CA2367369A1

CA2367369A1 - Process and apparatus for atomizing fcc feed oil

Info

Publication number: CA2367369A1
Application number: CA002367369A
Authority: CA
Inventors: Russell John Koveal Jr.; Jackson I. Ito
Original assignee: Individual
Current assignee: ExxonMobil Technology and Engineering Co
Priority date: 1999-03-18
Filing date: 2000-03-17
Publication date: 2000-09-21
Also published as: AU3754700A; CN1344173A; EP1169093A1; JP2002539289A; WO2000054845A1

Abstract

A liquid atomization process comprises forming a two-phase fluid mixture of a liquid and a gas, under pressure, dividing the fluid into two separate strea ms which are passed into and through an impingement mixing zone (22) in which they are impingement mixed to form a single stream of two-phase fluid. The mixed, single stream is then passed into and through a shear mixing zone (24 ) and then into a lower pressure expansion zone (30), in which atomization occurs to form a spray of atomized drops of the liquid. The impingement (22) and shear (24) mixing zones comprise respective upstream (16) and downstream (18) portions of a single fluid passageway (14) in a nozzle (10). This is useful for atomizing the hot feed oil in an FCC process.

Description

PROCESS AND APPAWATUS FOR ATOMIZING FCC FEED OIL
FIELD OF THE INVENTION
The invention relates to a liquid atomizing process and apparatuses, namely apparatuses and processes used in conjunction with fluid catalytic cracking (FCC),processes that require high fluid throughput and low pressure drop. The process comprises forming a two-phase fluid mixture of the hot feed oil and a dispersion gas, such as steam. dividing the fluid mixture into two separate streams which are passed under pressure through an impingement mixing zone. a shear mixing zone to recombine the streams into a single stream which passes into a lower pressure atomization zone, where atomization occurs to form a spray of atomized liquid droplets.
BACKGROUND OF THE INVENTION
Fluid atomization is well known and used in a wide variety of applications and processes. including aerosol sprays. the application of pesticides and coatings. spray drying. humidification. mixing. air conditioning, and chemical and petroleum refinery processes. In many applications. a pressurized fluid (with or without the presence of an atomizing agent) is forced through an atomization nozzle having a relatively small orifice. Atomization occurs at the downstream side of the orifice. and the degree of atomization is determined by the orifice size. the pressure drop across the orifice. fluid density, yiscositv, and surface tension. Atomization is increased and the droplet size is decreased with dc:crcasin<1 orifice size and increasing pressure drop.
Increasin<~ the degree of atomization of relatively viscous fluids at high flow rates is particularly challenging. especially for the heavy petroleum oil feeds that may be used in l~ CC processes. FCC processes are widely used in the petroleum refining industry primarily for converting high-boiling petroleum oils to more valuable lower-boiling products including gasoline and middle distillates such as kerosene. _jet and diesel fuel. and heating oil.
In FCC processes. a preheated feed is often mixed with an atomization promoting fluid. such as steam. to assist in the atomization of the feed. The atomized feed contacts a particulate. hot cracking catalyst flowing up through a riser which comprises the FCC reaction zone. Smaller oil teed droplet sizes in the reaction zone result in more feed conversion to valuable products.
particularly with the incorporation of heavy feed material, such as a resid.
into the FCC feed. In some instances, feed material .that does not contact the uprising catalyst particles thermally cracks primarily to methane and coke-generally undesirable products. Consequently. efforts continue to try to find economically viable means to decrease the droplet size of the atomized oil. preferably without an unacceptably high pressure drop through the atomizer or nozzle and/or without increasing the amount of steam or other atomization promoting agent.
Examples of such efforts are disclosed in U.S. Patents x.289.976 and S.I73.I75.
which disclose an average feed droplet size in the range of about 400-1000 microns. There is still a need for t3ner atomization of the heavy oil feed for the FCC process and of other fluids for other processes as well. It would be particularly beneficial if the atomized liquid droplet size could be reduced to less than 300 microns.

SUMMARY OF THE INVENTION
()ne embodiment ot~the present invention comprises a liquid atomization apparatus comprising a body comprising a fluid inlet and a fluid outlet and configured to define an impingement mixing zone and a shear mixin<~ zone. The zones are positioned between the inlet and the outlet. The tltlld inlet comprises a splitter that can split an incoming fluid stream into at least two streams.
The impingement mixing zone comprises at (east one impingement surface configured to impinge at least a portion ot~ one fluid stream against another impinged stream wherein the included angle between two impinged streams is between about I?0° and ?~0°. The shear mixing zone has a cross-sectional area defined by a first dimension and a second dimension, wherein the first dimension decreases along a longitudinal axis through the body in a direction toward the fluid outlet.
Another embodiment ofthe present invention comprises a liquid atomization apparatus comprising a body comprising at least one fluid inlet.
at least one fluid outlet. and a fluid passageway extending between the inlet and the outlet. The passageway defines an impingement mixing acid a shear mixing zone downstream ti'om the impingement mixing zone. The passageway also defines at least one impingement surface configured to be substantially perpendicular to a longitudinal axis extending through the body. The impingement surface is configured to impart radiallv inward flow ( in a direction normal to the overall flow direction) to a portion of fluid flowing through the passageway. The shear mixing zone has a cross-sectional area defined by a first dimension and a second dimension. wherein the first dimension decreases along a longitudinal axis through the body in a direction toward the fluid outlet.
Another embodiment of the present invention comprises a process for forming a spray of liquid droplets comprising the steps ot~: (a) forming at least ~t two streams ot~a nvo-phase fluid comprising a gas phase and a liquid phase:
(b) passing the streams to an impingement mixing zone wherein at least a portion of each stream is unpin<~ed against at least a portion of another stream and wherein the included angle hew etn the impinged streams is between about ( ;
()° anti l90° to form a single mixed stream: (c) passing the single rnixcd stream to a shear mixing zone anti impartin<~ shear mixing forces to the single: mixed stream to form a shear mixed stream: and. (d) passing the shear mixed stream to an atomizing zone wherein the gas phase expands and increases the surface area of the liquid phase. thereby producing a spray of liquid droplets.
Another embodiment of the present invention comprises a process for forming a spray of liquid droplets comprising the steps of: (a) forming a plurality of streams of a two-phase fluid comprising a gas phase and a liquid phase; (b) impinging at least a portion oteach stream against at least a portion otanother stream to form a single mixed stream, wherein the included angle between the impinged streams is between about 120° and 240°; (c) subjecting the single mixed stream to shear mixing forces. thereby forming a shear mixed stream:
and.
(d) expanding the gas phase in the shear mixed stream. thereby producing a spray of liquid feed droplets.
Another embodiment of the present invention comprises a catalytic cracking process comprising the steps of: (a) forming at least two streams ota two-phase fluid comprising a ~7as phase and a liquid phase. the liquid phase comprising a FCC feed: (b) passing the streams to an impingement mlxlng zone wherein at least a portion of each stream is impinged against at least a portion of another stream and wherein the included angle between the impinged streams is between about 120° and 240°. thereby forming a single mixed stream: (c) passing the single mixed stream to a shear mixing zone and imparting shear mixing forces to the single mixed stream to form a shear mixed stream: (d) passing the shear mixed stream to an atomizing zone wherein the gas phase J
expands and increases the surface area of the liquid phase. thereby producing a spray of liquid Iced droplets: ( ~ ) passing the spray of liquid feed droplets into a E~CC reaction zone: and. ( y contacting the liquid teed droplets with a catalvtlc cracking catalyst under catalytic crackine conditions. In one embodiment the impingement zone and the shear mining zone are contained within an embodiment of a nozzle described herein.
Another embodiment of the present invention comprises a catalytic cracking process comprising the steps of: (a) forming a plurality of streams of a vvo-phase t7uid comprising a gas phase and a liquid phase. the liquid phase comprising a FCC feed: (b) impinging at least a portion ofeach stream against at least a portion of another stream to form a single mixed stream, wherein the included angle between the impinged streams is between about 170° and 190°:
(c) subjecting the single mixed stream to shear mixing forces. thereby forming a shear mixed stream: (d) expanding the gas phase in the shear mixed stream.
thereby producing a spray of liquid feed droplets; and. (e) contacting the liquid feed droplets with a catalytic cracking catalyst under catalytic cracking conditions.
In each process andior apparatus of the present invention. the included angle between the impinged streams is more preferably between about ( ; ~' and about 180°. most preferably about 180°.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1(a) illustrates an axially downstream view of one embodiment of a nozzle viewed looking into the t7uid inlet of the nozzle. Figure I(b) illustrates a cross-sectional side view of the embodiment shown in Figure 1 ( a) taken along the 1(b)-1(b) axis. Figure 1(c) illustrates an axially upstream view ofthe embodiment shown in Figure I(a) looking into the t7uid outlet of the nozzle.

