a stable emulsion.
Implementation Method 2
The emulsion is incident against an impingement section to form an emulsion film on at least a portion of the impingement section by shearing mechanism.
Implementation Method 3
Two or more jet tubes are oriented towards the inner conduit at a certain angle from a nozzle exit. A stream of atomizing steam is transmitted onto the emulsion film formed on the two or more conical plates through the jet tubes. The atomizing steam impinges the emulsion film to atomize the hydrocarbon feedstock.
Implementation Method 4
The atomizing steam impinges the emulsion film to atomize the hydrocarbon feedstock.
Implementation Method 5
Greater the surface area per unit volume better is the possibility for the hot cracking catalyst to come in contact with the hydrocarbon feed stock and faster is the vaporization in the FCC reactor.
Data Source
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AI summary
The present disclosure relates to an assembly implementing the process disclosed for atomizing a hydrocarbon feedstock. The method includes receiving the hydrocarbon feedstock (2) and a diluent mixed steam (3) from a first inlet (5) and a second inlet (6), respectively, by an inner conduit (1), where the flow of the hydrocarbon feedstock (2) is in a motion opposing the diluent mixed steam (3); mixing the hydrocarbon feedstock (2) with the diluent mixed steam (3) in the inner conduit (1) to produce an emulsion (4). The method further includes impacting the emulsion (4) against an impingement section (11) to form an emulsion film on at least a portion of the impingement section (11) by shearing mechanism. The method further includes transmitting streams of atomizing steam (17) through a plurality of jet tubes (18) onto the emulsion film for atomization to generate a plurality of droplets of the hydrocarbon feedstock (2).