JP2002539289A - Method and apparatus for atomizing FCC feedstock - Google Patents

Abstract

(57) [Summary] The liquid atomization method forms a two-phase fluid mixture of a liquid and a gas under pressure, divides the fluid into two separate streams, and passes this through an impingement mixing zone to impinge and mix. To form a single flow of the two-phase fluid. The mixed single stream is passed through a shear mixing zone and introduced into a low pressure expansion zone where atomization occurs, forming an atomized droplet spray of liquid. The impingement and shear mixing zones include each upstream and downstream portion of a single fluid passage in the nozzle. This is useful for atomizing hot feedstocks in FCC processes.

Description

DETAILED DESCRIPTION OF THE INVENTION

FIELD OF THE INVENTION The present invention relates to a liquid atomization method and apparatus, ie, an apparatus and method used in combination with a fluid catalytic cracking (FCC) process that requires high fluid throughput and low pressure drop. According to the method, a two-phase fluid mixture of a hot feedstock and a dispersed gas, such as steam, is formed and the fluid mixture is separated into two separate streams and passed under pressure to an impingement mixing zone and a shear mixing zone. The two streams are then recombined into a single stream, which passes through a low pressure atomization zone where it is atomized to form a spray of atomized droplets.

BACKGROUND OF THE INVENTION Fluid atomization is well known and is used in a variety of processes, including aerosol spraying, insecticide and coating applications, spray drying, humidification, mixing, air conditioning and chemicals, petroleum refining processes, and the like. Used in applications and processes. In many applications, pressurized fluid (with or without the presence of an atomizing agent) is injected from an atomizing nozzle having a relatively small orifice. Atomization occurs downstream of the orifice, and the degree of atomization is determined by orifice size, orifice pressure drop, fluid density, viscosity and surface tension. As the orifice size decreases and the pressure drop increases, atomization increases and droplet size decreases.

[0003] Increasing the atomization of relatively viscous fluids at high flow rates is of particular interest for heavy oil feedstocks used in FCC processes. The FCC process mainly converts high-boiling oils into gasoline and kerosene, jet and diesel fuels,
It is widely used in the petroleum refining industry to convert to more valuable low boiling products, including middle distillates such as heating oils.

[0004] In the FCC process, the preheated raw material is used to assist in atomizing the raw material,
It is often mixed with an atomization promoting fluid such as steam. The atomized raw material is FCC
The catalyst comes into contact with a fine particulate hot cracking catalyst flowing through a riser constituting a reaction zone. The smaller the feed oil droplet size in the reaction zone, the more feed conversion to valuable products. This is remarkable when a heavy raw material such as residual oil is mixed with the FCC raw material. Feedstock that is not in contact with the rising catalyst particles can be pyrolyzed primarily to methane and coke (usually undesirable products). Thus, preferably, an economical method for reducing the droplet size of the atomized oil without producing unacceptably high pressure drops in the atomizer or nozzle and / or without increasing the amount of steam or other atomization enhancers. Efforts are underway to find a viable solution. An example of such an effort is about 400
U.S. Pat. No. 5,289,97 showing an average feed droplet size of .about.1000 microns.
No. 6 and 5,173,175. In addition, heavy oil feedstocks from the FCC process and other fluids from other processes also need to be atomized more finely. It would be very beneficial if the droplet size of the atomized liquid could be reduced to less than 300 microns.

[0005] One embodiment of the present invention is a liquid atomizer having a body having a fluid inlet and a fluid outlet and configured to form an impingement mixing zone and a shear mixing zone. These mixing zones are located between the inlet and the outlet. The fluid inlet has a splitter that can split the incoming fluid stream into at least two streams. The impingement mixing zone has at least one impingement surface for impinging at least a portion of one fluid stream on the other impinging stream, and the narrow angle between the two impinging streams is between about 120 ° and 240 °. is there. The shear mixing zone has a cross-sectional area formed by a first dimension and a second dimension, the first dimension decreasing along the longitudinal axis through the body in the direction of the fluid outlet. I have.

[0006] Another embodiment of the present invention is a liquid atomizer having a body having at least one fluid inlet, at least one fluid outlet, and a fluid passage extending between the inlet and the outlet. The passageway forms impingement mixing and a shear mixing zone downstream from the impingement mixing zone. The passage also forms at least one impingement surface configured substantially perpendicular to a longitudinal axis extending through the body. The impingement surface is configured to provide a radially inward flow (normal to the overall flow direction) to a portion of the fluid flowing through the passage. The shear mixing zone has a cross-sectional area formed by a first dimension and a second dimension, the first dimension decreasing along the longitudinal axis through the body in a fluid exit direction. .

[0007] Another embodiment of the present invention is directed to a method of (a) providing at least two of a two-phase fluid having a gas phase and a liquid phase.
Forming two streams; and (b) causing at least a portion of each stream to collide with at least a portion of the other streams, wherein the narrow angle between the impinging streams is about 170 °.
Passing the stream through an impingement mixing zone to form a single mixing stream at １９０190 °; and (c) passing the single mixing stream through a shear mixing zone and applying a shear mixing force to the single mixing zone. Applying to the stream to form a shear-mixed stream; and (d) passing the shear-mixed stream through the atomization zone to create a droplet spray such that the gas phase expands and the surface area of the liquid phase increases. And forming a droplet spray.

[0008] Another embodiment of the present invention comprises: (a) forming a plurality of streams of a two-phase fluid having a gas phase and a liquid phase; Partial impact, narrow angle between impact streams about 120 ° -240 °
(C) applying a shear mixing force to the single mixed stream to form a shear mixed stream; and (d) expanding the gas phase in the shear mixed stream Generating a spray of raw material droplets.

[0009] Another embodiment of the present invention provides a method comprising: (a) a method comprising:
Forming at least two streams of phase fluid; and (b) impinging at least a portion of each stream on at least a portion of the other stream, wherein the narrow angle between the impinging streams is about 120 ° to 240 ° and a single Forming a mixed stream of
c) passing a single mixing stream through the shear mixing zone and applying a shear mixing force to the single mixing stream to form a shear mixing stream; and (d) expanding the gas phase and surface area of the liquid phase. Passing the shear mixing stream through the atomization zone so that
Contact comprising: producing a raw material droplet spray; (e) passing the raw material droplet spray through an FCC reaction zone; and (f) contacting the raw material droplet with a catalytic cracking catalyst under catalytic cracking conditions. It is a decomposition method. In one embodiment, the impingement zone and the shear mixing zone are included in the nozzle embodiments described herein.

[0010] Another embodiment of the present invention provides a method comprising: (a) a method comprising:
Forming a plurality of streams of phase fluid; and (b) at least a portion of each stream impinging on at least a portion of the other stream, wherein a narrow angle between the impinging streams is between about 170 ° and 190 °. (C) applying a shear mixing force to a single mixing stream to form a shear mixing stream; and (d) providing a shear mixing stream to form a mixing stream. This is a catalytic cracking method comprising the steps of: expanding a gas phase therein to generate a raw material droplet spray; and (e) contacting the raw material droplet with a catalytic cracking catalyst under catalytic cracking conditions.

In each method and / or apparatus of the present invention, the narrow angle between the impinging streams is more preferably from about 175 ° to about 180 °, most preferably about 180 °.

DETAILED DESCRIPTION In this specification, the region through which the fluid flows or the cross-sectional region of the band is referred to as x shown in the drawings.
This is a region that is normal to the axis and is formed by the dimensions of the y-axis and the x-axis. As used herein, "along" an axis, as shown in the drawing,
Or it is meant to be substantially parallel to that axis. As used herein, the longitudinal axis of the nozzle body or fluid passage is along the x-axis (s) of the overall fluid flow passing through the nozzle.

The two-phase fluid supplied to the nozzle 10 may be gas-continuous or liquid-continuous, or may be a foamy floss for which it is not certain that one or both phases are continuous. Reference will be made to open and closed cell sponges, which will be further understood. Sponge generally has a 1: 1 volume ratio of air to solids. Open cell sponges are both gas (air) and solid open, while closed cell sponges are solid open and contain discrete (dispersed) gas bubbles. In an open-cell sponge, the solid comprises a membrane and a ligament (as in a two-phase gas-liquid floss or foam). In closed cell sponges, the gas comprises a dispersion of discrete gas globules in a solid. Some sponges are between them, such as a two-phase fluid containing a gas phase and a liquid phase.