Fi~lure 1(d) illustrates a top cross-sectional view ot~the embodiment shown in E~i~~ure l(a) taken alcm~~ the I(d)-l(d) axis shown in Figure 1(b).
Figure ~(a) illustrates a cross-sectional side view of~another embodiment ut~the nozzle. Figure ~'(b) illustrates an axially upstream view ot~the embodiment shown in Ii~~ure ?(a) looking into the fluid outlet ot~the nozzle.
Figure ?(c) illustrates a top cross-sectional view of the embodiment shown in Figure ?(a) and incorporates one embodiment ofa spray distributor. Figure ?(d) is an embodiment ot~ the platelets that may be used to construct the embodiment shown in Figure ?(a). For clarity. the platelet lines within the fluid passageway are not shown in Figures ?(a) and 2(c).
Figure 3(a) illustrates an axially downstream view ot~ another embodiment of a nozzle viewed looking into the fluid inlet ot~the nozzle. Figure 3(b) illustrates a cross-sectional side view of the embodiment shown in Figure 3(a) taken along the 3(b)-3(b) axis. Figure 3(c) illustrates an axially upstream view of the embodiment shown in Figure 3(a) looking into the fluid outlet of the nozzle. Figure 3(d) illustrates a top cross-sectional view of the embodiment shown in Figure 3(a) taken along the 3(d)-3(d) axis shown in Figure 3(c).
Figure ~(a) illustrates a cross-sectional side view of another embodiment of the nozzle. Figure ~(b) illustrates an axially upstream view ofthe embodiment shown in Figure ~(a) looking into the fluid outlet ot~the nozzle.
Figure ~(c) illustrates a top cross-sectional view ofthe embodiment shown in Figure ~(a) and incorporates another embodiment of a spray distributor.
Figure ~ is a cross-sectional view of a nozzle (and spray distributor) in fluid communication with a fluid conduit that Leeds the nozzle.

Fieure 6(a) illustrates an axially downstream view of~another embodiment ol~a nozzle viewed loc>kina into the lluid inlet ot~the nozzle. Fi~~ure h(h) illustrates a cross-Sectional aide view of the embodiment shown in I~ i~~ur~
O(a) taken along the 6(b)-O(hl axis shown in Figure 6(a). Figure 6(c) illustrates a cross-sectional side viwv of the embodiment shown in Figure 6(a) taken along the 6(c)-6(c) axis shown in Fi<lure 6(a).
Figure 7 illustrates a cross-sectional view ofa FCC teed injection unit employing an embodiment of a nozzle.
Figure 8 illustrates a FCC process into which an embodiment of~ the nozzle or the process may be incorporated.
DETAILED DESCRIPTION
As used herein. the cross-sectional area ot~ an area or zone through which a fluid flows shall be that area normal to the x-axis shown in the F i cures and that area defined by dimensions in the v- and z-axes. As used herein. "alonQ~~ an axis shall mean along that axis or substantially parallel to that axis as shown in the Figures. As used herein. the lon~itudinai axis ot~the nozzle body or tluid passageway is along the x-axis. or axis ot~ overall fluid flow through the nozzle.
The two-phase fluid fed into nozzle 10 may be gas-continuous or liquid-continuous. or it may be a bubbly froth. where it is not known with certainty it~
one or both phases are continuous. This may be further understood with reference to an open-cell sponge and a closed-cell sponge. Spon~~es typically have a l:l volumetric ratio ot~air to solid. An open-cell sponge is both 'gas (air) and solid continuous. while a closed-cell sponge is solid continuous and contains discrete ( dispersed ) gas cells. (n an open-cell sponge. the solid comprises membranes and ligaments (such as may exist in a cvo-phase gas-liquid troth or toam). In a closed-ve:ll apon'~e. the 'gas may comprise a dispersion ol~discrctc <~as Globules in the ;c>lid. dome sponGes fall in between the w~c~, as do some m~o-phase fluids eomprisin~~ a ~~as phase and a liquid phase.
It is not possible to haw a sponge that is 'gas-continuous anti nou also solid-continuous. but it is possible to have a two-phase yas and liquid fluid that is gas-continuous only. hheretore. the particular morphology ot~the fluid as it passes into and through the mining nozzle of the invention. is not always known with certainty. There must be sufficient gas present in the tluid entering the nozzle for the impact and shear mixing to increase the surface area ot~ the liquid phase. This is reelected in reducing ( i) the thickness of any liquid membrane. ( ii) the thickness and/or length of any liquid rivulets. and (iii) the size of any liquid Globules in the fluid. either before or during the atomization. In practice.
the impingement and shear mining in nozzle 10 and through the one or more orifices will only occur with a m~o-phase tluid comprising a gas phase and a liquid phase.
Preferably. the fluid comprises mostly Gas on a volumetric basis (e.g.. a volumetric Gas to liquid ratio of at least ?: I ) for efficient shear mixinG.
~ single-phase fluid (e.G.. liquid) passed through nozzle 10 will have its kinetic enerGv increased directly proportional to the pressure drop across the nozzle 10.
With a nvo-phase fluid. the Gas velocity is increased relative to the velocity ot~the liquid phase. (i) in the impingement mixinG zone ?'_'. (ii) in the shear mixing zone ?4.
and (iii) when the fluid passes through an orifice of smaller cross-sectional area than the fluid conduit upstream of tluid inlet I=to (a pressure-reducing orifice).
The velocity difference between the Gas and liquid phases results in ligamentation of the liquid. particularly with a viscous liquid such as a hot FCC
teed oil. Ligamentation means that the liquid forms elongated Globules or rivulets. The velocity difference is decreased during shear mixing. Thus.

g passing a nvo-phase fluid through a pressure-reducing orifice or mixin~~ it in impingement mivin~z ~on~ ~? produces a velocity differential betmcn the ~~as and liquid which results in ligamentation ot~the liquid andior dispersion ot~the liquid in the gas due to shearing ot~the liquid into elongated ligaments andior dispersed drops. Additional shear ot~the liquid occurs when the fluid enters the fluid inlet lea (openings ?6. ~'6~) ot~nozzle 10 and through one or more atomizing oriticels) positioned within the tluid passageway I-1. The additional shear also adds to reduction ofthe ultimate liquid droplet size in the atomized spray. Preferably, the cross-sectional area of the nozzle outlet lib (orifice 30) is smaller than the sum of the cross-sectional areas of tluid openings ?6. ?6'.
Nozzle tt7 may also comprise an atomization zone 68 at a lower pressure than the pressure upstream of the atomizing orifice. Zone 68 may be configured within nozzle 10 or may be configured as part of a spray distributor 6~
attached to nozzle 10. Consequently, the gas in the fluid passing through the atomizing orifice rapidly expands. thereby dispersing the liquid rivulets andior droplets into the atomization zone 68. The rivulets break into two or more droplets during the atomization. The atomizing zone may be a discrete. readily discernable orifice downstream from shear mixing zone ?~. or it may comprise a zone 68 ot~the smallest cross-sectional area in shear mixin~~ zone ?-1 as illustrated in Fi<~ure 6(b). In the later case. fluid atomization begins in shear mixing zone ?-1.
In the strictest technical sense, atomization may refer to increasing the surface area of a liquid when the steam or other atomizing gas is mixed with.
or injected into, the liquid to be atomized. In the context of the invention.
atomization means that as the tluid passes through the atomizing orifice. the liquid phase breaks up. or begins to break up. into discrete masses in the gas phase and this continues as the fluid continues downstream and the liquid is atomized into a spray of droplets dispersed in the gas phase.

