U.S. patent number 3,876,363 [Application Number 05/429,559] was granted by the patent office on 1975-04-08 for atomizing method and apparatus.
This patent grant is currently assigned to Aqua-Chem, Inc.. Invention is credited to John W. Bjerklie, Paul G. La Haye.
United States Patent |
3,876,363 |
La Haye , et al. |
April 8, 1975 |
ATOMIZING METHOD AND APPARATUS
Abstract
A method and apparatus for finely atomizing a fluid such as oil
or the like includes producing an emulsion of the oil with a
secondary fluid pressurizing and heating the emulsion to a level
below the vaporizing point of the secondary fluid and the
constituents of the primary fluid, and releasing the resulting
heated and pressurized emulsion to a lower pressure to vaporize the
secondary fluid and the light ends of the primary fluid thereby
subdividing the primary fluid or all into fine or small drops. When
used to atomize fuel oils for combustions, the subdivided oil may
be premixed with air or a mixture of air, CO.sub.2 and other gases
permitting a substantial reduction in the emission of particulate
matter and noxious products.
Inventors: |
La Haye; Paul G. (Elizabeth,
ME), Bjerklie; John W. (Elizabeth, ME) |
Assignee: |
Aqua-Chem, Inc. (Milwaukee,
WI)
|
Family
ID: |
23703771 |
Appl.
No.: |
05/429,559 |
Filed: |
January 2, 1974 |
Current U.S.
Class: |
431/11; 239/135;
239/13; 431/210 |
Current CPC
Class: |
F23G
7/05 (20130101); F23K 5/12 (20130101) |
Current International
Class: |
F23K
5/02 (20060101); F23G 7/05 (20060101); F23K
5/12 (20060101); F23d 011/44 () |
Field of
Search: |
;431/2,11,210
;239/13,135,136,8 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Favors; Edward G.
Attorney, Agent or Firm: Wiviott; Fred
Claims
We claim:
1. The combination including first means for producing an emulsion
of a liquid fuel and a second liquid, second means coupled to said
first means for pressurizing and heating said liquid to an energy
level such that said emulsion will atomize upon being discharged
into a lower pressure atmosphere, third means defining a combustion
zone, nozzle means disposed within said combustion zone and coupled
to said second means for receiving said pressurized fluid and for
releasing the same into the lower pressure atmosphere of said
combustion zone whereby said emulsion will atomize, said second
means including heating means and pressurizing means, said heating
means including first heat exchange means external of said
combustion zone for receiving said emulsion, and second heat
exchange means exposed to heat generated in said combustion zone
and for transferring the same to said first heat exchange
means.
2. The combination set forth in claim 1 wherein said second means
comprises a high pressure pump.
3. The combination set forth in claim 2 and including a first flow
circuit for said fuel and a second flow circuit for said second
fluid, and fourth means coupled to each of said circuits for
maintaining a predetermined ratio of said fluids flowing to said
first means.
4. The combination set forth in claim 3 wherein said first means
includes a vessel for receiving said fuel and said second liquid,
and impeller means within said vessel for mixing said liquids to
produce an emulsion thereof.
5. The combination comprising first means including a vessel for
receiving a liquid fuel and a second liquid, and impeller means
within said vessel for mixing said liquids to produce an emulsion
thereof, second means coupled to said first means for pressurizing
and heating said emulsion to an energy level such that said
emulsion will atomize upon being discharged into a lower pressure
atmosphere, discharge means coupled to said second means for
receiving said pressurized fluid and for releasing the same to the
lower pressure atmosphere whereby said emulsion will atomize.