Although it is not possible to obtain a sponge that is gas continuous and not solid, it is possible to obtain a two-phase gas-liquid fluid that is gas continuous only. Thus, the particular form of the fluid passing through the mixing nozzle of the present invention is not necessarily known with certainty. In order to increase the surface area of the liquid phase, sufficient gas must be present in the fluid entering the impact and shear mixing nozzle. This reflects (i) the thickness of the liquid film, (ii) the thickness and / or length of the liquid flow, (iii) reducing the size of the liquid globules in the fluid before or during atomization. are doing. In fact, impingement and shear mixing through one or more orifices in nozzle 10 occur only with two-phase fluids, including gas and liquid phases.

Preferably, the fluid is predominantly gaseous on a volume basis (gas to liquid volume ratio of at least 2: 1) for sufficient shear mixing. The single-phase fluid (liquid) passing through the nozzle 10 has a kinetic energy that increases in direct proportion to the pressure drop of the nozzle 10. For two-phase fluids, the gas velocity is relative to the velocity of the liquid phase, (i) in the impingement mixing zone 22, (ii) in the shear mixing zone 24, and (iii) in the cross-sectional area narrower than the fluid conduit upstream of the fluid inlet 14a. As the fluid passes through the orifice (pressure reducing orifice), it relatively increases.

The velocity difference between the gas and liquid phases leads to liquid religation, especially in viscous liquids such as hot FCC feedstocks. Riggation means that the liquid forms elongated globules or streams. The difference in speed decreases during shear mixing. Thus, as the two-phase fluid passes through the vacuum orifice or mixes in the impingement mixing zone 22, there is a velocity difference between the gas and the liquid, which shears the liquid into elongated ligaments and / or dispersed droplets. Therefore, liquid in the gas is religated and / or
Or disperse. Further shearing of the liquid occurs as the fluid enters the fluid inlet 14 a (openings 26, 26 ′) of the nozzle 10 and passes through one or more atomizing orifices located in the fluid passage 14. The additional shear also reduces the final droplet size of the atomizing spray. The cross-sectional area of the nozzle outlet 14b (orifice 30) is preferably smaller than the sum of the cross-sectional areas of the fluid openings 26, 26 '.

The nozzle 10 may also include an atomization zone 68 at a pressure lower than the pressure upstream of the atomization orifice. The atomization zone 68 may be configured as part of the spray distributor 64 within or attached to the nozzle 10. Accordingly, the gas in the fluid passing through the atomization orifice expands rapidly, thereby dispersing the liquid stream and / or droplets into the atomization zone 68. The stream is broken into two or more droplets during atomization.
The atomization zone is either a separate orifice downstream from the shear mixing zone 24 that can be easily discerned, or comprises an atomization zone 68 of the smallest cross-sectional area in the shear mixing zone 24, as shown in FIG. May be. In the latter case, fluid atomization begins at the shear mixing zone 24.

In the most rigorous and technical sense, atomization means increasing the surface area of a liquid as it is mixed or injected with a vapor or other atomizing gas into the liquid to be atomized. In the present invention, atomization means that as the fluid passes through the atomization orifice, the liquid phase begins to break or break up into a discrete mass in the gas phase, which is followed by the fluid continuing downstream and the liquid moving into the gas phase. It is meant to be sprayed into a dispersed droplet spray.

The present invention relates to both a method and apparatus for atomizing a liquid, wherein the liquid experiences both impingement and shear mixing. Both impingement mixing and shear mixing provide at least one expansion zone 20.
, A fluid passage 14 extending longitudinally through the interior of the hollow nozzle 10 forming an impingement mixing zone 22 and a shear mixing zone 24. The fluid passage 14 is open at both ends (fluid inlet 14a, fluid outlet 14b). The fluid inlet 14a is connected to the nozzle upstream end 16
And the fluid outlet 14b is at the downstream end 18 of the nozzle.

In an embodiment of the method of the present invention, at least two separate streams, two-phase fluids containing gas and the liquid to be atomized, pass simultaneously and sequentially under pressure through impingement mixing zone 22 and shear mixing zone 24. I do. In the impingement mixing zone 22, the separate streams are mixed to form a single mixed stream by hitting or impinging at least a portion of each stream on each other.

In the collision mixing zone 22, separate streams are mostly (> 50%) due to collisions
Are mixed. Shear mixing means that the mixing occurs mainly by shear forces. Impingement mixing between two fluid streams is such that the half angle between the streams is at least 1
It occurs between 5 ° and 90 °, where the total narrow angle between the impinging streams is between about 30 ° and about 180 °, with 180 ° providing the most severe chaotic mixing. Shear mixing occurs when the half angle is from about 0 ° to about 15 °.

In practice, at least a portion (eg, ≧ 20%) of each fluid stream in impingement mixing zone 22
) Also have a flow component that is parallel in the downstream direction, and not all mixing occurs in the impingement mixing zone 22 due to collisions. In a preferred embodiment, at least the lateral outer or peripheral portion of each fluid stream is oriented towards the other in the impingement mixing zone 22 and is preferably 90 to the longitudinal flow (normal direction or total fluid flow direction) of the fluid. ° ± 30 ° normal angle, preferably 90 ° ± 10 °, more preferably 90 ° ± 5 °, even more preferably 90 ° ± 2 °, most preferably about 9 °.
0 ° (or substantially parallel to the y-axis as shown in the drawing). Fluid expansion in the impingement mixing zone 22, shear mixing zone 24 is minimized.

The impingement mixing zone 22, shear mixing zone 24 and atomization zone 68 are all in flow communication.
After impact, the mixed stream passes through a shear mixing zone 24, where the mixed stream is further mixed. The impingement and shear mixing zones 22, 24 have respective upstream and downstream portions of the fluid passage 14. The downstream end of the impingement mixing zone 22 is in flow communication with the upstream end of the shear mixing zone at the interface between the collision mixing zone and the shear mixing zone. The kinetic energy imparted to the fluid by impingement and shear mixing forms a single stream that upon atomization produces liquid droplets dispersed in the gas continuous phase. The average size of the droplets dispersed in the gas phase after passing through the nozzle is smaller than upstream of the nozzle (at least 10% smaller,
Preferably at least 50% smaller).

The shear mixing zone 24 is in flow communication with the atomizer or atomization zone 68 of the spray disperser 64, and as described herein, the atomization zone 68 is configured as part of the shear mixing zone 24. Is also good.

The nebulizer may have an orifice with a smaller cross-sectional area than the smallest cross-sectional area of the shear mixing zone 24, which results in a nebulizer pressure drop and a two-phase when entering the low pressure atomization zone 68. The fluid is further sheared. For example, in FIG.
The atomizer has a disperser inlet 158 or nozzle orifice 30. This shearing further reduces the droplet size. As the fluid passes through the atomization zone 68, it expands rapidly to create an atomized droplet spray. This rapid expansion and generation of a droplet spray is atomization.

The fluid outlet of the shear mixing zone 24 is in flow communication with a spray disperser 64 that forms a spray in the desired form. The spray disperser 64 forms a part of the atomization area 68, but does not have to form a part of the nozzle 10. Preferably, the spray disperser 64 is used to minimize coalescence of the liquid phase prior to atomization. In other embodiments, the shear mixing zone 24 may be in flow communication with an atomizer having a hollow fluid conduit open at both ends, an atomizing orifice, and a spray distributor at its downstream end.
In this embodiment, the cross-sectional area of the conduit perpendicular to the direction of fluid flow is the shear mixing zone 2
4 and the orifice are preferably larger than the smallest cross-sectional area. This minimizes agglomeration or coalescence of the liquid phase as the fluid flows through the nebulizer.