The present invention comprises both a process and an apparatus for atomizing a liquid. wherein the liquid experiences both impingement and shear mixing. TIze impin~~emcnt mixing and shear mixinU both occur in a fluid passageway I-~ lon'~itudinallv extending through the interior of a hollow nuzzle 10 that defines an at least one expansion zone ?0. an impingement mixing zone '_'?. and a shear miain~~ zcme ~-1. The fluid passageway l~ is open at both ends (fluid inlet I-Ia. tluid outlet lib). Fluid inlet lea is at the nozzle upstream end 16. and fluid outlet 1-~b is at the nozzle downstream end 18.
In a process embodiment of the present invention. at least two separate streams of a two-phase fluid comprising a gas and the liquid to be atomized are simultaneously and sequentially passed. under pressure. through impingement mixing zone ?? and shear mixing zone 24. In the impingement mixing zone ??, the separate streams are mixed to form a single mixed stream by colliding or impinging at least a portion of each stream against the other.
In the impingement mixing zone ?2. the separate streams mix mostly (>
50 °'°) by impingement. Shear mixing means that mixing occurs mostly by shear forces. Impingement mixing between two fluid streams occurs when the half angle between the streams ranges between at least 15° up to 90°.
and the total included angle between the impinging streams ranges ti-om about 30° to about 180°. with 180° producing the most violent and chaotic mixing.
Shear mixing occurs when the half angle ranges from about 0° to about 15°.
In the practice. at least a portion (e.g.. >_ ?0 %) of each fluid stream in the impingement mixing zone ''? also has a flow component parallel to the downstream flow direction. so that not all mixing in zone ?? occurs by impingement. In a preferred embodiment. at least the laterally outer or peripheral portion of each fluid stream is directed against the other in the unpin<~ement 1711x1118 !()Ile ?~. preferably at an angle of9()° -3()° normal to the longitudinal tlow direction ofthc fluid (direction ofordinary or overall Iluid flow). more preferably ~)()v - l()°, more preferably ~0° ~
~°. more preferably c)0°
- ~°. most preferably about ~)()° (or substantially parallel to the y-axis shovyn in the Figures). Fluid expansion in the impingement mlxlng zone ~~' and shear Illlxlna zone '?-1 is minimized.
The impingement Illlxlng zone ??. the shear mixing zone ?=t. and the atomization zone 68 are all in fluid communication. After impingement. the mixed stream passes through shear mixing zone ?=t where further mixing ot~the mixed stream occurs. The impingement and shear mixing zones ~'_'. ?-1 may comprise respective upstream and downstream portions of t7uid passageway 14.
The downstream end of impingement mixing zone ?? tluidlv communicates with the upstream end ofthe shear mixing zone at the impingement mixing zone-shear mixing zone interface. The kinetic energy imparted to the fluid by the impingement and shear mixing forms a single stream that. when atomized.
produces small liquid droplets dispersed in a gas continuous phase. The average size of the liquid drops or droplets dispersed in the gas phase after passing through the nozzle is smaller (e.g.. at least 10 °~ smaller and preferably at least ~0 °..'~ smaller) than upstream ofthe nozzle.
Shear mixing zone '?-1 tluidlv communicates with an atomizer or atomization zone 68 in a spray distributor 6~. or as discussed herein.
atomization zone 68 may be cont7gured as part of shear mixing zone ?4.
The atomizer may comprise an orifice having a smaller cross-sectional area than the smallest cross-sectional area in the shear mixing zone ~'-~.
resulting in a pressure drop across the atomizer and further shear of the nvo-phase tluid as it enters the lower-pressure atomization zone 68. For example. in Fi~>ure ~(a).

the atomizer may c:omprisc distributor inlet I ~8 or nozzle orifice ~(). This shear further reduces the liquid droplet size. ;1s the fluid passes into atomization cone 68, it rapidly expands and produces a spray ot~atomized liquid droplets. this rapid expansion and production ot~a spray of liquid droplets comprises atomization.
The fluid outlet of~shear mixing zone 2~1 fluidly communicates with a spray distributor 6~ that shapes the spray into a desired shape. Spray distributor 6~ may comprise part of the atomization zone 68 and may or may not comprise part of nozzle 10. Spray distributor 6~1 is preferably used to minimize coalescence ofthe liquid phase prior to atomization. In another embodiment.
shear mixing zone ?4 may fluidly communicate with an atomizer that comprises includes a hollow fluid conduit open at both ends and an atomizing orifice and a spray distributor at its downstream end. In this embodiment. the cross-sectional area ofthe conduit perpendicular to the direction of fluid flow is preferably Greater than the smallest cross-sectional area of shear mixing zone 2-1 and the atomizing orifice. This minimizes agglomeration or coalescence of the liquid phase as the fluid flows through the atomizer.
This process and apparatus are useful for atomizing a lame volume of hot teed oil into the riser reaction zone ofa FCC unit to achieve a relatively small feed droplet size and uniform droplet size distribution of the atomized teed droplets with a minimal pressure drop across the mixing zones ?'_'. '_'-1 and atomizer. For example. with a ~-inch diameter nozzle. it is possible to atomize 30 pounds per second of the hot oil teed. at a pressure drop across the nozzle of less than ~0. and preferably less than ~10 pounds per square inch (psi). When used to atomize a FCC teed oil. nozzle 10 will comprise part of a teed injector 182 (see Figure 71 that house nozzle 10 as is discussed later. Typically a plurality of feed injectors 182 are employed. preferably positioned circumferentially around the upstream end ofthe FCC reaction zone that is proximate to the bottom ot~ the riser. The hot teed oil is usually mixed with >team (andior other dispcrsioniatomizing has) upstream ot~nozzle lU to form a uyo-phase fluid comprising a steam phase and a hot. FCC feed oil liquid phase.
This mixing also increases the velocity ot~the flowing two-phase fluid.
l~Ii~cing of the steam and oil upstream of nozzle 10 is typically achieved in feed injector 182. by steam or other dispersion gas sparging means. as is known.
The two-phase fluid stream is split or divided into two separate streams.
preferably using a splitter 28. In one embodiment. such as that shown in Figure ~. both streams flow simultaneously over splitter 28 and through two separate fluid openings 26. ?6'. Splitter 28 may be suitably positioned at fluid inlet lea so that sputter 28 and fluid passageway 14 define the at least two fluid openings 26, 26'. Fluid openings 26, 26' are preferably symmetrically identical. and they are equidistantly and laterally spaced from the longitudinal axis (the x-axis in the Figures) of fluid passageway 1~.
In the impingement mixing zone 22. a flow component is imparted to each stream and is directed radially inward and preferably perpendicular to the longitudinal axis of fluid passageway l~ (i.e.. along or substantially parallel to the v-axis shown in the Figures). The flow component is directed toward at least a portion of the other stream that has a corresponding flow component directed radiallv inward. At least a portion of each stream impinges against the other.
resulting in turbulent impingement mixing and a concomitant reduction in the liquid droplet size. The resulting mixed fluid stream then passes into shear mixing zone 2=1 for further mixing with less pressure drop than occurs in impingement mixing zone '_''_'. The mixed stream then passes into the lower-pressure atomization zone 68.
The cross-sectional area of the atomizing orifice normal to the fluid flow direction is typical ly smaller than the cross-sectional area of the fluid conduit( s ) NOT TO BE TAKEN INTO ACCOUNT FOR THE PURPOSE OF INTERNATIONAL
PROCESSING

1~
between the sidewalk dctincs fluid passageway 1-t. which may have an overall rectangular cross-section.
The cross-sectional area ot~an area of fluid passageway I-I may he varied by yarving the distance between at least a portion ot~at least one pair ot~opposing walls in either a first dimension along the v-axis or a second climension along the z-axis. In some embodiments. the cross-sectional area of shear mixing zone ?4 decreases or converges in the direction of fluid outlet 1 fib. In other embodiments, the cross-sectional area ot~shear mixing zone ?=t decreases part of the way toward fluid outlet 1 ~b and may increase as zone ?~ progress toward outlet 1=fib. The cross-sectional area may be varied in either direction ( t3rst or second dimensions(s)), i.e. along the z-axis or along the v-axis. The cross-sectional area of tluid passageway l~ is greatest at the upstream end ot~the impingement mixing zone '_'?. near tluid openings 26, ?6'. In other embodiments. the cross-sectional area of shear mixing zone ?~ will not vary because the distance along the v-axis will decrease at the same rate as the distance along the z-axis increases.
Figures 1(a)-I(d) illustrate one embodiment ofnozzie 10. ~iozzle l0 comprises a body l'?. the interior ot~which comprises a single. unitary and generally longitudinal fluid passageway 1=1 having a tluid inlet 1-la (openings ?6.
?6~) and a fluid outlet lib. Fluid passageway l~ has a longitudinal axis (x-axis) coincident with the longitudinal axis ( x-axis) of nozzle 10. The upstream end and downstream end ot~ fluid passageway 14 are located at the respective upstream end 16 and downstream end 18 of nozzle 10.
Viewing Figure I(b). fluid passageway l~ has a rectangular cross-section and is divided into three sequential zones (expansion zone ~(). impingement mixing zone ~?. and shear mixing zone ~-t). all of which are in fluid communication. with adjacent zones in direct fluid communication.

