阅读说明：本技术 涡轮机型化学反应器 (Turbine type chemical reactor ) 是由 西尔瓦诺·R·萨雷托 柯克·瑞安·吕普克斯 于 2019-09-16 设计创作，主要内容包括：提出了一种用于处理过程流体的涡轮机型化学反应器。该涡轮机型化学反应器包括至少一个叶轮部分和设置在下游的固定式扩散器部分。叶轮部分将过程流体加速为超音速流。在固定式扩散器部分中产生冲击波,该冲击波使该冲击波下游的过程流体的静态温度瞬间增加,以用于处理过程流体。穿过冲击波,过程流体的静态压力同时增加。该涡轮机型化学反应器显著减少了过程流体在化学反应器中的停留时间,并提高了化学反应器的效率。(A turbine-type chemical reactor for treating a process fluid is presented. The turbine-type chemical reactor includes at least one impeller portion and a stationary diffuser portion disposed downstream. The impeller portion accelerates the process fluid into a supersonic flow. A shock wave is generated in the stationary diffuser section that momentarily increases the static temperature of the process fluid downstream of the shock wave for treating the process fluid. The static pressure of the process fluid is simultaneously increased across the shock wave. The turbine-type chemical reactor significantly reduces the residence time of the process fluid in the chemical reactor and increases the efficiency of the chemical reactor.)

1. A chemical reactor for treating a process fluid, the chemical reactor comprising:

an outer housing comprising an inflow port for the entry of the process fluid and an outflow port for the exit of the process fluid, wherein a flow path is defined within the outer housing, the flow path extending axially along an inner shroud of the outer housing between the inflow port and the outflow port;

a rotating shaft extending into the outer housing and coupled to a rotor disk, wherein the rotor shaft is driven by a power supply;

an impeller portion comprising a plurality of rotating impeller vanes positioned on the rotor disk, wherein the plurality of rotating impeller vanes extend radially outward from the rotor disk into the fluid path;

a stationary diffuser portion disposed downstream of the impeller portion, wherein the stationary diffuser portion comprises a plurality of diverging diffuser flow channels;

a discharge portion disposed downstream of the stationary diffuser portion, wherein the discharge portion comprises a plurality of converging discharge flow channels,

wherein the plurality of rotating impeller vanes are configured to accelerate the process fluid into a supersonic flow by changing a flow direction of the process fluid from a leading edge direction to a trailing edge direction,

wherein the plurality of discharge flow channels are configured to provide a back pressure such that a shock wave is generated in the stationary diffuser portion,

wherein the plurality of diffuser flow channels are configured to provide flow characteristics of the process fluid through the shockwave for treating the process fluid.

2. The chemical reactor of claim 1 wherein the flow characteristic of the process fluid comprises a ratio of static temperatures of the process fluid through the shockwave.

3. The chemical reactor of claim 1 wherein the flow characteristic of the process fluid comprises a ratio of static pressures of the process fluid through the shockwave.

4. The chemical reactor of claim 1, wherein the stationary diffuser portion comprises a plurality of stationary diffuser vanes positioned on a stationary diffuser hub, wherein the plurality of stationary diffuser vanes are circumferentially spaced apart from each other and extend radially outward from the stationary diffuser hub into the flow path, and wherein each diffuser flow channel is circumferentially defined between adjacent stationary diffuser vanes and radially defined between the stationary diffuser hub and the inner shroud.

5. The chemical reactor of claim 4 wherein a divergence rate of each diffuser flow channel is adjusted to provide the flow characteristics of the process fluid through the shockwave.

6. The chemical reactor of claim 4 wherein the stationary diffuser portion comprises at least one aperture disposed on the stationary diffuser hub downstream of the shockwave, and wherein the aperture is configured to extract low molecular weight components from the process fluid.

7. The chemical reactor of claim 1, wherein the discharge portion comprises a plurality of stationary discharge vanes positioned on a stationary discharge hub, wherein the plurality of stationary discharge vanes are circumferentially spaced apart from one another and extend radially outward from the stationary diffuser hub into the flow path, and wherein each discharge flow channel is circumferentially defined between adjacent stationary discharge vanes and radially defined between the stationary discharge hub and the inner shroud.

8. The chemical reactor of claim 7 wherein a rate of convergence of each discharge flow channel is adjusted to provide the flow characteristic of the process fluid through the shockwave.

9. The chemical reactor of claim 1, further comprising:

a further impeller section arranged downstream of the impeller section, an

A fixed bucket portion disposed between the impeller portion and the other impeller portion.

10. The chemical reactor of claim 1, further comprising a quench zone disposed downstream of the impeller portion, wherein the quench zone includes at least one nozzle for introducing a flow of coolant into the process fluid.