[0027] The method and apparatus introduces a large volume of hot feedstock into the riser reaction zone of the FCC unit and atomizes it while minimizing pressure drops in the mixing zones 22, 24 and the atomizer.
It is useful for relatively small source droplet sizes and for providing atomized source droplets with a uniform droplet size distribution. For example, for a 4 inch diameter nozzle, the nozzle pressure drop is
It is possible to atomize 30 pounds per second of hot feedstock at less than 50 pounds per square inch (psi), preferably less than 40 pounds per square inch (psi). When used for atomizing FCC raw material oil, the nozzle 10 forms a part of a raw material injector 182 (see FIG. 7) that houses the nozzle 10 as described later. Generally, a plurality of raw material injectors 182 are used. Preferably, it is located around the upstream end of the FCC reaction zone close to the riser bottom. The hot feedstock is typically mixed with steam upstream of nozzle 10 (and / or other dispersing / atomizing gas) to form a two-phase fluid that includes a vapor phase and a hot FCC feedstock liquid phase. This mixing also increases the velocity of the flowing two-phase fluid. Mixing of the steam and oil upstream of the nozzle 10 is performed in the raw material injector 182 by a known steam or other dispersed gas spraying means.

The two-phase fluid stream is separated or split into two separate streams, preferably using a splitter 28. In one embodiment, as shown in FIG. 5, both streams flow simultaneously through splitter 28 and separate fluid openings 26, 26 '.
A splitter 28 is suitably located at the fluid inlet 14a such that the splitter 28 and the fluid passage 14 form at least two fluid openings 26, 26 '. The fluid openings 26, 26 'are preferably symmetric and identical, and are equally spaced from the longitudinal axis (x-axis in the drawing) of the fluid passage 14 to the sides.

In the impingement mixing zone 22, a flow component is applied to each stream, radially inward, preferably perpendicular to the longitudinal axis of the fluid passage 14 (along the y-axis of the drawing or substantially parallel thereto). To). The flow component is directed to at least a portion of another stream having a corresponding flow component directed radially inward. At least a portion of each stream impinges on the other, resulting in vigorous impingement mixing and a corresponding decrease in droplet size. The resulting mixed fluid stream enters the shear mixing zone 24 and is further mixed with a lower pressure drop than occurs in the impingement mixing zone 22. The mixed stream flows to the low pressure atomization zone 68.

The cross-sectional area of the atomizing orifice, which is normal to the direction of fluid flow, is generally smaller than the cross-sectional area of the fluid conduit 164 (see FIG. 5) that supplies fluid to the nozzle 10. This increases the velocity of the fluid flowing through the orifice 30 to the low pressure atomization zone 68.
The cross-sectional area of the orifice 30 is also preferably smaller than the sum of the cross-sectional areas of the fluid openings 26, 26 '. This increase in velocity further shears the two-phase fluid,
Combined with the rapid expansion of the gas phase, the size of the droplets is further reduced.

The spray distributor 64 has a fan-shaped fluid passage 154 that is open at its upstream and downstream ends.
May be formed in an expanded fan shape. The spray disperser 64 is preferably located proximate downstream of the atomizing orifice to control the shape of the atomized spray. The spray disperser 64 may or may not be configured as part of the nozzle 10, but is preferably attached to the nozzle 10 by conventional means such as pinning. Another embodiment of the spray disperser 64 will be described with reference to FIGS. 2 (a) to 2 (d).

The apparatus of the present invention includes a nozzle having a single fluid passage 14 having a longitudinal axis (x-axis) extending through the nozzle. At the fluid inlet 14 a at the upstream end 16 there is at least two fluid openings 26, 26 ′ and at least one fluid outlet 14 b terminating at an orifice at the downstream end 18. The inlet 14a and the outlet 14b are vertically spaced along the longitudinal axis. The cross-sectional area of the collision mixing area 22 of the fluid passage 14 is:
It is smaller at the downstream end than at its upstream end. At least a portion of the cross-sectional area of the shear mixing zone 24 in the fluid passage 14 decreases or converges toward the fluid outlet 14b.
In one embodiment, fluid passage 14 is formed by at least two sets of spaced-apart opposing sidewalls. Each wall of each set is equidistant from the vertical axis. The region between the side walls forms a fluid passage 14 which may be generally rectangular in cross section.

The cross-sectional area of the fluid passage 14 varies a distance between at least a portion of at least one pair of opposing walls in a first dimension along the y-axis or a second dimension along the z-axis. May be changed. In some embodiments, the cross-sectional area of the shear mixing zone 24 decreases or converges in the direction of the fluid outlet 14b. In other embodiments,
The cross-sectional area of the shear mixing zone 24 decreases on the way to the fluid outlet 14b and may increase as the shear mixing zone 24 approaches the outlet 14b. The cross-sectional area may change along any direction (first or second dimension), ie, along the z-axis or y-axis. The cross-sectional area of the fluid passage 14 is greatest at the upstream end of the impingement mixing zone 22 near the fluid openings 26, 26 '. In another embodiment, the distance along the y-axis is z
As the distance along the axis increases at the same rate, the shear mixing zone 2
The cross-sectional area of No. 4 does not change.

FIG. 1A to FIG. 1D show one embodiment of the nozzle 10. Nozzle 10
By itself, it comprises a body 12 having a generally vertical fluid passage 14 therein having a fluid inlet 14a (openings 26, 26 ') and a fluid outlet 14b. The fluid passage 14 is
It has a vertical axis (x-axis) that corresponds to the vertical axis (x-axis) of the nozzle 10. Fluid passage 14
Are located at the respective upstream end 16 and downstream end 18 of the nozzle 10.

Referring to FIG. 1 (b), the fluid passage 14 has a rectangular cross section and is divided into three continuous zones (expansion zone 20, impingement mixing zone 22, shear mixing zone 24), all of which flow. It is a communication area and a close area in direct flow communication.

Referring to FIG. 1A, the fluid inlet 14 a has a pair of symmetric, identical circular segment-shaped fluid openings 26, 26 ′ separated by a splitter 28. Splitter 28 is comprised of a rectangular flat plate that divides a two-phase fluid stream flowing in two through fluid inlet 14a into two separate streams flowing through fluid openings 26, 26 '. The end of the splitter 28 forms a chordal portion of each fluid inlet 26, 26 '.

The downstream end of the fluid passage 14 has a non-circular outlet orifice 30. In this embodiment, the orifice 30 is square. Non-circular orifices 30 are preferred, although other shapes may be used. The orifice 30 may or may not constitute at least a portion of the atomizer or atomization zone 68. Non-circular orifices 34 also produce atomized oil droplets with a more uniform size distribution than circular or arcuate orifices.

With reference to FIGS. 1B to 1D, the fluid passage 14 has two different pairs of opposing walls (36-38-23)-(36'-38'-23 ') and 34-. 34 '. The walls 34, 34 'are identical, flat, parallel and rectangular in shape, but 36-3.
8-23 and 36'-38'-23 'are symmetric. The same point on the opposite wall is equidistant from the longitudinal axis of each wall, and the walls (36-38-23) -34 and (36'-38'-2)
3 ')-34' intersect at right angles, however, depending on the embodiment, the intersection may be arc-shaped or completely R-shaped. Wall 36-38-2
3 and 36'-38'-23 'start from the upstream in an arc or circle perpendicular to the longitudinal axis of the nozzle 10, respectively, the feed conduit 164 (see FIG. 5) and the fluid opening 26.
, 26 'substantially along the circular or arcuate shape. The shape of the fluid passage 14 is maintained along the fluid passage 14 at the entrance to the shear mixing zone 24 up to steps 38-38 '(also referred to herein as impingement mixing surfaces). In the shear mixing zone 24, the shape of the fluid passage 14 is changed to a flat square shape that continues to the orifice 30,
The collision mixing momentum may be used more efficiently.

The fluid openings 26, 26 ′ are radially radial and equidistantly spaced from the longitudinal axis. The cross-sectional area together with the openings 26, 26 'is smaller than the cross-sectional area of the expansion zone 20, but less than the cross-sectional area downstream of the steps 38, 38', to reduce the pressure drop in the shear mixing zone 24 where the fluid is introduced. Is wide. The fluid openings 26, 26 'increase velocity because their cross-sectional area is smaller than the cross-sectional area of the fluid conduit 164, as shown in FIG.

Referring to FIG. 1 (b), the two-phase fluid stream is split into two equal streams at splitter 28 and enters the fluid passage through openings 26, 26 ′.
Since the pressure drop of the splitter 28 may be too large for some applications, low pressure drop means may be used to introduce fluid to the nozzle. Since the light gas phase is accelerated faster than the heavy liquid phase, the flow entering the expansion zone 20 through the openings 26, 26 'provides shear. The expansion zone 20 is a controlled expansion zone 20 in that the fluid cannot expand freely, as in the atomization zone 68. The expansion zone 20 is reduced to such an extent that there is no pressure drop.