6. A combination process comprising the steps of:
emulsifying a liquid fuel and a second liquid which is immiscible
in said fuel,
providing a combustion zone,
said second liquid having a lower flash temperature relative to the
pressure of said combustion zone than said fuel,
heating said emulsion to an elevated temperature in excess of said
flash temperature of said second liquid and lower than the flash
temperature of said fuel relative to the pressure of said zone,
containing said heated emulsion in a flow system,
pressurizing said emulsion in said flow system to a pressure in
excess of the pressure that said second fluid flashes at said
elevated temperature, whereby said second fluid is prevented from
flashing in said flow system,
discharging said pressurized and heated emulsion in said combustion
zone whereby at least a substantial portion of said second liquid
flashes to atomize said fuel,
and igniting said atomized fuel.
7. The process set forth in claim 6 wherein said second liquid is
water.
8. The process set forth in claim 7 wherein said emulsion is
pressurized to a pressure of about 2,000-10,000 psig.
9. The process set forth in claim 8 wherein said emulsion is
pressurized to a pressure of about 4,000 psig.
10. The process set forth in claim 8 wherein said emulsion is
relatively heavy fuel oil, and heating said emulsion to a
temperature of about 450.degree. - 700.degree. F prior to discharge
into said combustion zone.
11. The process set forth in claim 10 wherein said ratio of fuel to
water is about 5:1 to 25:1.
12. The process set forth in claim 11 and including the step of
providing a combustion supporting gas to said combustion zone.
13. The method set forth in claim 12 wherein said combustion
supporting gas is air.
14. The method set forth in claim 12 wherein said combustion
supporting gas contains CO.sub.2.
15. The process set forth in claim 7 wherein said emulsion is
pressurized to a pressure of about 4,000 psig.
16. The process set forth in claim 7 wherein said fuel is
relatively heavy fuel oil, and heating said emulsion to a
temperature of about 450.degree.-700.degree. F prior to discharge
from said nozzle.
17. The process set forth in claim 7 wherein said ratio of fuel to
water is about 5:1 to 25:1.
18. The process set forth in claim 7 and including the step of
providing a combustion supporting gas to said combustion zone.
19. The process set forth in claim 18 wherein said combustion
supporting gas includes air and CO.sub.2.
20. A process of atomizing fuel comprising the steps of:
emulsifying a liquid fuel and a second liquid which is immiscible
in said fuel,
providing a receiving zone,
said second liquid having a lower flash temperature relative to the
pressure of said receiving zone than said fuel,
heating said emulsion to an elevated temperature in excess of said
flash temperature of said second liquid and lower than the flash
temperature of said fuel relative to the pressure of said zone,
containing said heated emulsion in a flow system,
pressurizing said emulsion in said flow system to a pressure in
excess of the pressure that said second fluid flashes at said
elevated temperature,
discharging said pressurized and heated emulsion in said receiving
zone whereby at least a substantial portion of said second liquid
flashes to atomize said fuel.
21. The process set forth in claim 20 wherein said second liquid is
water and said fuel is oil.
22. The process set forth in claim 21 wherein an oxygen containing
gas is introduced into said receiving zone to at least partially
oxidize said oil.
23. The process set forth in claim 22 wherein said emulsion is
pressurized to a pressure of about 2,000-10,000 psig.
24. A process of atomizing fuel comprising the steps of:
mixing a liquid fuel and a second liquid which is miscible in said
fuel,
providing a receiving zone,
said second liquid having a lower flash temperature relative to the
pressure of said receiving zone than said fuel,
heating said mixture to a temperature in excess of the phase change
temperature of at least some of the components of said second
liquid and lower than the flash temperature of said fuel relative
to the pressure of said zone,
containing said heated mixture in a flow system,
pressurizing said mixture in said flow system to a pressure in
excess of the pressure that said second fluid flashes therein,
discharging said pressurized and heated mixture in said receiving
zone whereby at least a substantial portion of said second liquid
flashes to atomize said fuel.
25. The method set forth in claim 24 wherein said second liquid is
dispersed in said first liquid with the mean size of the droplets
of said second liquid being less than about 5 microns in diameter,
said mixture being substantially homogeneous.
26. The method set forth in claim 25 wherein said first liquid is
fuel oil.