Referring to f~i<~urc l(a). fluid inlet 1-la comprises a pair of wmmctricallv identical and circ(~ ay~m~nt-shaped fluid openings ?6. ~'6' separated by a splitter ~8. Splitter ?8 l:e)t11pC1SW a ~~e:nerallv rectangular-shaped plate that hisects fluid inlet lea to split a stream oU~ flowing two-phase fluid into two separate streams that flow through fluid openings ~6, ?6'. The ed_es of sputter ?8 lorm the chordal portion of each respective fluid entrance ?6. ?6'.
The downstream end of the fluid passageway I ~ comprises a non-circular exit orifice 30. In this embodiment. orifice 30 is square-shaped. althou~~h other sl3apes may also be employed. but a non-circular orifice 30 is preferred.
Orifice 30 may or may not comprise at least a portion of the atomizer or atomlzlng zone 68. The non-circular shape oforitice 34 also produces a more uniform size distribution of the atomized oil droplets than a circular or arcuate orifice would.
Referring to Fi~~ures 1(b)-l(d). fluid passaQewav 14 is formed by two different pairs ot=opposing walls (36-38-23) - (36'-38'-23') and 3~-3~'. as shown. Walls 3-1 and 3~' are identical. flat. parallel and are rectangular in shape, while 36-38-23 and 36'-38'-?3' are symmetrical. The same point on a wall pair is equidistant from the longitudinal axis for each wall. with the intersection of walls (36-38-23)-3~ and (36'-38'-?3')-3=1' each forming a right angle.
although in some embodiments. the intersection points are arced or full radiused. Walls 36-38-?3 and 36'-38'-23' each begin upstream with an arcuate or circular shape perpendicular to the longitudinal axis of nozzle 10. substantially conforming to the circular or arced shape of teed conduit 164 (see Figure ~) and fluid openings ?6. ?6'. The shape of fluid passageway l~ is maintained along fluid passageway 1-1 until steps 38-38' (also referred to herein as the impingement mixing surfaces) at the entrance to shear mixing zone ~-1. In shear mixing zone ?-1.
the shape of fluid passageway I -1 may chance to a generally flat. four-sided shape that continues to orifice 30. to more effectively utilize the impingement mixing momentum.

f=luid opcnin'~s ~6. ~6~ are diametrically opposite and radiallv and mluidistantlv spaced apart t~rom the longitudinal axis. l'he: combined c:ross-,ectional areas ot~opcnings ?6, ~'6~ is smaller than the cross-sectional area ol~
expansion zone ~U. hut lar~7er than the cross-sectional area,just downsu"~~llll ol~
steps 38. 38~ to reduce the pressure drop ot~the tluid entering shear miain~~
zone '_'-I. Fluid openings ~6. ~'6~ are yelocitv-increasing openings because their cross-sectional area is smaller than the cross-sectional area ot~the fluid conduit 16~ as shown in Figure ~.
Referring to Figure 1 (h), a two-phase fluid stream splits into two equal streams over sputter ~8 and enters fluid passageway through openings ~6. ~6~.
The pressure drop across splitter ?8 may be too high for some applications and, hence. a lower pressure drop means for introducing fluid into the nozzle can be employed. Flow through openings ?6. ?6~ into expansion zone ?0 imparts shearing forces because the lighter gas phase accelerates more quickly than the heavier liquid phase. Expansion zone 20 is a controlled expansion zone ?0 in the sense that the tluid is not permitted to freely expand. as it is atomization zone 68. The expansion zone ?0 reduces the pressure drop from what it would otherwise be it~it were not present.
At least the outer peripheral portion of both streams impacts or impinges directly onto the right-angle steps (impingement surfaces) 38-38' and is torced radially imvard to impinge directly into another impinged stream in impingement mixing zone ~?. In an embodiment having right-angled impingement surfaces or steps 38-38'. the included angle between the impinging fluids is 180°.
Thus. the impingement surfaces are formed in the v-z plane normal to the x-axis. The impingement directs the radiallv inW and component of both streams to substantially along the longitudinal axis of fluid passageway ( ~ to produce maximum impingement mixing.

As the tluid continues downstream. it enters shear mixing zone ~-I where the cross-sectional aria clcrcases in the downstream direction to increase the flow v:~e(ocitv and (~urth~r reduce the size of the liquid droplets. primarily with shearing forces. ~'Vhile there is no abrupt change tcom impingement n~ivin'~
zone ?? to shear mixin<~ zone ~~. shear mixing substantially beg ins downstream of steps 38-38~. (>ne pair ot~opposing walls ?3, ?3' defining shear mixing zone ?-I are sloped and converge inward toward orifice 30. The gradual decrease in the cross-sectional area ot~ shear mixing zone 24 increases the tluid velocity. and the maximum fluid velocity occurs preferably at orifice 30.
In another embodiment not shown. two separate fluid streams ii-om any convenient source that comprise a two-phase mixture of a gas and a liquid pass into fluid passageway 1=l through fluid openings 26, ?6'. In this embodiment.
the two separate feed lines must be sized to achieve the desired fluid inlet velocity.
Figure ? (a) illustrates another embodiment of nozzle 10. fabricated of a plurality of stacked metal platelets. ~0-62. For clarity. the intersection lines of platelets ~0-62 within passagemav 14 are not shown. The individual metal platelets are prepared having the required passages therein. as holes, slots.
or orifices extending through the platelet. They are then stacked together.
bolted and/or diffusion bonded together. to form nozzle 10. Starting ti-om upstream end 16, platelet ~0 comprises a disk having two circle segment-shaped openings ?6.
~6' detlned by stream splitter ?8 similar to that shown in Figure 1(b). Figure ~(d) illustrates platelet ~6. Platelet ~6 comprises two shoulders 80. 80~ on opposite sides of orifice 1 ~. Shoulders 80. 80' and orifice 1 ~ are sized and configured to appropriately define impingement surfaces (steps) 38. 38'.
Progressing downstream. the sizes ot~ orifices 1 ~ in each subsequent platelet decreases as shown similar to the convergence of shear mixing zone ?-I shown in Figure 1(b). While each of the radiallv inward steps of each successive disk ~7-h? is not lame enough to impart as much radiallv iwvard momentum to the (lowing fluid as shoulders ~(). 80'. they impart a ra diallv iwvard mixing component to the flowing fluid. The orifices is ot~the platelet that define shear mixing zone ?-1 have varvin~ first dimensions, wherein the first dimension ot~the orifice 1 ~ ot~ each platelet defining shear mixing zone ?~ is smaller than the first dimension ot~the orifice 1 ~ of'the platelet preceding it. Preferably, the orifices l ~ ot'at least one platelet that define shear mixing zone ?~ have yawing second dimensions. wherein the second dimension ofthe orifice l~ of~each platelet detinin~ shear mixing zone ?-t is greater than the second dimension ot'the orifice t ~ of the platelet preceding it.
Referring to Figure ? (a). nozzle 10 may also comprise a spray distributor 6=1 positioned at downstream end 10 and in fluid communication with fluid outlet lib to produce a generally flat and tan-shaped spray ot'the atomized liquid.
Distributor 64 may be welded, bolted. brazed or otherwise attached to nozzle and form a part thereof. As shown. distributor 6~ comprises a flange 63 to allow distributor to effectively attach to nozzle 10. Distributor 6~ has a passaQewav 70 (with an inlet 70a) passing therethrough configured to be substantially the same size andior shape as orifice 30, although the cross-sectional area ot'passaaewav 0 may suitably vary to promote formation of a desired spray shape.
Passageway 70 opens up downstream into a generally flat and divergent tan-shaped spray distribution tip 71. defined by opposing wall pairs 66-66' and -t-7~'. which define a tan-shaped atomization zone 68. As shown in Figure ~(a?. atomization zone 68 has a first dimension that may converge. or decrease.
vertically (along the v-axis) when progressing toward orifice ; ? so that the first dimension is greater at the inlet than at the outlet to control the rate ot~shear nllxln°_. In some embodiments. however. the first dimension of zone 68 may remain constant. .=atomization zone 68 has a second dimension that diverges.
or increases. ( along the z-axis ) when progressing toward orifice ?? so that the second dimension is ~~reatcr at the outlea than at the inlet. )-ip 71 tcrminatcs at orifice 7'_'. ()riticc i'_' may he oriented normal to the outward llow spray direction and has its lon<_cst dimension along the z-axis. preterahy Imvin rounded or full-radiuscd ends (walls 7-1. 7-~~1. Walls 7~. 7-l~ ''emrallv have the same curvature, hut in come embodiments. the curvatures may he independently selected. Preferably. the curvature is circular. The preferred radius c>fuurvature is about one-halfthe dimension ofpassagewav 70 in the v-axis. While not required, the center ot~~ach wall's 7-1. 7~l' radius ofcurvature is generally located near the centerpoint ofthe v-axis (centerpoint of first dimension). In embodiments where first dimension varies along the x-axis. the radius of curvature may also vary.
In alternate embodiments not shown. the converging and/or diverging dimensions may be along different axes. but preferably. along axes having a 90°
separation. The first and second dimensions of passageway 70. or zone 68, are preferably measured at the widest point ofseparation between opposing walls.
i.e. at the widest point of curvature from the center or longitudinal axis or passageway 70.
In one embodiment. the width of inlet 70a along the z-axis is at least about 1.~ times the length of distributor ( measured along the x-axis ). and the width at exit orifice 7'_' is at least about l.~ times the width of inlet i()a.
Fluid exitinU orifice 30 enters atomization zone 68 and passageway 70 to further shear the fluid and further reduce the liquid droplet size. Expansion zone 68 is at a lower pressure than orifice 30. resulting in a rapidly expandinU
gas phase that atomizes the liquid to produce a spray of liquid droplets. This further shears the liquid droplets. and the fan shape of the atomizing tip 71 produces a fan-shaped spray of the liquid droplets that flow into the reaction zone of the FCC riser reactor ns shown in Figure ,.