At least the outer peripheral portion of both streams directly impacts or collides with the right-angled steps (collision surfaces) 38-38 ′, applying a radially inward force to the other collision streams in the collision mixing zone 22. Collide directly. Right angle impact surface or stairs 38-38
In the 'embodiment, the narrow angle of the impinging fluid is 180 °. Thus, the collision surface is formed by the yz plane normal to the x-axis. The impulse directs the radially inner components of both streams substantially toward the longitudinal axis of the fluid passage 14 to maximize impingement mixing.

The fluid is downstream and enters the shear mixing zone 24, where the cross-sectional area decreases in the downstream direction,
The flow velocity increases, further reducing the droplet size, mainly due to shear forces. Collision mixing zone 2
There is no abrupt change from 2 to the shear mixing zone 24, but the shear mixing is performed in steps 38-38 '.
Begins downstream of The pair of opposing walls 23, 23 'forming the shear mixing zone 24 are inclined and converge the inwardly facing orifice 30. The cross-sectional area of the shear mixing zone 24 gradually decreases and the fluid velocity increases, and preferably the maximum fluid velocity is
Occurs at 0.

In another embodiment, not shown, a separate two-fluid stream from any convenient source, including a two-phase mixture of gas and liquid, passes through fluid openings 26, 26 ′ to fluid passage 14. I do. In this embodiment, the separate dual feed lines must be sized to provide the desired fluid inlet velocity.

FIG. 2A shows another embodiment of the nozzle 10 made of a plurality of laminated metal flat plates 50-62. The intersection of the flat plates 50-62 in the fluid passage 14 is not shown for clarity. Individual metal slabs are made with the necessary passages, such as holes, slots or orifices, extending through the slab. They are stacked together, bolted and / or diffusion bonded to form the nozzle 10. Starting from the upstream end 16, the flat plate 50 is divided into two circular segment-shaped openings 26, 26 formed by a stream splitter 28 similar to that shown in FIG.
Have a disk with '. FIG. 2D shows the flat plate 56. The plate 56 has two shoulders 80, 80 'opposite the orifice 15. Shoulders 80, 80 '
And orifice 15 is sized and configured to properly form impact surfaces (steps) 38, 38 '. Going downstream, the size of the orifice 15 in each succeeding plate decreases as well as the convergence of the shear mixing zone 24 shown in FIG. 1 (b). The subsequent radial inner steps of each disk 57-62 are not large enough to provide radial inner momentum equal to shoulders 80, 80 ', respectively, but provide radial inner mixing components with fluid. Give to the flow. The orifices 15 of the flat plate forming the shear mixing zone 24 have different first dimensions, and the first dimension of the orifice 15 of each flat plate forming the shear mixing zone 24 is determined by the orifice of the preceding flat plate. 15 smaller than the first dimension. Preferably, at least one plate orifice 15 forming the shear mixing zone 24 has a different second dimension, and the second dimension of each plate orifice 15 forming the shear mixing zone 24 is It is larger than the second dimension of the front plate orifice 15.

Referring to FIG. 2 (a), the nozzle 10 also includes a spray disperser disposed at the downstream end 10 and in flow communication with the fluid outlet 14b to create a flat fan spray of atomized liquid. . Disperser 64 is attached to, and forms a part of, nozzle 10 by welding, bolting, brazing, or the like. As shown, the disperser 64
Has a flange 63 that effectively attaches the disperser to the nozzle 10. Disperser 6
4 has a passage 70 (inlet 70 a) configured with substantially the same size and / or shape as the orifice 30. However, the cross-sectional area of the passage 70 may be appropriately changed in order to promote formation of a desired spray shape.

The passage 70 has a pair of opposing walls 66-66 ′, 74 forming a fan-shaped atomization area 68.
A flat, diverging fan-shaped spray dispensing tip 71 formed at -74 'is open downstream. As shown in FIG. 2 (a), the atomization zone 68 has a first dimension that converges or decreases vertically (along the y-axis) toward the orifice 72;
Are larger on the inlet side than on the outlet side to control the shear mixing speed. However, in some embodiments, the first dimension of the atomization zone 68 may remain constant.
The atomization zone 68 has a second dimension that converges or increases (along the z-axis) when going to the orifice 72, the second dimension being larger on the outlet side than on the inlet side. Tip 71 terminates in orifice 72. The orifices 72 are oriented normal to the outer flow spray direction and are the longest dimensioned along the z-axis, preferably arcuate or completely R-shaped (walls 74, 74 '). The walls 74, 74 'typically have the same curvature, but in some embodiments the degree of curvature may be independently selected. Preferably, it is curved in a circular shape. The preferred radius of the curved portion is about one-half the dimension of the passage 70 in the y-axis. Although not required, the center of the radius of curvature of each wall 74, 74 'is located near the center of the y-axis (the center of the first dimension). In embodiments where the first dimension varies along the x-axis, the radius of curvature may also vary.

In a variant of the embodiment not shown, the convergence and / or divergence dimensions are along different axes, but preferably along the axis of 90 ° separation. The first and second dimensions of the passage 70 or atomization zone 68 are preferably measured at the widest separation point between the opposing walls, ie, at the center or longitudinal axis or at the widest point of curvature from the passage 70.

In one embodiment, the width of the inlet 70 a along the z-axis is about 1.5 times the length of the disperser (measured along the x-axis) and the width of the outlet orifice 72 is 70a
At least about 1.5 times the width of

The fluid outlet orifice 30 enters the atomization zone 68 and passage 70 to further shear the fluid and further reduce the droplet size. The expansion zone 68 is at a lower pressure than the orifice 30 and causes the gas phase to expand rapidly, atomizing the liquid and forming a droplet spray. This further shears the droplets, and the fan shape of the atomization tip 71 changes the FCC shown in FIG.
A fan-shaped spray of droplets flowing into the reaction zone of the riser is created.

FIG. 3 shows another embodiment of a nozzle 10 that is operated and configured in the same manner as described above. Referring to FIG. 3 (c), the outlet orifice 30 has an arcuate side end 130,
130 ′ (preferably completely R-shaped), and the dimension along the z-axis is longer than the dimension along the y-axis, as shown in FIG. Lonely end 1
In order to correspond to the complete R end of the disperser 64, it is preferable that the reference numerals 30 and 130 ′ have completely R shapes. As shown in FIGS. 3B and 3D, the shear mixing zone 24 is formed by two pairs of opposed walls 126, 126 ′ and 130, 130 ′ that are radially opposed to each other. The walls 126, 126 'converge inward in the downstream direction, and the walls 130, 126'
130 'diverges outward in the downstream direction. The net effect is that a constant cross-section is obtained throughout the shear mixing zone 24, or about 10% to 50% greater than the lowest cross-sectional area in the shear mixing zone 24, which decreases or converges and diverges or increases. Is either.

In other words, the shear mixing zone 24 has a first dimension along the y-axis that reduces progress toward the outlet 30, and preferably along a z-axis that increases progress toward the outlet 30. Having a second dimension.

The diverging and converging wall design creates a shear mixing zone 24 with a lower fluid pressure drop than the embodiment shown in FIG. Also, the possibility of coalescence is reduced in the shear mixing zone 24 as compared to the embodiment shown in FIG.

The entrance to the shear mixing zone 24 is the radial inner end of the steps 38, 38 ′ and the wall 12
4-130, formed by the intersection of 124'-130 '. The cross-sectional area at the inlet to the shear mixing zone 24 is smaller than the combined cross-sectional area of the openings 26, 26 'to increase the velocity of the fluid flowing into the shear mixing zone 24. In this embodiment,
The convergence and divergence of the shear mixing zone 24 form a fluid flow in a rectangular shape with arcuate ends as shown in FIG. This shape facilitates a smooth diversion of fluid flow from nozzle 10 to disperser 64.