11. A method for treating a process fluid, the method comprising:

providing a chemical reactor, the chemical reactor comprising:

an outer housing comprising an inflow port for the entry of the process fluid and an outflow port for the exit of the process fluid, wherein a flow path is defined within the outer housing, the flow path extending axially along an inner shroud of the outer housing between the inflow port and the outflow port;

a rotating shaft extending into the outer housing and coupled to a rotor disk, wherein the rotor shaft is driven by a power supply;

an impeller portion comprising a plurality of rotating impeller vanes positioned on the rotor disk, wherein the plurality of rotating impeller vanes extend radially outward from the rotor disk into the fluid path;

a stationary diffuser portion disposed downstream of the impeller portion, wherein the stationary diffuser portion comprises a plurality of diverging diffuser flow channels;

a discharge portion disposed downstream of the stationary diffuser portion, wherein the discharge portion comprises a plurality of converging discharge flow channels,

rotating the plurality of rotating impeller vanes by the rotor shaft for accelerating the process fluid into a supersonic flow by changing a flow direction of the process fluid from a leading edge direction to a trailing edge direction;

generating a shock wave in the stationary diffuser portion by providing a back pressure; and

processing the process fluid using flow characteristics of the process fluid through the shockwave.

12. The method of claim 11, wherein the flow characteristic of the process fluid comprises a ratio of static temperatures of the process fluid through the shockwave.

13. The method of claim 11, wherein the flow characteristic of the process fluid comprises a ratio of static pressures of the process fluid through the shockwave.

14. The method of claim 11, wherein the stationary diffuser portion comprises a plurality of stationary diffuser vanes positioned on a stationary diffuser hub, wherein the plurality of stationary diffuser vanes are circumferentially spaced apart from one another and extend radially outward from the stationary diffuser hub into the flow path, and wherein each diffuser flow channel is circumferentially defined between adjacent stationary diffuser vanes and radially defined between the stationary diffuser hub and the inner shroud.

15. The method of claim 14, further comprising adjusting a divergence rate of each diffuser flow channel to provide the flow characteristics of the process fluid through the shockwave.

16. The method of claim 14, wherein the stationary diffuser portion includes at least one aperture disposed on the stationary diffuser hub downstream of the shockwave, and wherein the method further comprises extracting low molecular weight components from the process fluid through the aperture.

17. The method of claim 11, wherein the discharge portion comprises a plurality of stationary discharge vanes positioned on a stationary discharge hub, wherein the plurality of stationary discharge vanes are circumferentially spaced apart from one another and extend radially outward from the stationary diffuser hub into the flow path, and wherein each discharge flow channel is circumferentially defined between adjacent stationary discharge vanes and radially defined between the stationary discharge hub and the inner shroud.

18. The method of claim 17, further comprising adjusting a rate of convergence of each exhaust flow channel to provide the flow characteristic of the process fluid through the shockwave.

19. The method of claim 11, further comprising:

providing a further impeller section arranged downstream of said impeller section, an

A fixed bucket portion is disposed between the impeller portion and the other impeller portion.

20. The method of claim 11, further comprising providing a quench zone downstream of the impeller portion, wherein the quench zone includes at least one nozzle for introducing a flow of coolant into the process fluid.

Technical Field

The disclosed embodiments relate generally to a turbine-type chemical reactor, particularly for treating a process stream, and more particularly for an endothermic process of a process fluid.

Background

An endothermic process may refer to a process that requires the addition of heat to a process fluid to facilitate an endothermic chemical reaction to occur. Endothermic processes may be used in refineries and petrochemical plants for fractionating or "cracking" heavier molecular weight hydrocarbons. After cracking, lighter molecular weight hydrocarbons are used as feedstock in the petrochemical industry for the production of other compounds. In known commercially practiced thermal cracking processes, the application of heat and pressure in a furnace-type chemical reactor in a low oxygen environment fractionates heavier molecular weight hydrocarbons into various lighter molecular weight olefins, such as ethylene, without causing combustion. Another example of an endothermic process may be steam reforming of methane. Typically, heavier molecular weight hydrocarbons are entrained in the heated steam. A process fluid containing steam and hydrocarbons flows through the heat exchanger of the chemical reactor. The imparted temperature and residence time of the process fluid within the heat exchanger are controlled to crack the entrained hydrocarbons into the desired output, i.e., lower molecular weight hydrocarbons.

Taking the production of ethylene by pyrolysis as an example, a process fluid comprising a hydrocarbon and steam mixture is heated from 1220 ° F to 1545 ° F in less than 400 milliseconds (ms) in a furnace-type chemical reactor. The rate at which heating is carried out and then quenched (to stop further chemical reaction) is important to produce the desired hydrocarbon mixture. To avoid hydrocarbon combustion, oxygen must be absent during the heating process. The reaction process in a furnace-type chemical reactor requires a large heat input and a relatively slow process fluid mass flow rate. To achieve the yield goals, ethylene production plants employ multiple parallel pyrolysis reactors, each requiring a large heat input. Each additional reactor required to achieve production goals adds capital expenditure, energy consumption to heat the process fluid, plant real estate space.

It is desirable to increase the mass flow of process fluid during hydrocarbon cracking processes with lower production energy input. The increased mass flow meets production goals with less plant capital expenditure and real estate space.

