Catalytic Cracking Spray Nozzle with Liquid Inlet Extension
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Solution Overview
Problem
Existing spray nozzle assemblies for fluidized catalytic cracking riser reactors face challenges in complete liquid atomization due to steam cross flow, leading to increased droplet size and the need for higher pressure pumps, which are costly and prone to breakdowns, and require complex and expensive nozzle bodies with separate impingement pins.
Innovation Solution
A simplified spray nozzle design featuring a tubular member with integrated liquid and steam inlets, where the liquid inlet extension and diffuser post shields the liquid flow from steam cross flow until impact, ensuring full impingement and subsequent atomization without the need for a separate impingement pin or high-pressure pumps, using a single length of pipe for the nozzle body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a separate impingement pin and complex nozzle body are used to achieve complete liquid atomization, then liquid atomization quality improves, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent integrates the impingement pin function directly into the nozzle body by forming an impingement surface on the liquid inlet extension, eliminating the need for a separate impingement pin and its mounting structure. This merging of functions simplifies the overall device while maintaining complete liquid atomization quality.
Solution Approach 2:
The nozzle body is designed to perform multiple functions: it serves as both the structural housing and contains the impingement surface for liquid shattering. The liquid inlet extension with its integrated impingement surface combines what were previously separate components, reducing part count while achieving the same atomization effect.
2Stability of the object's composition
If higher pressure pumps are used to overcome steam cross flow effects, then liquid flow stream stability improves, but operational cost and reliability worsen
Solution Approach 1:
The liquid inlet extension with its extended impingement surface creates a flow condition where liquid is forced to impact the impingement surface before the steam cross flow can significantly deflect it. This preliminary action of the extended geometry counteracts the steam cross flow effect, maintaining liquid flow stability without requiring higher pump pressures.
3Manufacturing precision
If liquid pressure is increased to prevent flow stream shift, then droplet size reduction improves, but energy consumption and operational cost increase
Solution Approach 1:
The patent changes the geometric parameters of the liquid inlet extension, specifically extending the impingement surface downstream. This geometric parameter change allows the liquid to maintain its flow direction and impact the impingement surface effectively at lower pressures, achieving the same droplet size control without increased energy consumption.
4Ease of manufacture
If a simplified single-piece nozzle body is used, then ease of manufacture and retrofitting improves, but achieving complete liquid atomization becomes more difficult
Solution Approach 1:
The patent extends the impingement surface in the downstream direction (adding a dimensional element) on the liquid inlet extension. This extended surface provides additional interaction area for the liquid stream, ensuring complete atomization is achieved even with the simplified single-piece nozzle body construction.
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
This design achieves effective and complete liquid atomization, reducing droplet size and eliminating the need for high-pressure pumps, while simplifying construction and enabling easy retrofitting, thus enhancing spray performance and reducing operational costs.
Implementation Method 1
the liquid inlet extension and diffuser post shields the liquid flow from steam cross flow until impact
Implementation Method 2
against which a pressurized liquid stream impinges and is transversely dispersed and across which pressurized steam from a gas inlet is directed for further interaction and shearing of the liquid into fine droplets
Implementation Method 3
pressurized steam from a gas inlet is directed for further interaction and shearing of the liquid into fine droplets
Implementation Method 4
The atomized liquid within the mixing chamber is directed under the force of the pressurized steam through an elongated tubular barrel
Data Source
AI summary
A gas assisted liquid spray nozzle assembly having a nozzle body that defines a mixing zone, a liquid inlet communicating with the mixing zone from a side thereof, and a pressurized gas inlet communicating with the mixing chamber from an upstream end. The liquid inlet includes a liquid inlet extension and diffuser post extending transversely into the mixing zone having a liquid extension passageway and a closed downstream end that defines an internal impingement surface disposed on a central axis of the mixing zone against which liquid impinges and is transversely directed into the mixing zone for atomization by pressurized gas directed centrally through the mixing zone from the gas inlet. The spray nozzle assembly includes a barrel extension zone downstream of said mixing zone with a spray tip for directing the atomized liquid in a predetermined spray pattern.