Method and apparatus for introducing fluids into a hydrocracking reactor
The invention provides a method and apparatus for introducing a high-density hydrocarbon liquid into a hydrocracking reactor. The method comprises atomizing the high-density hydrocarbon liquid and injecting the atomized liquid into the hydrocracking reactor. The method may also comprise mixing hydrogen with the high-density hydrocarbon liquid prior to atomizing the high-density hydrocarbon liquid. The apparatus comprises an injection valve for introducing a high-density hydrocarbon liquid into a hydrocracking reactor comprises an atomizer coupled to receive the high-density hydrocarbon liquid. The atomizer comprises a nozzle configured to atomize the high-density hydrocarbon liquid and inject the high-density hydrocarbon liquid into the hydrocracking reactor. The injection valve may also comprise a mixer coupled to receive hydrogen and the high-density hydrocarbon liquid. The mixer may be configured to mix the hydrogen and high-density hydrocarbon liquid and deliver the mixture to the atomizer.
1. An injection valve for introducing a high-density hydrocarbon liquid into a hydrocracking reactor, the injection valve comprising:
an atomizer coupled to receive the high-density hydrocarbon liquid, the atomizer comprising a nozzle connectable to the hydrocracking reactor and configured to atomize the high-density hydrocarbon liquid and inject the high-density hydrocarbon liquid into the hydrocracking reactor; and,
a mixer coupled to receive hydrogen and the high-density hydrocarbon liquid, the mixer configured to mix the hydrogen and the high-density hydrocarbon liquid and deliver a mixture of hydrogen and high-density hydrocarbon to the atomizer,
wherein the mixer comprises at least one swirl device, the at least one swirl device comprising a plurality of chambers arranged around a longitudinal axis of the injection valve, each of the chambers comprising a nozzle configured to expel fluid therefrom into an annular space to create the mixture of hydrogen and high-density hydrocarbon such that the mixture of hydrogen and high-density hydrocarbon flows downwardly through the annular space in a generally swirling motion with respect to the longitudinal axis of the injection valve.
2. An injection valve according to claim 1 wherein the at least one swirl device comprises a peripheral swirl device comprising:
a plurality of hydrogen chambers located around a periphery of the injection valve and connected to receive hydrogen and expel the hydrogen radially inwardly into the annular space; and
a plurality of hydrocarbon chambers located between the hydrogen chambers and connected to receive the high-density hydrocarbon liquid and expel the high-density hydrocarbon liquid radially inwardly into the annular space.
3. An injection valve according to claim 1 wherein the at least one swirl device comprises a central swirl device comprising:
a plurality of hydrogen chambers located near the longitudinal axis of the injection valve and connected to receive hydrogen and expel the hydrogen radially outwardly into the annular space; and
a plurality of hydrocarbon chambers located between the hydrogen chambers and connected to receive the high-density hydrocarbon liquid and expel the high-density hydrocarbon liquid radially outwardly into the annular space.
4. An injection valve according to claim 1 wherein the at least one swirl device comprises:
a peripheral swirl device comprising:
a plurality of hydrogen chambers located around a periphery of the injection valve and connected to receive hydrogen and expel the hydrogen radially inwardly into an inner annular space; and
a plurality of hydrocarbon chambers located between the hydrogen chambers and connected to receive the high-density hydrocarbon liquid and expel the high-density hydrocarbon liquid radially inwardly into the inner annular space; and
a central swirl device comprising:
a plurality of hydrogen chambers located near the longitudinal axis of the injection valve and connected to receive hydrogen and expel the hydrogen radially outwardly into an outer annular space; and
a plurality of hydrocarbon chambers located between the hydrogen chambers and connected to receive the high-density hydrocarbon liquid and expel the high-density hydrocarbon liquid radially outwardly into the outer annular space,
such that the mixture of hydrogen and high-density hydrocarbon from the peripheral swirl device flows from the inner annular space in a swirling motion over the central swirl device and through the outer annular space where the mixture of hydrogen and high-density hydrocarbon from the peripheral swirl device mixes with the mixture of hydrogen and high-density hydrocarbon from the central swirl device.