Disclosure of Invention

Briefly described, aspects of the disclosed embodiments relate to chemical reactors and methods for processing a process fluid.

According to one aspect, a chemical reactor for treating a process fluid is presented. The chemical reactor comprises an outer shell comprising an inflow opening for the entry of a process fluid and an outflow opening for the exit of the process fluid. A flow path is defined within the outer housing and extends axially along the inner shroud of the outer housing between the flow inlet and the flow outlet. The chemical reactor includes a rotating shaft that extends into the outer shell and is coupled to the rotor disk. The rotor shaft is driven by a power supply. The chemical reactor includes an impeller portion including a plurality of rotating impeller vanes positioned on a rotor disk. The plurality of rotating impeller vanes extend radially outward from the rotor disk into the flow path. The chemical reactor includes a stationary diffuser section disposed downstream of the impeller section. The stationary diffuser portion includes a plurality of diverging diffuser flow passages. The chemical reactor includes a discharge portion disposed downstream of the stationary diffuser portion. The discharge portion includes a plurality of converging discharge flow channels. The plurality of rotating impeller vanes is configured to accelerate the process fluid into a supersonic flow by changing a flow direction of the process fluid from a leading edge direction to a trailing edge direction. The plurality of discharge flow channels are configured to provide a back pressure to cause a shock wave to be generated in the stationary diffuser portion. The plurality of diffuser flow channels are configured to provide flow characteristics of the process fluid through the shockwave for treating the process fluid.

According to one aspect, a method for treating a process fluid is presented. The method includes providing a chemical reactor. The chemical reactor comprises an outer shell comprising an inflow opening for the entry of a process fluid and an outflow opening for the exit of the process fluid. A flow path is defined within the outer housing and extends axially along the inner shroud of the outer housing between the flow inlet and the flow outlet. The chemical reactor includes a rotating shaft that extends into the outer shell and is coupled to the rotor disk. The rotor shaft is driven by a power supply. The chemical reactor includes an impeller portion including a plurality of rotating impeller vanes positioned on a rotor disk. The plurality of rotating impeller vanes extend radially outward from the rotor disk into the flow path. The chemical reactor includes a stationary diffuser section disposed downstream of the impeller section. The stationary diffuser portion includes a plurality of diverging diffuser flow passages. The chemical reactor includes a discharge portion disposed downstream of the stationary diffuser portion. The discharge portion includes a plurality of converging discharge flow channels. The method includes rotating the rotating impeller vanes by the rotor shaft for accelerating the process fluid into a supersonic flow by changing a flow direction of the process fluid from a leading edge direction to a trailing edge direction. The method includes generating a shock wave in the stationary diffuser portion by providing a back pressure. The method includes treating the process fluid using flow characteristics of the process fluid through the shockwave.

The various aspects and embodiments of the present application as described above and below can be used not only in the explicitly described combinations but also in other combinations. Modifications will occur to others upon reading and understanding the specification.

Drawings

Exemplary embodiments of the present application are described in further detail with reference to the accompanying drawings. In the drawings:

FIG. 1 is a schematic longitudinal cross-sectional view of a chemical reactor according to an embodiment;

FIG. 2 is a schematic process diagram of a flow path of a process fluid through the chemical reactor shown in FIG. 1 according to an embodiment;

FIG. 3 is a schematic perspective view of the chemical reactor of FIG. 1 with the outer shell removed for clarity;

FIG. 4 is a schematic cross-sectional view of an impeller vane according to an embodiment;

FIG. 5 is a schematic illustration of a diffuser flow channel according to an embodiment;

fig. 6 is a schematic perspective view of a discharge flow channel according to an embodiment;

FIG. 7 is a schematic longitudinal sectional view of a chemical reactor according to another embodiment;

FIG. 8 is a schematic process diagram of a flow path of a process fluid through the chemical reactor shown in FIG. 7;

FIG. 9 is a schematic longitudinal sectional view of a chemical reactor according to yet another embodiment;

FIG. 10 is a schematic process diagram of a flow path of a process fluid through the chemical reactor shown in FIG. 9;

FIG. 11 is a schematic process diagram of a flow path of a process fluid flowing through a chemical reactor and a graph of calculated static pressure and static temperature of the process fluid at various locations along the flow path of the chemical reactor, according to an embodiment; and

fig. 12 is a schematic longitudinal sectional view of a chemical reactor according to still another embodiment.

To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures.

Detailed Description

Hereinafter, detailed descriptions related to aspects of the disclosed embodiments are described with reference to the drawings.

For purposes of this specification, the term "axial" or "axially" refers to a direction along the longitudinal axis of a chemical reactor, the term "radial" or "radially" refers to a direction perpendicular to the longitudinal axis of a chemical reactor, the term "downstream" or "aft" refers to a direction along the direction of flow, and the term "upstream" or "forward" refers to a direction opposite the direction of flow.