Fi<lure 3 illustrates another embodiment of nozzle l U that is operated and configured in a manner as previously described for other cmhodiments. Viewing Figure 3(c). exit orifice 30 has arced lateral ends 130, 130 (preferably lull-radiused) and has a dimension along the z-axis longer than the dimension glens the v-axis, similar to that shown in Figure ?(b) and described curlier. :~rccd ends 130. 130' are preierahly fiUl-radiused to correspond to the lull-radiusc:d ends of distributor 6~. As is shovyn in I=figures 3 (b) and 3 (d), shear mixing zolle ?-1 is defined by two pairs ofradiallv opposite and opposing walls 1?6. 1?6' and 130.
130'. Walls 1?6. 1?6~ converse inward in the downstream flow direction. and walls 130. 130' diverse outward in the downstream flow direction. The net ~t~fect is either a ~enerallv overall constant cross-section of shear mivin~
zone ?4. or one that d~c~reases or converses and then diverses or increases by about 10%-~0% larser than the minimum cross-sectional area in shear mixins zone 24.
In other words. shear mixins zone 2~ has a first dimension glens the v-axis that decreases progressing toward outlet 30 and preferably a second dimension along the z-axis that increases progressing toward outlet 30.
This design ofdiyeraing and converging walls produce a shear mixing zone ?4 having a lower fluid pressure drop across it than the embodiment illustrated in Figure 1. It also reduces the possibility of coalescence in shear mixing zone ?-I when compared to the embodiment shown in Figure I .
The entrance to shear mixins zone ?~ is defined by the radiallv inward edge of steps 38. 38~ and the intersection of walls 12~-130 and 1?~~-130. The cross-sectional area at the entrance to shear mixins zone 2~ is smaller than that of the combined cross-sectional areas of openings 26. ?6' to increase the velocity of the fluid as it tlovys into shear mixing zone ~-I. In this embodiment.
the divergence and convergence of shear mixing zone ?-1 shapes the fluid iMow into a generally rectangular shape that may have arced ends as shown in Figure 3(c). This shape promom smooth transition ot~llow ~ fluid from nozzle 10 to distributor f~~.
Figures -t(a)-~IIc) illustrate the embodiment shown in t=i~~ures 3(a)-3(d) with the addition ot~a spray distributor 64 attached to nozzle 10 in a conventional manner as previously discussed. Spray distributor 64. as show w in Figure ~).
comprises a generally tan-shaped body 1 ~2 containing a fan-shaped fluid passageway 1 ~4 within. detined by opposing and outwardly diverging walls 15~, 1 ~ ~' that serve to control the expansion of the atomizing fluid into a fan-shaped spray. Walls I ~ ~. I ~ ~ ~ comprise the rounded, full-radiused lateral ends of passageway I ~4 that preferably diverge along at least axis of passageway I ~4 to provide a fan-shaped spray. The embodiments shown in Figures 3(a)-3(d) and 4(a)-4(c) comprise arced walls 1~6, I?6' as shown. The tluid entrance 158 to spray distributor 6:) corresponds in shape to orifice 30 in nozzle 10. and the fluid outlet 160 of distributor 6-~ is larger to permit the atomized spray of liduid drops to continue expanding into a fan-shaped spray. The pressure in passageway 154 is lower than that in the nozzle fluid passageway 14. The mixed tluid exiting nozzle 10 and entering tluid passageway 154 atomizes into a fan-shaped spray of liquid droplets that flow through outlet 160 and into the FCC riser reaction as shown in Figure 7. Figure ~ illustrates a cut-aw~av view ~ ot~an atomizing nozzle and distributor 64. in association with an upstream fluid conduit 164.
Conduit 164 provides the flow path for a two-phase fluid to enter nozzle 10 through fluid inlet I-la Iopeninas ?6. ?6').
Figures 6(a)-6(c) illustrate another embodiment ot~atomizina nozzle l0 wherein an atomization zone f 1 ~ is configured to be part of shear mixing zone ~'-~. In all other respects. the nozzle 10 shown in Figures 6(a)-6(c) operates similarly to the embodiments already described. .as shown in Fi<~ure 6 la).
tluid openings ?6. ~'6~ need not be completely arced segments it~the pressure drop across salitter ~'8 is not too great.

2s Viewin~~ f=i~~ure f~(h). shear mixin<z zone ~-~ has a complwly shaped Ilow area where its cross-wctional area first decreases and then increases as it pro~~resses toward orifice 3(). IVvo partial cross-section views of~Illc nozzle taken at 6 ( b ) - f~ ( b ) and O 1 c ) - 6 ( c ) are shown in F i lure O ( h ) and H i ~~ure 6 ( c ).
to illustrate the somwhat complex nature ot~the shear mixin<~ aom ~-I.
Atomization zone 1 I ~ comprises the region or zone of smallest cross-sectional area within shear mixing zone ?~. Zone 1 I ~ is preferably positioned adjacent to or near orifice 30. Atomization zone 1 1 J may also terminate in orifice 30.
~ritice 30 preferably has the same size and shape as that described and shown in previous embodiments.
As shown. a first dimension of shear mixing zone 24 decreases toward fluid outlet 14b at a first rate for at least a portion of shear mixing zone ?~I and then decreases toward t7uid outlet 1 ~b at a second rate for the remainder ol~
shear mixing zone ?-t.--Preferably. a second dimension of shear mixing zone ?-I
increases toward fluid outlet 14b at a first rate for at least a portion of the shear mixing zone 2=~ and increases toward fluid outlet I ~b at a second rate tar the remainder of shear mixing zone ?~I.
In operation. as the nvo-phase fluid flows through passageway l-I into lower pressure atomization zone 1 I ~. atomization is promoted by the rapid gas expansion in the loner pressure region of atouization zone ( I ~ and by the rapid acceleration ofthe lighter compressible gas than the higher density (and incompressible) liquid phase. This induces shear between the phases until their velocities more nearly equalize. The shear forces decrease the ultimate size of the liquid droplets in the atomized spray.
Nozzle 10 can be fabricated in a number of different ways. A lost wax or investment casting process may be employed. or a forging and other casting process may he used. ~urzlc l0 may be fabricated from suitable ceramic ur metal material ur cumhinatiuns thereof: ~~s shown in Fi~~urcs ~(a)-?(d).
fabrication ot~nozzlc 1() usin<' a pluraliy ut~stacked. relatively lhlll metal platys ur platelets to li~rm a hudy I ~ hayin<~ a fluid passageway I-~ thcrcthruugh is known and disclosed as useful for rocket motors and plasma torches in. for maniple. L.~.S. Patents 3.881.?01 and ~.~~~.~(>l. This fabrication technique is also useful in fabricating nozzles 10 of the present invention, including the embodiments generally disclosed and shown in Fissures l -6. and nozzles of the invention have been fabricated using this technique. However. the invention is Trot intended to be limited to the use of this technique for nozzle tabricatiun.
Referring now to Figure 7. a FCC teed injection unit 180 that incorporates one or more the embodiments described herein is shown. Unit 180 comprises a hollow teed injector 182 attached to a teed nozzle means I 8~ via 186. 188. Feed nozzle means 18~ is shown as a conduit penetratin<~ through the wall 190 of a FC-C riser 206 and into riser reaction zone 192. Riser 206.
better seen in Figure 8. is preferably a cylindrical. hollow, and substantially yerticallv-oriented conduit. In reaction zone 192. at least a portion of the atomized oil teed 300 contacts uprising. hot catalyst particles. and feed 300 is cracked into more useful. lower boiling hydrocarbon products. Only a portion of riser ?06 is shown for convenience.
Feed injector 182 comprises a hollow conduit 19~ into which preheated oil feed 300 is introduced yia teed line 196. Feed line 196 forms a T-_j unction with the wall of the upstream portion of feed injector 182. The downstream portion of feed injector 18? comprises nozzle 10 and preferably spray distributor 6~. both of which are shovyn as boxes for convenience. Spray distributor 6~
produces a relati~ ely flat. fan-shaped spray of the atomized oil teed 3()() into reaction zone 19? .