27. The method set forth in claim 25 wherein said first fluid is
No. 6 residual oil and the second fluid Benzene.
28. The method set forth in claim 26 wherein said mixture is heated
to a temperature above that of parafinic or aeromatic material
which may be in said fuel oil.
29. A process for atomizing in a first zone a liquid having a
plurality of constituents having different vaporizing temperatures
for any given pressure, heating said liquid to a selected
temperature that is more than the flash temperature of a first
portion of the constituents of said mixture at the pressure of said
zone and below the flash temperature of the remaining constitutents
of said liquid at said pressure, containing said mixture in a
system, pressurizing said liquid to a pressure in excess of the
flash point pressure of said first portion of said constituents for
said predetermined temperature to prevent vaporization in said
system, and releasing said pressurized liquid into a lower pressure
atmosphere whereby at least one of the constituents of said liquid
will flash to subdivide the other constituents of said liquid into
smaller sized droplets.
30. Apparatus for atomizing a first liquid in a pressure medium,
first means for forming an emulsion of said first liquid and a
second liquid having a lower flash temperature in said pressure
medium than said first liquid, second means for containing said
emulsion, third means for heating said contained emulsion to a
temperature above the flash temperature of said second liquid in
said pressure medium and below the flash temperature of said first
liquid in said pressure medium, fourth means for pressurizing said
contained liquid to a pressure above the pressure at which said
second pressure will flash in said second means, and discharge
means for releasing said contained emulsion into said first
pressure medium whereby a substantial portion of said second liquid
flashes to atomize said first liquid.
31. The invention set forth in claim 30 wherein said first liquid
comprises a fuel and including means defining a combustion zone,
said discharge means comprising a nozzle means for discharging said
emulsion into said combustion zone.
32. The combination set forth in claim 31 wherein said fourth means
comprises a high pressure pump.
33. The combination set forth in claim 32 and including a first
flow circuit for said fuel and a second flow circuit for said
second liquid, and fifth means coupled to each of said circuits for
maintaining a predetermined ratio of said liquids flowing to said
nozzle means.
34. The combination set forth in claim 33 wherein said first means
includes a vessel for receiving said fuel and said second liquid,
and impeller means within said vessel for mixing said liquids to
produce an emulsion thereof.
35. The combination device set forth in claim 31 wherein said
fourth means includes a high pressure pump.
36. The combination set forth in claim 31 wherein said first means
includes a vessel for receiving said first and second liquids, and
impeller means within said vessel for mixing said liquids to
produce an emulsion thereof.
37. The combination set forth in claim 31 and including a first
flow circuit for said fuel and a second flow circuit for said
second liquid, and third means coupled to each of said circuits for
maintaining a predetermined ratio of said liquids flowing to said
first means.
Description
BACKGROUND OF THE INVENTION
It is known that the addition of water in a fine dispersion
throughout hydrocarbon liquid fuels, such as residual oil, prior to
combustion aids the combustion process in that smoke or fine
particles of carbonaceous materials normally emitted with the stack
effluent in contemporary combustion systems are reduced both in
size and quantity. All other factors being equal, such as furnace
configuration, firing rate, and other system parameters, the
addition of water has also been found to reduce certain pollutants
formed in the combustion process such as the oxides of nitrogen.
For example, water has been employed in gas turbines combustion
systems as a carrier fluid in which corrosion inhibiting chemicals
were dissolved and dispersed throughout the fuel by forming an
oil/water emulsion. Generally, the degree of fineness or the size
and dispersion of the water in the fuel influenced the
effectiveness of the inhibiting chemicals in alleviating high
temperature corrosion of the gas turbine components. Water is also
used to depress peak combustion temperatures in gas turbines to
alleviate the formation of oxides of nitrogen caused by the
fixation of atmospheric nitrogen. In some instances, the water is
premixed with the fuel and sufficiently well dispersed to reduce
the carbonaceous particulate discharged by the combustor, and in
other cases the water is introduced separately in which event there
would be little effect on the production of such particulates.