Fig. 1 shows a schematic longitudinal sectional view of a chemical reactor 10 according to an embodiment. In this embodiment, the chemical reactor 10 is a single stage chemical reactor 10 having one impeller portion 200 and one fixed diffuser portion 400. The impeller portion 200 and the stationary diffuser portion 400 function similar to a turbomachine. As shown in fig. 1, the chemical reactor 10 includes an outer shell 100 enclosing a plurality of components along a longitudinal axis 12. These components include the impeller portion 200 and the stationary diffuser portion 400. The outer housing 100 has an inflow 110 for process fluid F to enter. The outer housing 100 has an outflow opening 120 for the process fluid F to exit. The inflow 110 and outflow 120 ports may have a radial or axial orientation. In the exemplary embodiment of fig. 1, the inflow 110 has a radial orientation, while the outflow 120 has an axial orientation. It should be understood that the inflow 110 and outflow 120 ports may have any combination of radial or axial orientations.

The outer housing 100 has an inner cover 130 extending in the axial direction. An annular flow path 140 is defined axially within the outer housing 100 along the inner shroud 130 between the inflow 110 and outflow 120 ports. The process fluid F enters the flow path 140 via the inflow port 110 and exits the flow path 140 via the outflow port 120, thereby defining an axial flow path. As the process fluid F flows through the flow path 140, hydrocarbons in the process fluid F are cracked.

The chemical reactor 10 includes a rotating shaft 14 extending axially into an outer housing 100. The rotating shaft is connected to a power supply 16, the power supply 16 driving the rotating shaft 14 and rotating the rotating shaft 14 about the longitudinal axis 12 in a rotational direction R. In the exemplary embodiment shown in fig. 1, the direction of rotation R is clockwise. It should be understood that in other embodiments, the direction of rotation R may be counterclockwise. The power supply 16 includes an electric motor, a steam turbine, a gas turbine, or any internal combustion engine or power supply known in the industry.

Referring to fig. 1, wheel portion 200 includes a plurality of rotating wheel blades 210 positioned on a rotor disk 220. The rotating impeller vanes 210 may be manufactured integral with the rotor disk 220 as one component. Alternatively, the rotating impeller vanes 210 may be manufactured separately and mounted on the rotor disk 220. Rotor disk 220 is coupled to rotating shaft 14. Rotating impeller vanes 210 are circumferentially spaced apart from each other and extend radially outward from rotor disk 220 into flow path 140. The flow path 140 is formed between the rotor disc 220 and the inner shroud 130 of the outer casing 100. The impeller portion 200 is designed to accelerate the process fluid F in the flow path 140 into a supersonic flow having a Mach number M greater than 1.

The stationary diffuser portion 400 is disposed downstream of the impeller portion 200. The stationary diffuser portion 400 has a diverging shape. The stationary diffuser portion 400 includes a plurality of stationary diffuser vanes 410 positioned on a stationary diffuser hub 420. The stationary diffuser vanes 410 may be manufactured integral with the stationary diffuser hub 420 as one piece. Alternatively, the stationary diffuser blades 410 may be manufactured separately and mounted on the stationary diffuser hub 420. The stationary diffuser blades 410 are circumferentially spaced apart from each other and extend radially outward from the stationary diffuser hub 420 into the flow path 140. The flow path 140 is formed between the stationary diffuser hub 420 and the inner shroud 130 of the outer casing 100. The shock wave 416 (shown in FIG. 2) is generated in the stationary diffuser portion 400 by applying an appropriate back pressure at the outlet of the stationary diffuser portion 400.

The chemical reactor 10 includes a discharge portion 500 disposed downstream of the stationary diffuser portion 400. The discharge portion 500 includes a plurality of stationary discharge vanes 510 positioned on a stationary discharge hub 520. The stationary discharge vane 510 may be manufactured to be integrated with the stationary discharge hub 520 as one part. Alternatively, the stationary discharge vane 510 may be separately manufactured and mounted on the stationary discharge hub 520. The stationary discharge vanes 510 are circumferentially spaced apart from each other and extend radially outward from the stationary discharge hub 520 into the flow path 140. The flow path 140 is formed between the stationary discharge hub 520 and the inner shroud 130 of the outer housing 100. The discharge portion 500 includes a discharge cone 522 and an outlet transition 524 disposed downstream of the stationary discharge vane 510. The flow path 140 extends axially through the passage between the discharge cone 522 and the outlet transition 524 and exits the outer casing 100 at the flow outlet 120.

Fig. 2 is a schematic process diagram of a flow path 140 of a process fluid F through the chemical reactor 10 shown in fig. 1. Process fluid F enters the flow path 140 via the flow inlet 110. The process fluid F flows axially through the impeller portion 200 and is accelerated into a supersonic flow. The supersonic process fluid F is directed into the stationary diffuser portion 400 and decelerated through the shockwave 416 to a subsonic flow with mach number M less than 1. The shock wave 416 momentarily increases the static temperature T of the process fluid F significantly downstream of the shock wave 416, which generates sufficient heat to crack the hydrocarbons in the process fluid F. The shock wave 416 simultaneously causes a momentary increase in the static pressure P of the process fluid F downstream of the shock wave 416, which produces the desired outlet pressure of the chemical reactor 10. The process fluid F is directed into the discharge portion 500 and exits the flow path 140 via the outflow opening 120.