:1 steam spargin'u conduit 198, having a smaller diameter or cross-sectional area than the injector conduit 19~, wends into. and is co-axially aliened with. the lon~~itudinal axis otconduit 19~. In thlS emb()dlmt'.nt. the ~~ntral longitudinal axes ui conduits I ~)4. 198 are coincident. hhis provides an annular tlow path 197 tier hot oil teed 300 upstream of~the exit end ot~the injector. Steam conduit 198 terminates inside injector conduit 1 ~)-1~.
upstream of noZZle 10. ;~ plurality Wholes or orifices 199 are radiallv drilled circumferentiallv around the downstream end portion of conduit 198. 1-loles allow steam to sparge radiallv outward and into the annular t7ow path 197 to mix with the hot oil teed 300 tlowing through path 197 to produce a two-phase tluid comprising globules of hot oil dispersed in steam. The amount of steam sparged into oil feed 300'is typically between about 1 and about ~ wt. °,'o of the hot oil teed 300. The resulting fluid mixture. which may typically comprise. on a volume basis. 7~-8~ °'~ steam and 1 ~-2~ % oil feed 300 passes to nozzle I 0 which splits it into nvo separate streams that enter nozzle 10 to mix and atomize the oil feed 300 as previously described.
The atomized spray otoil teed droplets 300 pass into reaction zone 192 and contact the uptlowing stream of hot catalyst particles ( not shown ) to catalvticallv crack the heavy oil feed 300 into the desired lower hailing product ti-actions.
Figure 8 illustrates a conventional FCC process that may incorporate one or more embodiments of the present invention. FCC unit ?00 comprises a FCC
reactor ''0? and a regenerator ?04. Reactor ?0? comprises feed riser X06 containing reaction zone 19?. Reactor ~0? also comprises a vapor-catalyst disengaging zone '_' 10 and a stripping zone ? 12 comprising a plurality of baffles ~' 1-1 that look like arrays of metal "sheds' that resemble the pitched roots of houses. A suitable stripping agent. such as steam. is introduced into the stripping zone via line ~ l6. The stripped. spent catalyst particles pass into regenerator 30-~ via transfer line ~ 18.
~ preheated I~CC lirtd passes via line ?~'0 into the base of~ris~r X06 at need injection point ~'~-l. The preheated teed 300 may or may not be pre-mined with a predetermined ~luantim of steam. Feed injector 18? shown in f=i~~ure (, is located at 2?4. but is not shown in Figure 8 for simplicity. In practice. a plurality of teed injectors 18?. such as those shown in Figure 7, will be located around the circumference of riser 206. Steam may pass into teed injector 182 via line 2??. The atomized droplets of hot teed 300 contact the catalyst particles in the riser. This vaporizes and catalyticallv cracks the teed into lighter.
lower boiling fractions. including fractions in the gasoline boiling range (typically 100°-400°F. 30°-?OS°C). as well as higher boiling jet fuel. diesel fuel. kerosene and the like.
The FCC catalyst may comprise any suitable conventional catalytic cracking catalyst. The catalyst may comprise a mixture of silica and alumina containing a zeolite molecular sieve cracking component. as is known to those skilled in the art.
The FCC reactions commence start when the feed 300 contacts the hot catalyst in the riser X06 and continues until the product vapors are separated from the spent catalyst in the disengaging zone ? 10. The cracking reaction deposits strippable hydrocarbonaceous material and non-strippable carbonaceous material known as coke. to produce spent catalyst particles which must be stripped to remove and recover the strippable hydrocarbons. The catalyst is then regenerated by burning off the coke in the regenerator.
Reactor ~0? comprises cyclones (not shown) in the disengaging section '' 10. The cyclones separate both the cracked hydrocarbon product vapors and 2?
the stripped hydrocarbons ( as vapors ) ti-om the spent catalyst particles. f he hydrocarbon vapors arc withdrawn via line ~~'6. The hydrocarbon vapors arc typically fed into a distillation unit or tractionator (nut shown) which condenses the condensable portion ot~the vapors into liquids and ti-actionams the liquids into separate product streams.
The spent catalyst particles pass to stripping zone ? I? where they contact a stripping medium. such as steam. The steam passes into stripping zone'_12 via line ? 16 and removes the strippable hvdrocarbonaceous material deposited on tfie catalyst during the cracking reactions. These vapors are withdrawn along with the other product vapors via line ~'?6. The baffles 214 disperse the catalyst particles uniformly across the width of the stripping zone ? 12 and minimize internal retluxing or backmixing of catalyst particles in stripping zone ? I?.
The spent. stripped catalyst particles are removed ti-om the bottom of stripping zone 1? via transfer line ~ 18 and pass into a tluidized bed ?''8 within regenerator ?04. -The catalyst particles in tluidized bed ??8 contact air entering the regenerator via line ?-t0. Some ofthe catalyst particles pass up into disengaging zone 2=t?. The air oxidizes or burns oft the carbon deposits to regenerate the catalyst particles and heats them up to a temperature which typically ranges from about 9~0°-1400°F ( ~ 10°-760°C). Regenerator ?04 comprises cyclones (not shown) that separate liot regenerated catalyst particles from the gaseous combustion products. or tlue gas. which comprises mostly CO~_ CO. H~O and N, The cyclones pass the regenerated catalyst particles back down into tluidized catalyst bed ?''8 via diplegs (not shown). as is kno~jn to those skilled in the art.
Fluidized bed ~''_'8 is supported on a gas distributor grid ~'-~-t. which is illustrated as dashed line. The hot. regenerated catalyst particles in tluidized bed '_''_'8 overflow the weir ~-t6 formed by the top ofa tunnel ~-t8 that is connected at 2~
its bottom to the top of a downcomcr ~'~0. ~~lie bottom of~downcom~r >>() turns into a regenerated catalyst transfer line ~~~. ~hhe overtlowin<~. regtmratcd particles tlow down through funnel ?~~, downcomer ~~0 and into the transfer line ~~'? to pass back into reaction zone 19?. The flue 'gas is rcmovccl from the top of the regenerator via line ?s~.
Cat cracker feeds used in FCC processes typically include ';as oils. which are high boiling, non-residual oils, such as a vacuum has oil (VGO). a straight run (atmospheric) has oil, a Ii~Tht cat cracker oil (LCGO) and coker gas oils.
TI~Zese oils have an initial boiling point typically above about ~~0°F
(?3'?°C), and more commonly above about 6~0°F (3~3°C). with end points up to about 1 1 ~0°F
(621°C), as well~as straight run or atmospheric gas oils and coker gas oils. In addition. one or more heavy feeds having an end boiling point above I
()~0°F
(~66°C) (e.a.. up to 1300°F (70~°C) or more) may be blended in with the FCC
teed. Heavy feeds include. for example. whole and reduced crudes. resids or residua tcom atmospheric and vacuum distillation of crude oil, asphalts and asphaltenes. tar oils and cycle oils from thermal cracking of heaves petroleum oils. tar sand oil. shale oil. coal derived liquids. svncrudes and the like:.
These may be present in the FCC feed in an amount ot~ from about ? to ~0 v~c~fume °'o ot~
the blend. and more typically ti-om about ~ to 30 volume %.
Heavy feeds typically contain too high a content ot~ undesirable components, such as aromatics and compounds containing heteroatoms.
particularly sulfur and nitrogen. Consequently. these Yeeds are often treated or upgraded to reduce the amount of undesirable compounds by processes. sLlch as hvdrotreatina. solvent extraction. solid absorbents such as molecular sieves and the like. as is known.
Typical FCC reactor process conditions include a temperature ot~ tcom about 800°-1?00°F 1-~?7°-big°C). preferably ~~0°-110°F (-~~-Iy-f,?I~CI and still more preferably ~)()()°-1 I ~0°F (-I8?°-~~?
1°C), a pressure hemccn ahout ~-C~0 prig, preferably ~-.~() psi~~ with teed;'catalvst contact times heUveen about (>.~-I
seconds, preferably about I-~ seconds, and with a catalyst to Iced ratio c~f~about ().~-10 and preferably '_'-~. The FCC teed is preheated to a temperature ot~not more than 80'1 (-l~-~yC). preferably no <~reater than H00°I (-~?7°C) and ypicallv within the range of li-om about s00°-800°F (260°-~?7°C 1.
The invention will be i-urther understood with reference to the following non-limiting example.
Example In this experiment. an atomizing injector similar in design to that shown in Figure 7 with an embodiment of atomizing nozzle similar in desi<zn to that shown in Figure ~. was compared to a commercially proven slot and tan design.
similar to that shown in U.S. patent ~,173.I7~. The commercial nozzle simulated a pipe with an end cap containing a rectangular. slotted orifice.
with an attached downstream diverging flat tan atomizing tip. Both nozzles included a tan-shaped atomizing distributor or tip and were fabricated at a scale of one half the size of a typical commercial nozzle. The injector was the same for both cases except for the nozzle design. Both injectors produced a flat. tan-shaped spray and were mounted horizontally and oriented to produce a flat. tan-shaped spray with the maximum width in the vertical direction. in the laser light beam path of a Malvern particle sizer. This instrument is well known and used for measuring liquid spray characteristics. Light diffraction patterns. each associated with a characteristic drop size range. are focused by a Fourier transform lens onto a multi-element photodetecter. The light energy distribution is converted. via a computer. into a corresponding liquid droplet size distribution.