FIGS. 4A to 4C show FIGS. 3A to 3D by the above-described ordinary method.
An embodiment in which a spray disperser 64 is added to the nozzle 10 of FIG. The spray distributor 64 shown in FIG. 9 includes a fan-shaped fluid passage 154 formed by outwardly diverging opposing walls 155, 155 ', which serves to control the atomization fluid from expanding into a fan-shaped spray. A fan-shaped main body 152 is provided. The walls 155, 155 'have a rounded full R side end passage 154, preferably along at least the axis of the passage 154, to provide a divergent fan spray. 3 (a) to 3 (d), FIG. 4 (a)
4 (c) has arcuate walls 126, 126 '. The fluid inlet 158 to the spray disperser 64 corresponds in shape to the orifice 30 in the nozzle 10 and the fluid outlet 160 of the disperser 64 allows the atomized spray of droplets to continue to expand into a fan-shaped spray. It is getting bigger. The pressure in passage 154 is lower than the pressure in nozzle fluid passage 14. The mixed fluid exiting nozzle 10 and entering fluid passage 154 is atomized through outlet 160 into a fan-shaped spray of droplets that travels to the FCC riser reaction, as shown in FIG. FIG. 5 shows a cutaway view of the atomizing nozzle 10 and the disperser 64 connected to the upstream fluid conduit 164. Conduit 164 is connected to fluid inlet 1
4a (openings 26, 26 ') to provide a flow path to the two-phase fluid to enter the nozzle 10.

FIGS. 6 (a) to 6 (c) show another embodiment of the atomizing nozzle 10 in which the atomizing zone 115 is configured as a part of the shear mixing zone 24. In all respects, FIG.
The nozzle 10 shown in FIG. 6 to FIG. 6 (c) operates in the same way as in the previously described embodiment. As shown in FIG. 6 (a), the fluid openings 26, 26 'need not be completely arcuate segments if the pressure drop across the splitter 28 is not too great.

Referring to FIG. 6 (b), the shear mixing zone 24 has a fully formed flow region. The cross-sectional area decreases first as it progresses to orifice 30 and then increases. The shear mixing zone 24 has a somewhat complicated property, and 6 (b) -6 (b)
, 6 (c) -6 (c) show two partial cross sections of the nozzle in FIGS. 6 (b) and 6 (c).
It was shown to. The atomization zone 115 has the smallest cross-sectional area or band in the shear mixing zone 24. The atomization zone 115 is preferably located near the orifice 30. Atomization zone 115 may also terminate at orifice 30. Orifice 30 preferably has the same size and shape as described and illustrated in the previous embodiment.

The first dimension of the shear mixing zone 24 decreases at a first rate toward the fluid outlet 14 b in at least a portion of the shear mixing zone 24, and then the second dimension in the remainder of the shear mixing zone 24.
At the fluid outlet 14b. Preferably, the second dimension of the shear mixing zone 24 is such that at least a portion of the shear mixing zone 24 has a first rate of fluid outlet 14b
To the fluid outlet 14 at a second rate in the remainder of the shear mixing zone 24.
It increases toward b.

In operation, as the two-phase fluid flows through the passage 14 to the low pressure atomization zone 115, due to the rapid gas expansion in the low pressure region of the atomization zone 115, and to a high density (incompressible) A) Atomization is promoted by the rapid promotion of compressible gas which is lighter than the liquid phase. This causes shear between the phases until the velocities are approximately equal. Shearing forces reduce the final size of the droplets in the atomizing spray.

The nozzle 10 can be manufactured in various different ways. Lost wax or investment casting processes may be used, as well as forging and other casting processes. Nozzle 10 may be manufactured from any suitable ceramic, metal material, or combination thereof. As shown in FIGS. 2 (a) to 2 (d), a nozzle 10 having a fluid passage 14 therein is formed by using a plurality of laminated relatively thin metal flat plates.
Is known to be made, for example, in U.S. Pat. Nos. 3,881,701 and 5,455,401, which discloses that the process is useful for rocket motors and plasma torches. This manufacturing technique is also useful for manufacturing the nozzle 10 of the present invention, including the embodiments disclosed and illustrated in FIGS. 1-6, and the nozzle of the present invention was manufactured using this technique. However, the invention is not limited to using this technique for manufacturing nozzles.

Referring to FIG. 7, an FC incorporating one or more embodiments described herein.
The C raw material injection unit 180 is shown. Unit 180 is 186, 18
8, a hollow raw material injector 182 attached to the raw material nozzle means 184.
It has. Feed nozzle means 184 is shown as a conduit through wall 190 of FCC riser 206 and into riser reaction zone 192. The riser 206, shown clearly in FIG. 8, is preferably a cylindrical, hollow, substantially vertically oriented conduit. In reaction zone 192, at least a portion of the atomized oil feedstock 300 contacts the rising hot catalyst particles and the feedstock 300 is cracked into a more useful low boiling hydrocarbon product. For convenience, only a part of the riser 206 is illustrated.

The feedstock injector 182 has a hollow tube 194 into which the preheated oil feedstock 300 is introduced via a supply line 196. The supply line 196 forms a T connection with the wall of the upstream portion of the raw material injector 182. Raw material injector 182
Has a nozzle 10 and preferably a spray disperser 64, both shown as boxes for convenience. Spray disperser 64 produces a relatively flat, fan-shaped spray of atomized oil feedstock 300 into reaction zone 192.

Steam distribution tube 1 with smaller diameter or cross-sectional area of injector conduit 194
98 extends coaxially along the longitudinal axis of conduit 194. In this embodiment,
The central longitudinal axes of the conduits 194, 198 coincide. This provides an annular flow path 197 upstream of the hot oil feed 300 at the outlet end of the injector. The steam tube 198 terminates inside an injector tube 194 upstream of the nozzle 10. A plurality of holes or orifices 199 are drilled radially around the downstream end of conduit 198. The holes 198 allow the steam to be radiated outwardly into the annular flow passage 197, mixed with the hot oil feed 300 flowing through the flow passage 197, and containing a two-phase fluid containing hot oil globules dispersed in the steam. Is generated. The amount of steam sprayed to the oil feedstock 300 is about 1 to about 5 wt. %. 7 by volume
The resulting fluid mixture containing 5 to 85% steam, 15 to 25% oil feed 300,
Through nozzle 10, separated into two separate streams, entering nozzle 10,
The oil raw material 300 is mixed and atomized as described above.

The atomized spray of oil feed droplets 300 passes through reaction zone 192 and contacts the upstream stream of hot catalyst particles (not shown) to convert heavy oil feed 300 to the desired low boiling product fraction. Decomposes catalytically.

FIG. 8 illustrates a typical FCC process incorporating one or more embodiments of the present invention. The FCC unit 200 has an FCC reactor and a regenerator 204. The reactor 202 has a raw material riser 206 including a reaction zone 192. Reactor 202 also has a steam / catalyst separation zone 210 and a stripping zone 212 having a plurality of baffles 214 that look like rows of metal "sheds" resembling a sloped house roof. ing. A suitable stripping agent, such as steam, is introduced via line 216 into the stripping zone. The stripped spent catalyst particles are transferred to regenerator 20 via transfer line 218.
Send to 4.

The preheated FCC feed is sent via line 220 to the base of riser 206 at feed injection point 224. The preheated raw material 300 may be previously mixed with a predetermined amount of steam. The raw material injector 182 shown in FIG. 6 is at 224, but is not shown in FIG. 8 for simplicity. In practice, a plurality of raw material injectors 182 are arranged around the riser 206 as shown in FIG. Steam is applied to line 22
2 may be sent to the raw material injector 182. The atomized droplets of the hot feed 300 contact the catalyst particles at the riser. The feedstock evaporates and the gasoline boiling range (
(100 ° -400 ° F., 30 ° -205 ° C.), which are catalytically cracked into lighter, lower boiling fractions, higher boiling jet fuels, diesel fuels, kerosene, and the like.

The FCC catalyst may be any suitable ordinary catalytic cracking catalyst. The catalyst may comprise a mixture of silica and alumina containing a zeolite molecular sieve cracking component known to those skilled in the art.

The FCC reaction begins when the feedstock 300 contacts the hot catalyst in the riser 206 and continues until product vapor is separated from the spent catalyst in the cutoff zone 210. The cracking reaction deposits a strippable hydrocarbon material, a carbonaceous material known as non-stripable coke, to produce spent catalyst particles. In order to remove and recover strippable hydrocarbons, they must be stripped. The catalyst is regenerated by burning off the coke in the regenerator.