Fig. 3 is a schematic perspective view of the chemical reactor 10 shown in fig. 1. In fig. 3, the outer housing 100 is removed for clarity. Fig. 4 is a schematic view of a rotating impeller vane 210. FIG. 5 is a schematic view of adjacent stationary diffuser vanes 410. Fig. 6 is a schematic view of adjacent stationary discharge vanes 510.

Referring to fig. 1, 3 and 4, wheel portion 200 includes a plurality of rotating wheel blades 210 positioned on a rotor disk 220. Rotating impeller vanes 210 are circumferentially spaced apart from each other and extend radially outward from rotor disk 220 into flow path 140. As shown in fig. 4, each rotating impeller vane 210 has an upstream facing leading edge 211 and a downstream facing trailing edge 212. Each rotating impeller vane 210 has a concave side 213 and a convex side 214 between a leading edge 211 and a trailing edge 212. Rotating impeller vanes 210 accelerate process fluid F by changing the direction of flow of process fluid F from direction 215 at leading edge 211 to direction 216 at trailing edge 212 as rotation occurs through rotor disk 220. The flow direction 215 at the leading edge 211 flow and the flow direction 216 at the trailing edge 212 are tangential with respect to the longitudinal axis. The rotating impeller vanes 210 have a supersonic vane profile. The rotating impeller vanes 210 accelerate the process fluid F into a supersonic flow at the trailing edge 212. The rate of acceleration of process fluid F is determined by the amount of change in the direction of flow. The higher the rate at which process fluid F is accelerated, the greater the amount of change in the direction of flow from leading edge 211 to trailing edge 212. The static pressure and temperature of the process fluid F does not change significantly at the trailing edge 212 as compared to the leading edge 211.

Referring to fig. 1, 3 and 5, supersonic process fluid F is discharged from impeller portion 200 into stationary diffuser portion 400. The stationary diffuser portion 400 includes a plurality of stationary diffuser vanes 410 positioned on a stationary diffuser hub 420. The stationary diffuser blades 410 are circumferentially spaced apart from each other and extend radially outward from the stationary diffuser hub 420 into the flow path 140. As shown in FIG. 5, each stationary diffuser vane 410 has an upstream-facing leading edge 411 and a downstream-facing trailing edge 412. Each stationary diffuser vane 410 has two opposing sides 413 and 414 between a leading edge 411 and a trailing edge 412. Diffuser flow passages 415 are formed circumferentially between adjacent stationary diffuser blades 410 and radially between the stationary diffuser hub 420 and the inner shroud 130. Diffuser flow passage 415 cross-sectional area D_ABy the cross-sectional height D of the diffuser flow passage 415_HAnd a cross-sectional width D_WAnd (4) determining. Diffuser flow channel 415 cross-sectional height D_HRadially defined between the fixed diffuser hub 420 and the inner shroud 130. Diffuser flow channel 415 cross-sectional width D_WCircumferentially defined between adjacent facing sides 413 and 414 of adjacent stationary diffuser vanes 410. The diffuser flow passage 415 is designed to diverge in the axial direction.

The shockwave 416 of the process fluid F is generated at an axial position in the stationary diffuser portion 400 by applying a suitable back pressure at the outlet of the stationary diffuser portion 400, in this embodiment at the trailing edges 412 of the stationary diffuser vanes 410. Cross-sectional area D of flow passage 415 with diffuser_AThe larger, supersonic process fluid F is continuously accelerated along the diverging stationary diffuser portion 400. The region of supersonic acceleration of process fluid F is terminated by shock wave 416. Axial location of shock wave 416 in stationary diffuser portion 400The set is a function of the back pressure. The lower the back pressure, the more downstream the axial position of shock wave 416, the longer the region of supersonic acceleration of process fluid F. By adjusting the divergence rate of the diffuser flow channel 415, or by adjusting the backpressure at the trailing edge 412 of the stationary diffuser vanes 410, or by adjusting both the divergence rate of the diffuser flow channel 415 and the backpressure at the trailing edge 412 of the stationary diffuser vanes 410, the process fluid F can achieve a high supersonic Mach number M upstream of the shockwave 416. By adjusting the cross-sectional area D of the diffuser flow passage 415 in the axial direction_ATo adjust the divergence ratio, cross-sectional area D, of the diffuser flow passage 415_ACan be adjusted by adjusting the cross-sectional height D of the diffuser flow passage 415 in the axial direction_HBy adjusting the cross-sectional width D of the diffuser flow passage 415 in the axial direction_WTo achieve or by adjusting the cross-sectional height D of the diffuser flow passage 415 in the axial direction_HAnd a cross-sectional width D of the diffuser flow passage 415 in the axial direction_WBoth are implemented.