Gaseous nitro~~cn was used to simulate the gas phase and liquid water was used to simulate the liquid phase.
A grid ot~comparative e~cperiments was conducted varying water and nitrogen flow rates and the tauter mean liquid drop diameter was calculated.
assuming a Rosin-IZammi~r distribution function. The results for the two dit~ferent nozzle designs are compared in the Table below.
Injector Type I Water i Nitrogen i tauter mean diameter (mass Ib/sec j (scf/sec) ~ (microns) ~ Commercial Tan ~ 4.93 0.9 4.99 0.39 ~ 442 ' I

4.47 0.62 3 I 3 t 3.64 0.40 I 4;1 i I

~.~3 ~ 0.94 '_'S3 ~

The Invention i -1.84 0.93 4.97 ~ 0.X0- ;4~

j 1.36 0.63 ~ ''91 3.46 0.39 ~ '_'62 1.00 1 G? i In all cases. at comparable water and nitrogen flow rates. a nozzle ot~ the present invention produced an atomized spray having smaller Sauter mean diameter liquid droplets. than did the commercial design. This shows that better atomization was achieved with a nozzle of the present invention.
It is understood that various other embodiments and modifications in the practice ofthe invention will be apparent to. and can be readily made by.
those skilled in the art without departing from the scope and spirit ot~the invention described above. .~ccordinal~~. it is not intended that the scope oFthe claims appended hereto be limited to the enact description set forth above. but rather that the claims be construed as encompassing all ot~the teatures ot~patcntable novelty which reside in the present invention. including all the features and embodiments which would he treated as equivalents thereo(~by those skilled in the art to which the invention pertains.

Claims

CLAIMS:

1. A liquid atomizing apparatus comprising:
a body comprising a fluid inlet and a fluid outlet, said body configured to define an impingement mixing zone and a shear mixing zone, said zones positioned between said inlet and said outlet. said fluid inlet comprising a splitter that can split an incoming fluid stream into at least two streams:

said impingement mixing zone comprising at least one impingement surface, said impingement surface configured to impinge at least a portion of a fluid against another impinged stream wherein the included angle between two impinged streams is between about 120° and 240°; and, said shear mixing zone having a cross-sectional area defined by a first dimension and a second dimension, wherein said first dimension decreases along a longitudinal axis through said body in a direction toward said fluid outlet.

2. The apparatus according to claim 1 wherein said impingement mixing surface is configured to be substantially perpendicular to the overall direction of fluid flow through said body.

3. The apparatus according to claim 1 wherein said impingement zone comprises at least one right-angle step.

4. The apparatus according to claim 1 wherein the wherein the included angle between two impinged streams is between about 170° and 190°.

5. The apparatus according to claim 1 wherein the wherein the included angle between two impinged streams is about 180°.

6. The apparatus according to claim 1 wherein said impingement surface imparts impingement flow to the portion of said stream contacting in a direction of about 90° normal to the longitudinal axis through said body.

7. The apparatus according to claim 1 wherein said fluid outlet has a non-circular shape.

8. The apparatus according to claim 7 wherein said second dimension of said shear mixing zone increases along said longitudinal axis toward said fluid outlet.

9. The apparatus according to claim 8 wherein said first dimension decreases toward said fluid outlet at a first rate for at least a portion of said shear mixing zone and then decreases toward said fluid outlet at a second rate for the remainder of said shear mixing zone.

10. The apparatus according to claim 8 wherein said second dimension increases toward said fluid outlet at a first rate for at least a portion of said shear mixing zone and then increases toward said fluid outlet at a second rate for the remainder of said shear mixing zone.

11. The apparatus according to claim 10 wherein said shear mixing zone has rounded lateral ends.

12. The apparatus according to claim 11 further comprising a spray distributor in fluid communication with said fluid outlet, said distributor defining an expansion zone having a pressure less than the pressure within said shear mixing zone.

13. The apparatus according to claim 12 wherein said distributor comprises a distributor fluid passageway extending therethrough, said passageway having a first dimension that diverges along the longitudinal axis of said passageway in a direction toward said outlet of said distributor, said passageway comprising rounded lateral ends.

14. The apparatus according to claim 13 wherein said body is configured to define a first expansion zone positioned between said splitter and said impingement mixing zone, said expansion zone having a cross-sectional area.

15. The apparatus according to claim 14 wherein said body and said splitter define at least two fluid openings. each said fluid opening having a cross-sectional area, and wherein the sum of the cross-sectional areas of said openings is less than the cross-sectional area of said expansion zone.

16. The apparatus according to claim 11 wherein said shear mixing zone comprises an atomization zone, said atomization zone comprising an area of smallest cross-sectional area within said shear mixing zone.

17. The apparatus according to claim 13 wherein said body comprises a plurality of plates. said plates comprising an orifice extending therethrough, whereby the orifices of said plates define said fluid passageway.

18. The apparatus according to claim 17 wherein the orifices of said plates that define said shear mixing zone have varying first dimensions, wherein the first dimension of the orifice of each plate defining said shear mixing zone is smaller than the first dimension of the orifice of the plate preceding it.

19. The apparatus according to claim 18 wherein the orifices of at least one said plates that define said shear mixing zone have varying second dimensions.

wherein the second dimension of the orifice of each plate defining said shear mixing zone is greater than the second dimension of the orifice of the plate preceding it.

20. A liquid atomizing apparatus comprising:
a body comprising at least one fluid inlet, at least one fluid outlet, and a fluid passageway extending between said inlet and said outlet:
said passageway defining an impingement mixing and a shear mixing zone downstream from said impingement mixing zone:
said passageway configured to define at least one impingement surface.
said impingement surface configured to direct fluid in a direction substantially normal to a longitudinal axis extending through said body:
said shear mixing zone having a cross-sectional area defined by a first dimension and a second dimension, wherein said first dimension decreases along a longitudinal axis through said body in a direction toward said fluid outlet.

21. The apparatus according to claim 20 wherein the portion of fluid contacting said impingement surface is a peripheral portion of the fluid flowing through said passageway.

22. The apparatus according to claim 20 wherein the wherein the included angle between two impinged streams is about 180°.

23. The apparatus according to claim 20 wherein said impingement surface imparts impingement flow to the portion of said stream contacting in a direction of about 90° normal to the longitudinal axis through said body.

24. The apparatus according to claim 20 wherein said fluid outlet has a non-circular shape.

25. The apparatus according to claim 20 wherein said second dimension0 increases along said longitudinal axis toward said fluid outlet.

26. The apparatus according to claim 20 wherein said first dimension decreases toward said fluid outlet at a first rate for at least a portion of said shear mixing zone and then decreases toward said fluid outlet at a second rate for the remainder of said shear mixing zone.

27. The apparatus according to claim 26 wherein said second dimension increases toward said fluid outlet at a first rate for at least a portion of said shear mixing zone and then increases toward said fluid outlet at a second rate for the remainder of said shear mixing zone.

28. The apparatus according to claim 20 wherein said shear mixing zone has rounded lateral ends.

29. The apparatus according to claim 20 further comprising a spray distributor in fluid communication with said fluid outlet, said distributor defining an expansion zone haying a pressure less than the pressure within said shear mixing zone.

30. The apparatus according to claim 29 wherein said distributor comprises a distributor fluid passageway extending therethrough. said passageway having a first dimension that diverges along the longitudinal axis of said passageway in a direction toward said outlet of said distributor, said passageway comprising rounded lateral ends.

31. The apparatus according to claim 20 wherein said body is configured to define a first expansion cone positioned between said splitter and said impingement mixing zone, said expansion zone having a cross-sectional area.

32. The apparatus according to claim 31 wherein said body and said splitter define at least two fluid openings, each said fluid opening having a cross-sectional area, and wherein the sum of the cross-sectional areas of said openings is less than the cross-sectional area of said expansion zone.

33. The apparatus according to claim 20 wherein said shear mixing zone comprises an atomization zone, said atomization zone comprising an area of smallest cross-sectional area within said shear mixing zone.

34. The apparatus according to claim 20 wherein said body comprises a plurality of plates. said plates comprising an orifice extending therethrough.
whereby the orifices of said plates define said fluid passageway.