In certain prior art apparatus, such as gas turbine combustion
systems employing fuel-water emulsions, the energy of vaporization
of the water is obtained directly from the combustion process by
exposing the fuel droplets containing the water, and atomized by
conventional means, to the heat of combustion in the furnace. In
such cases the furnace heat penetrates the fuel droplets and
vaporizes the water contained therein before the droplets are
consumed in combustion thus shattering the fuel droplets into
smaller droplets thereby aiding the combustion process. The
secondary atomizing or shattering effect is adequate to obtain some
benefit from a phase change (fluid to vapor) of the auxiliary
secondary fluid or water. In some applications where fine
atomization of a liquid is desired, combustion is not involved and,
therefore, combustion heat is not available for atomization. Also,
in combustion applications where ultra fine atomization and
premixing of the atomized fuel with a gas other than combustion air
or a mixture of a gas and combustion air to obtain a premixed fuel
and gas mixture is desirable, the normally employed sources of
auxiliary fluid vaporizing energy, such as the boiler furnace heat,
as not suitable. An example of the latter type of combustion
application is a staged combustion or partial oxidation process
where it is desirable to premix the atomized, partially vaporized
fuel with combustion air or oxygen and CO.sub.2 and other gases to
optimize combustion and thereby minimize the formation of
carbonaceous particulate and undesirable noxious gases, such as
oxides of nitrogen. Some fuels, such as distillate oils, of which
No. 2 fuel oil is an example, can be totally vaporized by heating
the oil to a sufficiently high temperature prior to combustion. In
the vaporized form, such fuels can easily be premixed with gases or
other vapors. The addition of an auxiliary fluid, such as water, to
create a secondary atomization is not essential, since premixing
can be easily accomplished with vaporized fuels. However, heavier
fuels, such as No. 6 fuel oil or residual fuels, cannot readily be
vaporized prior to combustion simply by heating at the conditions
prevailing in a conventional combustion system.
SUMMARY OF THE INVENTION
An object of the invention is to provide a method and apparatus for
finely atomizing liquids by employing energy stored within the
liquid in the form of an emulsion.
A further object of the invention is to finely atomize heavy fluids
to facilitate certain chemical processes or subsequent physical
processes such as mixing, suspending, dispersing with or in other
fluids or gases.
A still further object of the invention is to atomize fluids which
are normally not easily vaporized to such a fine particle or
droplet size so as to facilitate thorough mixing with a premixing
gas or carrier gases.
Another object of the invention is to provide a method of atomizing
liquid fuels in a combustion process and apparatus which minimizes
pollutant discharge.
A further object of the invention is to provide a combustion method
and apparatus employing relatively heavy or residual liquid fuels
wherein the level of pollutant discharge is relatively low.
Another object of the invention is to provide a combustion method
and apparatus for more effectively atomizing relatively heavy or
residual liquid fuels.
Yet a further object of the invention is to provide a combustion
method and apparatus wherein secondary atomization of a fuel is
accomplished essentially simultaneously with a pressure atomizing
stage.
Another object of the invention is to provide a combustion method
and apparatus which develops fuel droplets of a size small enough
so as to reduce the combustion time of the droplet to less than the
usual time associated with the residence time within a flame zone
so that the flame can behave essentially as if the fuel were
prevaporized thereby reducing the combustion volume of furnace.
Still another object of the invention is to provide a combustion
method and apparatus for controlling the introduction of fuel into
a combustion zone so as to stratify the incoming premixed fuel and
carrier gas from the remainder of the gases in the furnace
zone.
An additional object of the invention is to provide a combustion
method and apparatus wherein atomization of the fuel is
accomplished without a separate auxiliary atomizing fluid or gas
such as steam or air.
A further object of the invention is to atomize a heavy liquid by
producing a water emulsion wherein the amount of water employed for
secondary atomization is minimized.