Still referring to fig. 1, 3, and 5, the stationary diffuser vanes 410 may have a helical profile. The process fluid F swirls while passing through the diffuser flow passage 415 formed between the adjacent spiral-shaped fixed diffuser vanes 410. The highly accelerated and swirling process fluid F in the stationary diffuser portion 400 upstream of the shock wave 416 may be separated into components having different molecular weights due to the high centrifugal forces in the stationary diffuser portion 400. A component having a low molecular weight, such as hydrogen, in the process fluid F flows toward the stationary diffuser hub 420 at a low radial position in the diffuser flow passage 415. Component of high molecular weight, such as CO, in the process fluid F₂Hydrocarbon or steam flows toward the inner shroud 130 at a high radial location in the diffuser flow passage 415. The stationary diffuser portion 400 may comprise at least one hole 421 arranged on the stationary diffuser hub 420 downstream of the shock wave 416. Low molecular weight components in process fluid F can be extracted through apertures 421 and removed from process fluid F for the remaining flow pathDiameter 140. A plurality of holes 421 may be disposed on the stationary diffuser hub 420 downstream of the shock wave 416.

The shockwave 416 momentarily lowers the supersonic process fluid F into a subsonic process fluid F that passes through the shockwave 416. The static temperature of process fluid F momentarily increases across shock wave 416. The static pressure F of the process fluid passes through the shock wave 416 while momentarily increasing. The static temperature increased process fluid F downstream of the shock wave 416 generates sufficient heat to crack heavier molecular weight hydrocarbons in the process fluid F. The shock wave 416 significantly reduces the heating and pressurization processing time of the process fluid F, thereby significantly reducing the residence time of the process fluid F within the chemical reactor 10. The ratio of the static temperature and the ratio of the static pressure across the shock wave 416 is a function of the upstream mach number M of the process fluid F and the properties of the process fluid.

Referring to fig. 1, 3 and 6, subsonic process fluid F is discharged from diffuser portion 400 to stationary discharge vanes 510 in discharge portion 500. As shown in FIG. 6, each stationary discharge vane 510 has an upstream-facing leading edge 511 and a downstream-facing trailing edge 512. Each stationary discharge vane 510 has two opposing sides 513 and 514 between the leading edge 511 and the trailing edge 512. A plurality of discharge flow channels 515 are formed between the adjacent stationary discharge vanes 510 and between the stationary discharge hub 520 and the inner shroud 130. Cross-sectional area E of the discharge flow channel 515_ABy the cross-sectional height E of the discharge flow channel 515_HAnd a cross-sectional width E_WAnd (4) determining. Cross-sectional height E of discharge flow channel 515_HRadially defined between the fixed discharge hub 520 and the inner shroud 130. Cross-sectional width E of the discharge flow channel 515_WCircumferentially between adjacent opposite side surfaces 513 and 514 of adjacent stationary discharge vanes 510. The discharge flow channel 515 is designed to converge in the axial direction. By adjusting the rate of convergence of the discharge flow channels 515, an appropriate back pressure can be applied at the outlet of the stationary diffuser portion 400. The desired supersonic mach number M of the process fluid F may be achieved upstream of the shockwave 416, as described above. Can be adjusted by adjusting the cross-sectional area E of the discharge flow channel 515 in the axial direction_ATo adjust the convergence rate, cross-sectional area E, of the discharge flow channel 515_ACan be adjusted by adjusting the cross-sectional height E of the discharge flow channel 515 in the axial direction_HTo achieve or by adjusting the cross-sectional width E of the discharge flow channel 515 in the axial direction_WTo achieve or by adjusting the cross-sectional height E of the discharge flow channel 515 in the axial direction_HAnd a cross-sectional width E of the discharge flow channel 515 in the axial direction_WBoth are implemented.

The process fluid F is discharged from the stationary discharge vane 510 to the flow path 140 between the discharge cone 522 and the outlet transition 524 to the flow outlet 120. According to another embodiment, the process fluid F may also be discharged from the stationary discharge vanes 510 to another stage of the chemical reactor 10 for further processing. The stationary discharge vanes 510 may align the flow direction of the process fluid F exiting the first stage with the leading edges 211 of the rotating impeller blades 210 of the other stage.

Referring to fig. 1, the chemical reactor 10 includes a quench zone 150 disposed downstream of an impeller portion 200. The quench zone 150 includes at least one nozzle 152. The nozzle 152 is in fluid communication with the process fluid F. The nozzle 152 may introduce a coolant flow into the process fluid F for stabilizing the temperature of the process fluid F. The nozzles 152 may also introduce an anti-fouling fluid into the process fluid F to inhibit fouling within the chemical reactor 10.