The reactor 202 has a cyclone (not shown) in the disconnection section 210. The cyclone separates both the cracked hydrocarbon product vapor and the stripped hydrocarbon (as vapor) from the spent catalyst particles. Hydrocarbon vapor is drawn in via line 226. The hydrocarbon vapor is generally fed to a distillation unit or fractionation column (not shown) to condense the condensable portion of the vapor into a liquid and fractionate the liquid into a separate product stream.

[0069] The spent catalyst particles are passed to a stripping zone 212 where they are contacted with a stripping medium such as steam. The stream is passed from line 216 to stripping zone 212 to remove strippable hydrocarbon material deposited on the catalyst during the cracking reaction. These vapors are drawn along with other product vapors via line 226. The baffle 214 uniformly distributes the catalyst particles across the width of the stripping zone 212 and minimizes internal reflux or back mixing of the catalyst particles in the stripping zone 212. Spent strip catalyst particles are removed from transfer line 218 below stripping zone 212 and passed to fluidized bed 228 in regenerator 204.

The catalyst particles in fluidized bed 228 come into contact with air entering the regenerator via line 240. Some of the catalyst particles go to the separation zone 242. Air oxidizes or burns off the carbon deposits to regenerate the catalyst particles and produces air at about 950 ° to 1400 ° F (510 ° C).
760 ° C.). The regenerator 204 has a cyclone (not shown) that separates hot regenerated catalyst particles from gaseous combustion products or flue gas containing primarily CO ₂ , CO, H ₂ O and N ₂ . As known to those skilled in the art, the cyclone returns the regenerated catalyst particles to the fluidized catalyst bed 228 via a dipreg (not shown).

The fluidized bed 228 is supported by a gas distribution grid 244 drawn in dotted lines.
The hot regenerated catalyst particles in the fluidized bed 228 overflow the weir 246 formed by the upper part of the funnel 248 connected from the lower part to the upper part of the downcomer 250. Downcomer 2
A regenerated catalyst transfer line 252 extends below 50. The regenerated particles overflowing down the funnel 248 and downcomer 250 to the transfer line 252 and back to the reaction zone 192. Flue gas is removed from the top of the regenerator via line 254.

The cat cracker raw material used in the FCC process is a vacuum gas oil (V
GO), straight run (normal pressure) gas oil, light catalytic cracking oil (LCGO), and gas oil which is a high boiling point oil without residual oil such as coker gas oil. These oils, similar to straight run or normal pressure gas oils and coker gas oils, have about 450
An initial boiling point greater than about 650 ° F (232 ° C), more usually greater than about 650 ° F;
It has an endpoint up to about 1150 ° F (621 ° C). Furthermore, the terminal point is 10
One or more heavy materials may be blended with the FCC material at 50 ° F. (566 ° C.) or more (eg, up to 1300 ° F. (704 ° C.) or more). As the heavy raw material, for example, crude oil, top crude oil, residual oil obtained by distilling crude oil under normal pressure and vacuum,
Examples include asphalt and asphaltene, tar oil obtained by pyrolysis of heavy petroleum oil, cycle oil, tar sand oil, shale oil, coal-derived liquid, synthetic crude oil, and the like. These add about 2 to 50% by volume of the blend to the FCC feed, more usually about 5 to 30%.
% By volume.

Heavy feedstocks contain high concentrations of aromatics and undesirable components such as compounds containing heteroatoms, especially sulfur and nitrogen. Accordingly, these raw materials are often subjected to processes such as known hydrogenation, solvent extraction, solid adsorption by molecular sieve or the like to reduce the amount of undesired compounds and to improve quality.

Typical FCC reactor process conditions are about 800 ° -1200 ° F. (4
27 ° -648 ° C.), preferably 850 ° -1150 ° F. (454 ° -621 ° C.)
), More preferably at a temperature of 900 ° to 1150 ° F. (482 ° to 621 ° C.) at a pressure of about 5 to 60 psig, preferably 5 to 40 psig, and a feedstock / catalyst contact time of about 0.5 to 15 seconds, preferably Is about 1-5 seconds, and the catalyst to feed ratio is about 0.5-10
, Preferably 2 to 8. The FCC feedstock is less than 850 ° F. (454 ° C.), preferably less than 800 ° F. (427 ° C.), usually about 500 ° -800 ° F. (260 ° F.).
４427 ° C.).

The present invention will be further understood by reference to the following examples. However, it is not limited to this embodiment.

Example In this experiment, an atomizing injector designed as shown in FIG. 7 was used in conjunction with an embodiment of an atomizing nozzle designed as shown in FIG. 4 in US Pat. No. 5,173,17.
Compared to commercial demonstration slot and fan designs as shown in No. 5. A commercial nozzle simulated a pipe with an end cap having a rectangular slot orifice with an attached downstream diverging, flat, fan atomizing tip.
Both nozzles had a fan-shaped atomizing disperser or tip and were made on a scale of 1/2 the size of a typical commercial nozzle. All injectors were the same except for the nozzle design. The injectors both produced flat fan sprays, were placed horizontally, and were oriented to produce a flat fan spray vertically widest in the laser beam path of the Malvern particle sizer. .
This instrument is well known and is used to measure liquid spray characteristics. The light diffraction patterns, each associated with a characteristic droplet size range, are focused by a Fourier transform lens on a multi-element photoelectric detector. The light energy distribution is converted by a computer into a corresponding droplet size distribution.

[0077] Nitrogen gas was used for the gas phase, and liquid water was used for the liquid phase.

A grid of comparative experiments was performed with varying water and nitrogen flow rates, and the Sauter mean droplet size was calculated assuming a rosin-Rammler distribution function. The results for the two different nozzle designs were compared in the table below.

[0079]

[Table 1]

For all cases, with comparable water and nitrogen flow rates, the nozzle of the present invention
An atomized spray having a Sauter mean droplet size smaller than the commercial design was produced.
This indicates that good atomization was obtained by the nozzle of the present invention.

It will be apparent to those skilled in the art that various other embodiments and modifications can be made in practicing the present invention, which can be easily performed without departing from the scope and technical spirit of the present invention described above. . Therefore, the scope of the appended claims is not limited to the above description, but encompasses all features of patentability and novelty of the present invention. All features and embodiments included as equivalents by those skilled in the art to which the present invention pertains are included.

[Brief description of the drawings]

FIG. 1 (a) shows an axial downstream portion of one embodiment (aspect) of a nozzle when looking into a fluid inlet of the nozzle. FIG. 1 (b) shows 1 (b)- FIG. 1 (c) shows a side cross-sectional view of the embodiment of FIG. 1 (a) along the 1 (b) axis. FIG. 1 (c) shows the embodiment shown in FIG. 1 (a) when looking into the fluid outlet of the nozzle. 1 (d).
FIG. 1B is a plan sectional view of the embodiment shown in FIG. 1A along the 1 (d) -1 (d) axis in FIG. 1B.

FIG. 2 (a) is a side sectional view showing another embodiment of the nozzle, and FIG. 2 (b) is an embodiment shown in FIG. 2 (a) when looking at a fluid outlet of the nozzle. FIG. 2 (c), an axial upstream embodiment, is a cross-sectional plan view of the embodiment shown in FIG. 2 (a), incorporating one embodiment of a spray disperser. Is an embodiment of a flat plate used to construct the embodiment shown in FIG. 2 (a); for clarity, FIGS. 2 (a) and 2 (c) show the lines of the flat plate in the fluid passage; Not.

FIG. 3 (a) shows the axial downstream of a nozzle according to another embodiment when looking into the fluid inlet of the nozzle. FIG. 3 (b) shows 3 (b) -3 ( b) Figure 3 (a) along the axis
FIG. 3 (c) is an axial upstream view of the embodiment shown in FIG. 3 (a) when looking into the fluid outlet of the nozzle, FIG. 3 (d). FIG. 3 (c)
3) is a plan sectional view of the embodiment shown in FIG. 3 (a) along the 3 (d) -3 (d) axis.

FIG. 4 (a) is a cross-sectional side view showing another embodiment of the nozzle, and FIG. 4 (b) is an embodiment shown in FIG. 4 (a) when looking at the fluid outlet of the nozzle. 4 (c) is a cross-sectional plan view of the embodiment shown in FIG. 4 (a), incorporating one embodiment of a spray disperser.

FIG. 5 is a cross-sectional view of a nozzle (and spray disperser) in flow communication with a fluid conduit supplying the nozzle.