These and other objects and advantages of the invention will become
more apparent from the detailed description thereof taken with the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically illustrates an embodiment of the present
invention;
FIG. 2 illustrates the operation of the apparatus shown in FIG. 1;
and
FIG. 3 schematically illustrates an alternate embodiment of the
invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 schematically illustrates a fuel supply system 10 for
delivering a fuel and water emulsion to the burner nozzle 11 of a
boiler furnace 12. In general, system 10 includes a fuel delivery
circuit 14 and a water delivery circuit 15 coupled to an emulsifier
16 which is operative to produce a fine dispersion of water in the
fuel. A high pressure pump 18 couples the emulsifier 16 to the
nozzle 11 through a fuel heater 20.
The fuel delivery circuit 14 includes a delivery or fuel transfer
pump 24 and a strainer 25 which are disposed in a conduit 27 which
couples the emulsifier 16 to a fuel source 28. A heater (not shown)
may be disposed in the line 27 or in the tank 28 to heat the fuel
to a temperature of 150.degree. to 250.degree. F. In addition, a
filter circuit 30 consisting of parallel connected filter elements
32 and 33 are connected in conduit 27 through three-way valves 35
and 36 so that the filter elements 32 or 33 may be alternately
disconnected from the system 10 and changed without interrupting
fuel flow to nozzle 11.
The water delivery circuit 15 includes a proportioning pump 40 and
a strainer 42 disposed in conduit 44 which connects the emulsifier
16 to a water source 45. A check valve 46 is located between the
emulsifier 16 and the proportioning pump 40 to prevent backflow
into the pump 40 when the latter is not operating. The output of
pump 40 is regulated to maintain the desired relationship between
water and fuel oil flow by means of a flow meter 47 connected in
fuel supply conduit 27 and a proportioning control circuit 50. The
flow meter 47 may be of any well-known type which is operative to
produce an electrical output signal functionally related to the
flow of fluid in conduit 27. Proportioning control circuit 50 may
also be of any well-known type which is operative to receive the
signals from flow meter 47 and to provide a control signal
functionally related to the flow rate in conduit 27 to a variable
speed motor 51 or a pump displacement varying means in pump 40.
When a variable speed motor is used the motor 51 varies in speed
and hence the output of pump 40 will thus be functionally related
to the flow of fuel in conduit 27. In this manner the delivery of
water to the emulsifier 16 can be maintained at a predetermined
flow volume relative to the delivery rate of fuel through conduit
27.
The emulsifier 16 may comprise any well-known device capable of
producing an emulsion of oil and water. For example, the emulsifier
16 may comprise a dispersator which is a device having a generally
cylindrical metallic tank 56 provided with a plurality of axially
oriented baffles 57 which extend radially inward from the outer
wall and which are spaced from the axis of chamber 56. The oil and
water conduits 27 and 44 are both connected to one end of tank 56
and the emulsion delivery conduit 59 is connected to the outer. An
impeller 60 is disposed in tank 56 and within the inner margins of
the baffles 57 and is supported on the shaft 62 of a drive motor
63. The rotation of impeller 60 within the oil and water and the
interaction with the baffles 57, blends the water and oil so as to
obtain a fine dispersion of water and oil wherein the water
droplets are uniformly distributed throughout the oil. An example
of a dispersator which may be employed in the preferred embodiment
of the invention is a motor driven mixer sold by the Gaulin
Corporation. While a specific emulsifier has been shown and
described, it will be appreciated that any well-known type of
device, such as a homogenizing valve, may be employed.