Fig. 7 is a schematic longitudinal sectional view of a chemical reactor 10 according to an embodiment. In this embodiment, the chemical reactor 10 is a single stage chemical reactor 10 having a dual impeller portion 200 and a stationary diffuser portion 400. A fixed tub portion 300 is disposed between the dual impeller portions 200. The stationary bucket portion 300 includes a plurality of stationary bucket blades 310 positioned on a stationary bucket blade hub 320. The stationary bucket blades 310 may be manufactured as one piece with the stationary bucket blade hub 320 as one component. Alternatively, the stationary bucket blades 310 may be manufactured separately and mounted on the stationary bucket blade hub 320. The stationary bucket blades 310 are circumferentially spaced apart from each other and extend radially outward from the stationary bucket hub 320 into the flow path 140. Each stationary bucket blade 310 has an upstream facing leading edge 311 and a downstream facing trailing edge 312. The stationary bucket blades 310 align the flow direction of the process fluid F exiting from the trailing edge 212 of the upstream rotating impeller blade 210 with the leading edge 211 of the downstream rotating impeller blade 210. The downstream impeller portion 200 may further accelerate the velocity of the process fluid F before the process fluid F enters the stationary diffuser portion 400. The rotating impeller vanes 210 in each impeller portion 200 may have the same or different configurations. A chemical reactor 10 having a dual impeller portion 200 may reduce the inlet velocity of the process fluid F at the flow inlet 110 compared to a chemical reactor 10 having one impeller portion 200. A chemical reactor 10 with a dual impeller portion 200 may reduce the velocity of the process fluid F at the flow inlet 120 and may require less flow direction change in the rotating impeller vanes 210 than a chemical reactor 10 with one impeller portion 200. Fig. 8 is a schematic process diagram of a flow path 140 for process fluid flowing through the dual impeller single stage chemical reactor 10 shown in fig. 7.

Fig. 9 illustrates a schematic longitudinal cross-sectional view of a chemical reactor 10 according to an embodiment. In this embodiment, the chemical reactor 10 is a two-stage chemical reactor 10. The two-stage chemical reactor 10 includes an upstream stage and a downstream stage. Each stage has an impeller portion 200 and a stationary diffuser portion 400. It should be understood that each of the two stages, or one stage, may have a twin impeller portion 200 and a stationary diffuser portion 400 as illustrated in fig. 7 and 8. The two stages may be enclosed within a common outer casing 100. Alternatively, the two stages may also be enclosed within two separate outer shells 100. The two-stage chemical reactor 10 generates upstream shock waves 416 and downstream shock waves 416 in upstream and downstream stages, respectively, to improve the cracking process of the process fluid F. The two-stage chemical reactor 10 may reduce the velocity of the process fluid F at the flow inlet 120 and may require less flow direction change in the rotating impeller vanes 210. Fig. 10 is a schematic process diagram of a flow path 140 of a process fluid F through the two-stage chemical reactor 10 shown in fig. 9.

Referring to fig. 9, the upstream stationary diffuser portion 400 includes at least one aperture 421 disposed on the stationary diffuser hub 420 downstream of the upstream shockwave 416. Low molecular weight components in process fluid F are extracted through apertures 421 and removed from process fluid F for use in the remaining flow path 140. The process fluid F with the high molecular weight component flows to downstream stages for further processing. The efficiency of the chemical reactor 10 is greatly improved.

Fig. 11 is a schematic process diagram of a flow path 140 of a process fluid F flowing through a chemical reactor 10 having a twin impeller portion 200 as shown in fig. 8. Below the process map, a graph of the calculated static temperature T and static pressure P of the process fluid F at various locations along the flow path 140 is arranged. The calculated static temperature T and static pressure P plots of process fluid F at various locations along flow path 140 shown in fig. 11 are for illustration purposes only. It should be understood that the values of the static temperature T and the static pressure P of the process fluid F at various locations along the flow path 140 vary corresponding to different geometries of the chemical reactor 10 and properties of the process fluid F. Process fluid F is a hydrocarbon-containing process fluid.

As shown in fig. 11, the static temperature and static pressure P increase instantaneously at the same time across the shock wave 416. As described above, by adjusting the geometry of the chemical reactor 10, such as by adjusting the profile of the rotating impeller vanes 210, the divergence rate of the diffuser flow channel 415, the convergence rate of the discharge flow channel 515, a desired ratio of static temperature T and static pressure P across the shock wave 416 is achieved to crack hydrocarbons in the process fluid F. For example, the ratio of the static temperature T across the shock wave 416 may be an increase of at least ten percent (10%). The rate of static pressure P through shock wave 416 may be an increase of less than ten percent (10%), or at least ten percent (10%), or as much as two or three times. The total increase in static pressure P through chemical reactor 10 is less than the increase in static pressure P through shock wave 416. The residence time in the chemical reactor 10 is significantly reduced, for example about 10 milliseconds, or about 5 milliseconds, or even about 1 millisecond, compared to several hundred milliseconds in known commercially practiced chemical reactors, such as furnace-type chemical reactors. The simultaneous heating and pressurizing of the process fluid F through the shock wave 416 in the turbine type chemical reactor 10 may reduce the gas compressors and heat exchangers used in furnace type chemical reactors and thus reduce the cost and complexity of and increase the reliability of refineries and petrochemical plants.