35. The apparatus according to claim 34 wherein the orifices of said plates that define said shear mixing zone have varying diameters. wherein the diameter of the orifice of each plate defining said shear mixing zone is smaller than the diameter of the orifice of the plate preceding it.

36. A liquid atomizing apparatus comprising:
a body comprising at least one fluid inlet, at least one fluid outlet, and a fluid passageway extending between said inlet and said outlet: said fluid inlet comprising a splitter. said splitter and said body defining at least two fluid openings to said passageway:

said passageway defining an impingement mixing and a shear miring zone downstream from said impingement mixing zone:
said passageway configured to define at least one impingement surface positioned near the periphery of said passageway, said impingement surface con figured to direct the fluid in a direction substantially normal to the longitudinal axis extending through said body;

said shear mixing zone having a cross-sectional area defined by a first dimension and a second dimension, wherein said first dimension decreases along a longitudinal axis through said body in a direction toward said fluid outlet.

37. The apparatus according to claim 36 further comprising a spray distributor, said distributor comprising a distributor fluid passageway extending therethrough, said passageway having a lateral dimension that diverges from a distributor inlet to said a distributor outlet, said distributor inlet configured to be substantially the same size and shape as said fluid outlet of said body.

38. A liquid atomizing apparatus comprising:
a body comprising at least one fluid inlet, at least one fluid outlet, and a fluid passageway extending between said inlet and said outlet: said fluid inlet comprising a splitter, said splitter and said body defining at least two fluid openings to said passageway: said body comprising a plurality of plates, said plates comprising an orifice extending therethrough, whereby the orifices of said plates define said fluid passageway, and wherein the orifices of said plates that define said shear mixing zone have varying diameters, wherein the diameter of the orifice of each plate defining said shear mixing zone is smaller than the diameter of the orifice of the plate preceding it:

39~

said passageway defining an impingement mixing and a shear mixing zone downstream from said impingement mixing zone:
said passageway configured to define at least one impingement surface positioned near the periphery of said passageway, said impingement surface configured to direct fluid in a direction substantially normal to a longitudinal axis extending through said body;
said shear mixing zone having a cross-sectional area defined by a first dimension and a second dimension, wherein said first dimension decreases along a longitudinal axis through said body in a direction from said inlet to said outlet, and wherein said second dimension increases along said longitudinal axis in a direction from said inlet to said outlet.

39. The apparatus according to claim 38 further comprising a spray distributor, said distributor comprising a distributor fluid passageway extending therethrough, said passageway having a lateral dimension that diverges from a distributor inlet to said a distributor outlet, said distributor inlet configured to be substantially the same size and shape as said fluid outlet of said body.

40. A liquid atomizing apparatus comprising:

a body comprising at least one fluid inlet, at least one fluid outlet, and a fluid passageway extending between said inlet and said outlet: said fluid inlet comprising a splitter, said splitter and said body defining at least two fluid openings to said passageway:
said passageway defining an impingement mixing and a shear mixing zone downstream from said impingement mixing zone:

said passageway configured to define at least one impingement surface positioned near the periphery of said passageway, said impingement surface configured to direct fluid in a direction substantially normal to a longitudinal axis extending through said body:
said shear mixing zone having a cross-sectional area defined by a first dimension and a second dimension, wherein said first dimension decreases along a longitudinal axis through said body in a direction from said inlet to said outlet.
and wherein said second dimension increases along said longitudinal axis in a direction from said inlet to said outlet;
wherein said first dimension decreases at a first rate in a direction toward said fluid outlet, then decreases at a second rate in a direction toward said fluid outlet, said first rate being greater than said second rate; and, wherein sand second dimension increases at a first rate in a direction toward said fluid outlet, then increases at a second rate in a direction toward said fluid outlet, said first rate being greater than said second rate.

41. A process for forming a spray of liquid droplets comprising the steps of:
(a) forming at least two streams of a two-phase fluid comprising a gas phase and a liquid phase:
(b) passing said streams to an impingement mixing zone wherein at least a portion of each stream is impinged against at least a portion of another stream and wherein the included angle between the impinged streams is between about 140° and 240° to form a single mixed stream;

(c) passing said single mixed stream to a shear mixing zone and imparting shear mixing forces to said single mixed stream to form a shear mixed stream;
and, (d) passing said shear mixed stream to an atomizing zone wherein said gas phase expands and increases the surface area of said liquid phase, thereby producing a spray of liquid droplets.

42. The process according to claim 41 further comprising the step of combining a gas phase stream with a liquid phase stream to form said two phase fluid.

43. The process according to claim 42 wherein said impingement zone and said shear mixing zone are contained within a nozzle comprising:
(i) a body comprising a fluid inlet and a fluid outlet, said body configured to define said impingement mixing zone and said shear mixing zone.
said zones positioned between said inlet and said outlet. said fluid inlet comprising a sputter that can split an incoming fluid stream into said at least two streams of a two-phase fluid:
(ii) said impingement mixing zone comprising at least one impingement surface, said impingement surface configured to impinge at least a portion of a fluid stream contacting said impingement surface against another impinged stream wherein the included angle between two impinged streams is between about 120° and 240°: and, (iii) said shear mixing zone having a cross-sectional area defined by a first dimension and a second dimension. wherein said first dimension decreases along a longitudinal axis through said body in a direction toward said fluid outlet.

44. The process according to claim 43 wherein said shear mixing zone has rounded lateral ends.

45. The process according to claim 44 wherein said nozzle further comprises a spray distributor in fluid communication with said fluid outlet.

46. The process according to claim 45 wherein said distributor defines said atomization zone, said atomization zone having a pressure less than the pressure within said shear mixing zone.

47. The process according to claim 46 wherein said distributor comprises a distributor fluid passageway extending therethrough, said passageway having a first dimension that diverges along the longitudinal axis of said passageway in a direction toward said outlet of said distributor, said passageway comprising rounded lateral ends.

48. The process according to claim 41 wherein the included angle between the impinged streams is between about 120° and about 240°.

49. The process according to claim 41 wherein the included angle between the impinged streams is about 180°.

50. A process for forming a spray of liquid droplets comprising the steps of:

(a) forming a plurality of streams of a two-phase fluid comprising a gas phase and a liquid phase:

(b) impinging at least a portion of each stream against at least a portion of another stream to form a single mixed stream, wherein the included angle between the impinged streams is between about 120° and 240°:
(c) subjecting said single mixed stream to shear mixing forces, thereby forming a shear mixed stream: and, (d) expanding said gas phase in said shear mixed stream, thereby producing a spray of liquid feed droplets.

51. The process according to claim 50 further comprising the step of combining a gas phase stream with a liquid phase stream to form said two phase fluid.

52. The process according to claim 51 wherein said impingement zone and said shear mixing zone are contained within a nozzle comprising:

(i) a body comprising a fluid inlet and a fluid outlet, said body configured to define said impingement mixing zone and said shear mixing zone.
said zones positioned between said inlet and said outlet, said fluid inlet comprising a splitter that can split an incoming fluid stream into said at least two streams of a two-phase fluid;

(ii) said impingement mixing zone comprising at least one impingement surface. said impingement surface configured to impinge at least a portion of a fluid stream contacting said impingement surface against another impinged stream wherein the included angle between two impinged streams is between about 170° and 190°: and, (iii) said shear mixing zone having a cross-sectional area defined by a first dimension and a second dimension, wherein said first dimension decreases along a longitudinal axis through said body in a direction toward said fluid outlet.

53. The process according to claim 52 wherein said shear mixing zone has rounded lateral ends.

54. The process according to claim 53 wherein said nozzle further comprises a spray distributor in fluid communication with said fluid outlet.

55. The process according to claim 54 wherein said distributor defines said atomization zone, said atomization zone having a pressure less than the pressure within said shear mixing zone.

56. The process according to claim 55 wherein said distributor comprises a distributor fluid passageway extending therethrough, said passageway having a first dimension that diverges along the longitudinal axis of said passageway in a direction toward said outlet of said distributor, said passageway comprising rounded lateral ends.

57. The process according to claim 56 wherein the included angle between the impinged streams is between about 175° and about 185°.

58. The process according to claim 56 wherein the included angle between the impinged streams is about 180°.

59. The apparatus according to claim 7 wherein said fluid openings have a cross-sectional area. wherein said fluid outlet of said body has a cross-sectional area, wherein the cross-sectional area of said fluid outlet of said body is less than the sum of the cross-sectional areas of said fluid openings.

60. The apparatus according to claim 20 wherein said fluid openings have a cross-sectional area, wherein said fluid outlet of said body has a cross-sectional area, wherein the cross-sectional area of said fluid outlet of said body is less than the sum of the cross-sectional areas of said fluid openings.