The high pressure pump 18 is connected in a delivery conduit 59
which is connected at one end to dispersator tank 56 and at its
other to the nozzle 11. A pressure accumulator 63 may be connected
to conduit 59 for dampening pulsations from the high pressure pump
18. In addition, a check valve 64 may also be disposed in conduit
59 to prevent the back flow of fuel from the nozzle 11 and an
on/off valve 65 may be disposed adjacent the heater 20 so that fuel
delivery may be discontinued in the event of an emergency, a flame
failure, or normal shutdown. A drain conduit 67 is connected at one
end to conduit 59 between valve 65 and heater 20 and at its other
end to the fuel source 28 and includes a normally closed dump valve
68 which may be opened to drain heater 20 and nozzle 11 when valve
65 is closed. In addition, a pressure relief valve 70 is connected
to conduit 59 downstream of pump 18 and the drain conduit 67 to
vent conduit 59 in the event of an over pressure in the line 59 to
protect the conduit and the high pressure pump.
The nozzle 11 may be of any well-known type for delivering fuel to
a furnace such as, for example, a variable aperture nozzle whose
discharge opening varies in relation to fuel pressure. The boiler
furnace 12 is schematically illustrated as comprising a furnace
chamber 74 having an opening 75 in one end for receiving the nozzle
11. A hollow throat section 77 extends from opening 75 in
surrounding relation to nozzle 11 and has an opening 76 in its
remote end through which combustion supporting gases, symbolized by
arrows 78, are introduced into the furnace chamber 74. For example,
the gases 78 delivered through the opening 76 may comprise air or a
mixture of air and stack gases, containing carbon dioxide. The
recirculation of stack gases is desirable because when fuel is
consumed in a carbon dioxide rich environment, the emission of
carbonaceous particles is reduced by the combination of carbon
dioxide from the stack gas and the carbon in the gaseous combustion
products to produce carbon monoxide which is further oxidized
downstream to carbon dioxide. In this manner, carbon, which would
otherwise result in visible smoke emitting from the stack, is
substantially oxidized to carbon dioxide. For a more complete
description of a furnace in which stack gases are recirculated,
reference is made to co-pending application Ser. No. 432,623 filed
Jan. 11, 1974 and which is assigned to the assignee of the present
invention.
The heater 20 may be any conventional heat exchanger which is
capable of drawing heat from the boiler or furnace 12 and
transferring the same to the fuel. Preferably, the heater 20 will
be constructed and arranged such that the water/oil emulsion does
not pass through the furnace 12. For example, heater 20 may include
a heat exchanger 80 connected in conduit 59 and which is disposed
externally of the furnace chamber 74. Heat from the furnace 12 may
be transferred to the oil passing through heat exchanger 80 by
means of a heat loop 82 disposed in heat exchange relation with the
hot gases within the furnace chamber 74 and which is connected to
heat exchanger 80.
While it will be appreciated that the invention may be employed
with any liquid fuel, it has particular application to relatively
heavy residual fuels, such as No. 6 fuel oil, which are not
normally burned in conventional oil burners because they tend to
produce high levels of pullutants such as unburned hydrocarbons,
particulate matter and nitrogen oxides in the discharge gases.
Typically, No. 6 residual oil contains 0.3 percent by weight
nitrogen and otherwise may have the following analysis:
Flash Point, deg. F No flash point; (Pensky-Mardens Closed Cup)
vapors support combustion Pour Point, deg. F 30 Water and Sediment,
%v. 1.2 Viscosity at 100 Deg. F, SUS 2,522 API Gravity at 60 deg. F
8.6 Carbon, % 86.87 Hydrogen, % 9.80 Sulfur, % 2.40 Nitrogen, % 0.3
Ash, % 0.061 BTU, Gross per lb. 17,706 per gal. 148,842 BTU, Net
per lb. 16,811 per gal. 146,414
In operation of the system illustrated in FIG. 1, the fuel will be
drawn from source 28 and through strainer 25 by transfer pump 24
for delivery to the dispersator tank 56 through one of the filter
cartridges 32 or 33, depending upon the setting of valves 35 and
36. It will be appreciated that the fuel pump 18 will include
conventional means, not shown, for controlling the fuel flow rate
in accordance with the combustion condition in furnace 12. One such
means would be a variable speed drive on the pump 18. Simultaneous
with the delivery of fuel, the proportioning pump 40 will draw
water from tank 45 and through strainer 44 for delivery to
dispersator tank 56. Flow meter 47 will sense the flow rate of oil
through conduit 27 and will adjust the displacement of the
proportioning pump 40 through control circuit 50 so that the
proportion of oil and water delivered to the dispersator tank 56
will follow a pre-established schedule. In addition, the
dispersator motor 63 will be energized to rotate impeller 60 and
thereby produce a dispersion of water droplets within the oil.