The process fluid F exiting the stationary diffuser portion 400 is directed to the stationary discharge vanes 510 of the discharge portion 500. The cracking reaction may be continued by the fixed discharge vanes 510. The cracking reaction may absorb heat from the process fluid F, which may effectively stop chemical reactions in the process fluid F and reduce the temperature of the process fluid F downstream of the shock wave 416. The process fluid F may exit the chemical reactor 10 at an effluent outlet 120 for the single stage chemical reactor 10. Alternatively, the process fluid F may enter the second stage for a two-stage chemical reactor 10 as shown in fig. 9 and 10, where the process fluid F is re-accelerated into a supersonic flow, causing a simultaneous instantaneous increase in the static temperature T and static pressure P across the second shock wave 416 in the second stage, similar to that illustrated in fig. 11. A quench zone 150 may be incorporated in the second stage reactor downstream of the second impeller portion 200 to control the cracking reaction rate by injecting cooling steam or other cooling fluid and/or anti-fouling fluid into the flow path 140.

Fig. 12 is a schematic longitudinal sectional view of a chemical reactor 10 according to an embodiment. In the exemplary embodiment, power supply 16 is a gas turbine 16. The heat exchanger 17 is operatively connected to the gas turbine 16 to extract gas turbine exhaust gas to preheat the process fluid F. The exhaust gases are then passed to a stack. A heating device 18 may be operatively connected to the heat exchanger 17 to further heat the process fluid F. The heating device 18 may be a furnace or any type of heating device known in the industry. The heated process fluid F is then introduced into the flow inlet 110 of the chemical reactor 10, as illustrated above with reference to fig. 1-11. This arrangement utilizes waste heat from the gas turbine 10 and increases the efficiency of the cracking process of the process fluid F.

According to an aspect, the proposed chemical reactor 10 is a turbine-type chemical reactor for cracking hydrocarbons in a process fluid F in oil refineries and petrochemical plants. The proposed turbomachine-type chemical reactor 10 comprises a stationary diffuser portion 400 and at least one impeller portion 200 to generate a shock wave 416 in the stationary diffuser portion 400. The shock wave 416 momentarily increases the static temperature T of the process fluid F downstream of the shock wave 416 to crack the process fluid F. The proposed turbine-type chemical reactor 10 significantly reduces the residence time of the process fluid F in the chemical reactor 10 and improves the efficiency of the chemical reactor 10.

According to one aspect, the proposed turbine-type chemical reactor 10 provides simultaneous heating and pressurization of the process fluid F through the shock wave 416. The proposed turbine-type chemical reactor 10 may reduce the gas compressor and heat exchanger used in furnace-type chemical reactors. The proposed turbine-type chemical reactor 10 is significantly more compact than a furnace-type chemical reactor. Thus, the proposed turbine-type chemical reactor 10 reduces the cost and complexity of and increases the reliability of refineries and petrochemical plants.

Although various embodiments which incorporate the disclosed concepts have been shown and described in detail herein, those skilled in the art can readily devise many other varied embodiments that still incorporate these disclosed concepts. The disclosed embodiments are not limited to the specific details of construction and arrangement of components set forth in the description or illustrated in the drawings. The disclosed concepts may be implemented by other embodiments and may be practiced or carried out in various ways, as will now become apparent to those skilled in the art. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of "including," "comprising," or "having" and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms "mounted," "connected," "supported," and "coupled" and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, "connected" and "coupled" are not restricted to physical or mechanical connections or couplings.

List of reference numerals:

10: chemical reactor

12: longitudinal axis

14: rotating shaft

16: power supply device

17: heat exchanger

18: heating device

100: outer casing

110: inlet port

120: outflow opening

130: inner cover

140: flow path

150: quenching zone

152: discharge nozzle

200: impeller part

210: rotating impeller blade

211: leading edge of a vane

212: trailing edge of vane

213: concave side of rotary impeller blade

214: convex side of rotating impeller blade

215: leading edge flow direction

216: trailing edge flow direction

220: rotor disc

300: stationary bucket section

310: fixed bucket blade

311: leading edge of fixed bucket blade

312: trailing edge of fixed bucket blade

320: fixed bucket blade hub

400: stationary diffuser section

410: fixed diffuser vane

411: leading edge of a stationary diffuser vane

412: trailing edge of stationary diffuser vane

413. 414: opposite sides of a stationary diffuser vane

415: diffuser flow channel

416: shock wave

420: fixed diffuser vane hub

421: hole(s)

500: discharge section

510: fixed type discharge blade

511: leading edge of stationary discharge vane

512: trailing edge of stationary discharge vane

513. 514: opposite sides of fixed discharge vanes

515: discharge flow channel

520: fixed type discharge blade hub

522: discharge cone

524: outlet transition