6 (a) is an axial downstream view of another embodiment of the nozzle when looking into the fluid inlet of the nozzle, and FIG. 6 (b) is 6 (b) of FIG. 6 (a). 6 (b) is a side sectional view of the embodiment shown in FIG. 6 (a) along the axis, and FIG. 6 (c) is a sectional view of FIG.
Fig. 7 is a side sectional view of the embodiment shown in Fig. 6 (a) along the 6 (c) axis.

FIG. 7 is a cross-sectional view of an FCC raw material injection unit using a nozzle embodiment.

FIG. 8 illustrates an FCC process incorporating a nozzle embodiment or method.

──────────────────────────────────────────────────続 き Continued on the front page (31) Priority claim number 09 / 526,576 (32) Priority date March 16, 2000 (March 16, 2000) (33) Priority claim country United States (US) ( 81) Designated countries EP (AT, BE, CH, CY, DE, DK, ES, FI, FR, GB, GR, IE, IT, LU, MC, NL, PT, SE), OA (BF, BJ, CF, CG, CI, CM, GA, GN, GW, ML, MR, NE, SN, TD, TG), AP (GH, GM, KE, LS, MW, SD, SL, SZ, TZ, UG, ZW), EA (AM, AZ, BY, KG, KZ, MD, RU, TJ, TM), AL, AU, BA, BB, BG, BR, CA, CN, CU, CZ, EE, GE, HR, HU, D, IL, IN, IS, JP, KP, KR, LC, LK, LR, LT, LV, MG, MK, MN, MX, NO, NZ, PL, RO, RU, SG, SI, SK, SL, TR, TT, UA, UZ, VN, YU, ZA (72) Inventor Ito, Jackson, Eye. Occidental Drive, Sacramento, CA 95826, USA 2507 F-term (reference) 4D075 AA06 AA71 AA85 BB16X EA05 4F033 AA13 BA01 BA03 DA01 EA01 NA01 4H029 BD08 BD20

Claims (60)