5. An injection valve according to claim 1 wherein the at least one swirl device comprises:
a central swirl device comprising:
a plurality of hydrogen chambers located near the longitudinal axis of the injection valve and connected to receive hydrogen and expel the hydrogen radially outwardly into an outer annular space; and
a plurality of hydrocarbon chambers located between the hydrogen chambers and connected to receive the high-density hydrocarbon liquid and expel the high-density hydrocarbon liquid radially outwardly into the outer annular space; and,
a peripheral swirl device comprising:
a plurality of hydrogen chambers located around a periphery of the injection valve and connected to receive hydrogen and expel the hydrogen radially inwardly into an inner annular space;
a plurality of hydrocarbon chambers located around a periphery of the injection valve and connected to receive the high-density hydrocarbon liquid and expel the high-density hydrocarbon liquid radially inwardly into the inner annular space; and
a plurality of mixture chambers located between the plurality of hydrogen and hydrocarbon chambers and connected to receive the mixture of hydrogen and high-density hydrocarbon from the central swirl device and expel the mixture radially inwardly into the inner annular space,
such that the mixture of hydrogen and high-density hydrocarbon from the peripheral swirl device flows from the inner annular space in a swirling motion toward the atomizer.
6. An injection valve according to claim 1 wherein the mixer comprises a helical channel configured to receive the mixture of hydrogen and high-density hydrocarbon from the at least one swirl device and deliver the mixture of hydrogen and high-density hydrocarbon to the atomizer.
7. An injection valve for introducing a high-density hydrocarbon liquid into a hydrocracking reactor, the injection valve comprising:
an atomizer coupled to receive the high-density hydrocarbon liquid, the atomizer comprising a nozzle connectable to the hydrocracking reactor and configured to atomize the high-density hydrocarbon liquid and inject the high-density hydrocarbon liquid into the hydrocracking reactor;
a mixer coupled to receive hydrogen and the high-density hydrocarbon liquid, the mixer configured to mix the hydrogen and the high-density hydrocarbon liquid and deliver a mixture of hydrogen and high-density hydrocarbon to the atomizer; and,
a pressure regulator for controlling a rate at which the mixture of hydrogen and high-density hydrocarbon is introduced into the hydrocracking reactor,
wherein the pressure regulator comprises:
a piston coupled to a valve movable between a closed position and an open position, the valve configured to prevent the mixture of hydrogen and high-density hydrocarbon from being introduced into the hydrocracking reactor in the closed position; and
a means for transmitting a pressure of a fluid mixture in the hydrocracking reactor to a chamber on a first side of the piston,
such that the pressure of the fluid mixture produces a force on the piston which urges the valve toward the closed position.
8. An injection valve according to claim 7 wherein the means for transmitting the pressure comprises a conduit for delivering a portion of the fluid mixture in the hydrocracking reactor to the chamber on the first side of the piston.
9. An injection valve according to claim 8 wherein the pressure regulator further comprises a conduit for providing a portion of the high-density hydrocarbon liquid provided to the mixer to a chamber on a second side of the piston opposite to the first side of the piston, such that a pressure of the portion of the high-density hydrocarbon liquid produces a force on the piston which urges the valve toward the open position.
10. An injection valve according to claim 9 wherein the pressure regulator comprises a conduit for providing a portion of the hydrogen provided to the mixer to another chamber on a second side of the piston opposite to the first side of the piston, such that a pressure of the portion of the hydrogen produces a force on the piston which urges the valve toward the open position.
11. An injection valve according to claim 10 wherein the pressure regulator further comprises a spring disposed to urge the valve toward the closed position.
12. An injection valve according to claim 11 wherein the pressure regulator further comprises a means for adjusting a tension of the spring.
13. An injection valve according to claim 7 wherein the mixer is connected to move with the piston.
14. An injection valve for introducing a high-density hydrocarbon liquid into a hydrocracking reactor, the injection valve comprising:
an atomizer coupled to receive the high-density hydrocarbon liquid, the atomizer comprising a nozzle connectable to the hydrocracking reactor and configured to atomize the high-density hydrocarbon liquid and insect the high-density hydrocarbon liquid into the hydrocracking reactor;
a mixer coupled to receive hydrogen and the high-density hydrocarbon liquid, the mixer configured to mix the hydrogen and the high-density hydrocarbon liquid and deliver a mixture of hydrogen and high-density hydrocarbon to the atomizer; and,
a means for maintaining a relatively constant ratio of high-density hydrocarbon liquid to hydrogen in the mixture of hydrogen and high-density hydrocarbon provided to the atomizer.