[Claims] 1. A fluid inlet having a splitter capable of splitting an incoming flow stream into at least two streams and a fluid outlet, wherein an impingement mixing zone and a shear mixing zone are disposed between said inlet and said outlet. A liquid atomization device having a body configured to form the impingement mixing zone having at least one impingement surface, the impingement surface directing at least a portion of a fluid to another impingement stream. Are configured to collide, 2
A narrow angle between the two impinging streams is between about 120 ° and 240 °, wherein the shear mixing zone has a cross-sectional area formed by a first dimension and a second dimension, wherein the first dimension is A liquid atomizing device, wherein the volume decreases along the longitudinal axis through the body in the direction of the fluid outlet. 2. The apparatus of claim 1, wherein the impingement mixing surface is configured to be substantially perpendicular to all directions of fluid flow through the body. 3. The apparatus according to claim 1, wherein said collision zone has at least one right-angled step. 4. The method of claim 1, wherein the narrow angle between the two impinging streams is between about 170 ° and 190 °.
The apparatus of claim 1, wherein: 5. The apparatus according to claim 1, wherein said narrow angle between two collision streams is about 180 °. 6. The impingement surface includes an impingement stream, approximately 90 degrees longitudinally through the body.
Apparatus according to claim 1, characterized in that it provides a part of the stream contacting in the direction of normal. 7. The method of claim 1, wherein the fluid outlet has a non-circular shape.
An apparatus according to claim 1. 8. The apparatus of claim 7, wherein the second dimension of the shear mixing zone increases along the longitudinal axis toward the fluid outlet. 9. The method of claim 1, wherein the first dimension decreases toward the fluid outlet at a first rate for at least a portion of the shear mixing zone, and then decreases at a second rate for a remaining portion of the shear mixing zone. 9. The device of claim 8, wherein said device decreases towards the fluid outlet. 10. The shear mixing zone increases in at least a portion of the shear mixing zone at a first rate toward the fluid outlet, and then in a remaining portion of the shear mixing zone at a second rate. 9. The device of claim 8, wherein the device increases toward the fluid outlet. 11. The apparatus according to claim 10, wherein said shear mixing zone has a rounded end. 12. The apparatus according to claim 11, further comprising a spray disperser in flow communication with said fluid outlet, wherein said spray disperser forms an expansion zone wherein a pressure is less than a pressure in said shear mixing zone. 13. The disperser has a disperser fluid passage extending therethrough, the passage diverging along the longitudinal axis of the passage toward the outlet of the disperser. 13. The method of claim 12, wherein said first dimension has a rounded end.
An apparatus according to claim 1. 14. The method of claim 14, wherein the body is configured to form a first expansion zone disposed between the splitter and the impingement mixing zone, the expansion zone having a cross-sectional area. An apparatus according to claim 13, characterized in that: 15. The body and the splitter define at least two fluid openings, each of the fluid openings having a cross-sectional area, the sum of the cross-sectional areas of the openings being the cross-sectional area of the expansion area. 15. The device of claim 14, wherein the device is smaller. 16. The apparatus of claim 11, wherein the shear mixing zone has an atomization zone, and wherein the atomization zone has a minimum cross-sectional area within the shear mixing zone. 17. The apparatus of claim 17, wherein the body has a plurality of flat plates, the flat plates having orifices extending therethrough, the orifices of the flat plates forming the fluid passages. 14. The device according to claim 13, wherein 18. The orifice of the plate forming the shear mixing zone has a different first dimension, and the first dimension of the orifice in each plate forming the shear mixing zone is 18. The apparatus of claim 17, wherein the first dimension of the orifice is less than a first dimension. 19. The orifice of at least one of the plates forming the shear mixing zone has a different second dimension, and the second one of the orifices in each plate forming the shear mixing zone. 19. The apparatus of claim 18, wherein the dimension is greater than a second dimension of the preceding orifice. 20. A liquid atomizer having a body having at least one fluid inlet, at least one fluid outlet, and a fluid passage extending between said inlet and said outlet, said passage being impinged. Forming a mixing and a shear mixing zone downstream from the impingement mixing zone, wherein the passage is configured to form at least one impingement surface, the impingement surface having a fluid extending through the body The shear mixing zone has a cross-sectional area formed by a first dimension and a second dimension, wherein the first dimension is A liquid atomizer, wherein the fluid atomizer decreases along the longitudinal axis through the body in the direction of the fluid outlet. 21. The apparatus of claim 20, wherein the portion of the fluid that contacts the collision surface is a peripheral portion of the fluid flowing through the passage. 22. The apparatus of claim 20, wherein said narrow angle between two collision streams is about 180 °. 23. The method of claim 20, wherein the impingement surface imparts impingement flow with a portion of the stream passing through the body in a direction approximately 90 ° normal to a longitudinal axis. apparatus. 24. The fluid outlet of claim 2, wherein the fluid outlet is non-circular.
The apparatus according to claim 0. 25. The apparatus of claim 20, wherein the second dimension increases along the longitudinal axis toward the fluid outlet. 26. The method according to claim 26, wherein the first dimension decreases toward the fluid outlet at a first rate in at least a portion of the shear mixing zone, and then decreases at a second rate in a remaining portion of the shear mixing zone. 21. The device of claim 20, wherein the device decreases toward the fluid outlet. 27. The second dimension increases at a first rate toward the fluid outlet in at least a portion of the shear mixing zone, and then increases at a second rate in a remaining portion of the shear mixing zone. 27. The device of claim 26, wherein the device increases toward the fluid outlet. 28. The apparatus of claim 20, wherein said shear mixing zone has a rounded edge. 29. The apparatus of claim 20, further comprising a spray disperser in flow communication with the fluid outlet, forming an expansion zone that is less than the pressure in the shear mixing zone. 30. The disperser has a disperser fluid passage extending therethrough, the passage diverging along the longitudinal axis of the passage toward the outlet of the disperser. 30. The method according to claim 29, wherein the first dimension has a rounded end.
An apparatus according to claim 1. 31. The apparatus according to claim 31, wherein the body is configured to form a first expansion zone disposed between the splitter and the impingement mixing zone, the expansion zone having a cross-sectional area. 21. The device according to claim 20, wherein 32. The body and the splitter define at least two fluid openings, each of the fluid openings having a cross-sectional area, the sum of the cross-sectional areas of the openings being the cross-sectional area of the expansion area. 32. The device of claim 31, wherein the device is smaller. 33. The apparatus of claim 20, wherein said shear mixing zone has an atomization zone, and wherein said atomization zone has a minimum cross-sectional area within said shear mixing zone. 34. The apparatus of claim 34, wherein the body has a plurality of flat plates, the flat plates having orifices extending therethrough, the orifices of the flat plates defining the fluid passages. 21. The device according to claim 20, wherein 35. The orifice of the flat plate forming the shear mixing zone has a different diameter, the diameter of the orifice of each flat plate forming the shear mixing zone being greater than the diameter of the orifice of the preceding flat plate. 35. The device of claim 34, wherein the device is small. 36. A liquid atomizer comprising: a body having at least one fluid inlet having a splitter, at least one fluid outlet, and a fluid passage extending between said inlet and said outlet. A splitter and the body forming at least two fluid openings to the passage, the passage forming impingement mixing and a shear mixing zone downstream from the impingement mixing zone; Configured to form at least one impingement surface disposed proximate the periphery, wherein the impingement surface is configured to be substantially normal to a longitudinal axis extending through the body. Wherein the shear mixing zone has a cross-sectional area formed by a first dimension and a second dimension, wherein the first dimension decreases along the longitudinal axis through the body in the direction of the fluid outlet. do it Liquid atomizing apparatus according to claim Rukoto. 37. A spray disperser, the disperser having a disperser fluid passage extending therethrough, the passage diverging from a disperser inlet to the disperser outlet. 37. The apparatus of claim 36, wherein the distributor inlet is configured to be substantially the same size and shape as the fluid outlet of the body. 38. A liquid atomizer having a body having at least one fluid inlet having a splitter, at least one fluid outlet, and a fluid passage extending between the inlet and the outlet. A splitter and the body forming at least two fluid openings to the passage; the body having a plurality of flat plates, the flat plates having orifices extending therethrough; The orifices of the plate form the fluid passages, the orifices of the plate forming the shear mixing zone have different diameters, and the orifice of each plate forming the shear mixing zone has a diameter of Less than the diameter of the orifice of the preceding flat plate, the passage forming impingement mixing from the shear mixing zone and downstream of the shear mixing zone, wherein the passage is near the periphery of the passage. Wherein the impact surface is configured to form at least one impact surface disposed thereon, the impact surface configured to be substantially normal to a longitudinal axis extending through the body. The shear mixing zone has a cross-sectional area defined by a first dimension and a second dimension, the first dimension decreasing along the longitudinal axis through the body in a direction from the inlet to the outlet. Wherein the second dimension increases along the longitudinal axis in a direction from the inlet to the outlet. 39. A spray disperser, the disperser having a disperser fluid passage extending therethrough, the passage diverging from a disperser inlet to the disperser outlet. 39. The apparatus of claim 38, wherein the disperser inlet is configured to be substantially the same size and shape as the fluid outlet of the body. 40. A liquid atomizer comprising: a body having at least one fluid inlet having a splitter, at least one fluid outlet, and a fluid passage extending between said inlet and said outlet. A splitter and the body forming at least two fluid openings to the passage; the passage forming impingement mixing and a shear mixing downstream from the impingement mixing zone; An impingement surface, wherein the impingement surface is configured such that fluid is directed substantially normal to a longitudinal axis extending through the body; A cross-sectional area defined by a first dimension and a second dimension, wherein the first dimension decreases along the longitudinal axis through the body from the inlet in the direction of the outlet; The dimensions of Increasing along the longitudinal axis from the inlet to the outlet, the first dimension decreasing at a first rate toward the fluid outlet, and then toward the fluid outlet at a second rate. The first rate is greater than the second rate, and the second dimension increases at a first rate toward the fluid outlet and then at a second rate. Wherein the first rate is greater than the second rate. 41. (a) forming at least two streams of a two-phase fluid having a gas phase and a liquid phase; and (b) impinging at least a portion of each stream with at least a portion of another stream; Passing the stream through an impingement mixing zone such that the narrow angle between the impinging streams is about 120 ° to 240 ° to form a single mixing stream; and (c) passing the single mixing stream into a shear mixing zone. And applying a shear mixing force to the single mixing stream to form a shear mixing stream; and (d) the shearing so that the gas phase expands and the surface area of the liquid phase increases. Passing the mixed stream through an atomization zone to produce a droplet spray. 42. The method of claim 41, further comprising combining a gas phase stream with a liquid phase stream to form the two-phase fluid. 43. The impingement zone and the shear mixing zone include: (i) a fluid inlet and a fluid outlet having a splitter capable of splitting an incoming flow stream into at least two streams of a two-phase fluid. A body configured to form an impingement mixing zone and a shear mixing zone disposed between the inlet and the outlet; and (ii) at least one impingement surface, wherein the impingement surface comprises At least a portion of the fluid stream in contact with the surface is configured to impinge on another impingement stream, wherein a narrow angle between the two impingement streams is between about 120 ° and 240 °
And (iii) a cross-sectional area formed by a first dimension and a second dimension, the first dimension passing through the body in the direction of the fluid outlet. 43. The method of claim 42, wherein the nozzle has a shear mixing zone decreasing along a vertical axis. 44. The method of claim 43, wherein said shear mixing zone has a rounded side edge. 45. The method of claim 44, wherein said nozzle further comprises a spray disperser in flow communication with said fluid outlet. 46. The method of claim 45, wherein the disperser forms an atomization zone where the pressure is less than the pressure in the shear mixing zone. 47. The disperser has a disperser fluid passage extending therethrough, the passage diverging along the longitudinal axis of the passage toward the outlet of the disperser. 47. The method of claim 46, wherein the first dimension has a rounded end.
The method described in. 48. The method of claim 41, wherein said narrow angle between impinging streams is between about 120 ° and 240 °. 49. The method of claim 41, wherein said narrow angle between impinging streams is about 180 °. 50. (a) forming a plurality of streams of a two-phase fluid consisting of a gaseous phase and a liquid phase; and (b) causing at least a portion of each stream to collide with at least a portion of another stream. Forming a single mixed stream with a narrow angle of about 120 ° to 240 °; (c) applying a shear mixing force to said single mixed stream to form a shear mixed stream; (d) Expanding the gas phase in the shear-mixed stream to produce a spray of raw material droplets to form a droplet spray. 51. The method of claim 50, further comprising combining a gas phase stream with a liquid phase stream to form the two-phase fluid. 52. The impingement zone and the shear mixing zone include: (i) a fluid inlet and a fluid outlet having a splitter capable of splitting an incoming flow stream into at least two streams of a two-phase fluid. A body configured to form an impingement mixing zone and a shear mixing zone disposed between the inlet and the outlet; and (ii) having at least one impingement surface, the impingement surface comprising: Said impingement mixing zone configured to impinge at least a portion of the fluid stream in contact with the surface with another impingement stream, wherein the narrow angle between the two impingement streams is between about 170 ° and 190 °; (Iii) the shear having a cross-sectional area defined by a first dimension and a second dimension, the first dimension decreasing along the longitudinal axis through the body in the direction of the fluid outlet. The method of claim 51, characterized in that contained in the nozzle and a coupling region. 53. The method of claim 52, wherein said shear mixing zone has a rounded side edge. 54. The method of claim 53, wherein the nozzle further comprises a spray disperser in flow communication with the fluid outlet. 55. The method of claim 54, wherein the disperser forms an atomization zone where the pressure is less than the pressure in the shear mixing zone. 56. The disperser has a disperser fluid passage extending therethrough, the passage diverging along the longitudinal axis of the passage in the direction of the outlet of the disperser. 6. The method of claim 5, wherein the first dimension has a rounded end.
5. The method according to 5. 57. The narrow angle between the impinging streams is between about 175 ° and 185 °.
57. The method of claim 56, wherein 58. The method of claim 56, wherein the narrow angle between the impinging streams is about 180 degrees. 59. The fluid opening has a cross-sectional area, the fluid outlet of the body has a cross-sectional area, and the cross-sectional area of the fluid outlet of the body is greater than the sum of the cross-sectional areas of the fluid opening. The device of claim 7, wherein the device is small. 60. The fluid outlet having a cross-sectional area, the fluid outlet of the body having a cross-sectional area, and the fluid outlet of the body having a cross-sectional area greater than a sum of the cross-sectional areas of the fluid opening. 21. The device of claim 20, wherein the device is small.