Typically, this dispersion may be as follows:
Range Mid Range Percent Diameter Diameter Percent Frequecny of
Microns Microns By Volume Occurrence
______________________________________ 0 to 4 2 10.0 53 4 to 8 6
75.0 45 8 to 12 10 15.0 2
______________________________________
Upon exiting the dispersator tank 56 through conduit 59, the
emulsion is pressurized to a level from 2,500 to 10,000 psig but
preferably in the order of 4,000 psig, by the high pressure pump
18. The emulsion is then passed through heat exchanger 85 where it
is heated prior to delivery to the nozzle 11.
Thermodynamically, the fuel injection cycle is illustrated in FIG.
2. The high pressure pump 18 is adjusted to deliver fuel at the
desired flow to the nozzle 11 at the pre-determined by design
pressure for example, about 3,500 psig. The difference between the
actual pump 18 discharge pressure and the pressure at the nozzle 11
represents the pressure losses in the conduit 59 and the heater 20,
which would not normally exceed about 500 psi so that the pump
discharge would not normally exceed about 4,000 psig. The
predetermined pressure at the fuel nozzle is selected to avoid
flashing of high pressure water into steam or the light hydrocarbon
components of the fuel into vapor at any point in the system prior
to the nozzle. This is accomplished by pressurizing well above the
critical point of water. The high operating temperature limits of
the emulsion are establihsed by the characteristics of the fluid
being atomized and the dwell time in the system after heating. The
volume of the hot portion of the system is held to a minimum to
minimize the dwell time thereby avoiding deposits in the conduits.
With No. 6 oil, temperatures of about 450.degree. to 700.degree.F
were found to work well in that no appreciable quantity of deposits
were found in the high pressure lines providing the pressure on the
system is maintained at a sufficiently high level to prevent
vaporization of the water and flashing of the lighter fuel
components into vapor; i.e., a phase change from liquid to vapor or
gas. It is known that if Benzene were used as a secondary fluid the
temperature levels of 1,000.degree. to 1,200.degree. F would be
possible if the Benzene did not contain contaminants in any
appreciable quantity.
The lower temperature limit is established by the following
considerations: The equipment available as previously indicated
provides a mean water droplet distribution of from 2 to 4 microns.
The amount of expansion of the water droplet in the oil subjected
to a fixed pressure drop is determined by the initial pressure and
the temperature of the emulsion for a given nozzle and furnace
design. Pressure in most installations is obtained from shaft power
such as an electric motor which is a high grade of energy whereas
heat energy or temperature can frequently be obtained from exhaust
or waste heat sources. It is, therefore, of economic advantage to
minimize pressure rise and to operate with the emulsion at the
highest possible temperature. That portion of the water which is
converted to stem in passing through the nozzle, all other factors
including pressure being equal, is a function of the emulsion
temperature. The lower the temperature, the lower the conversion
rate and the poorer the atomization efficiency. To obtain the
desired results, the system is preferably designed so that the
water in the emulsion will be present in sufficient quantity in
each drop of fuel so as to expand and shatter the "oversize" drop
to smaller acceptable drop sizes. While increasing the quantity of
water in the emulsion is a substitute for higher temperatures and
pressures, increased water will increase the vapor in the exhaust
effluent increasing the cycle losses and reducing the overall
combustion efficiency of the system.
A portion of residual oils consists of high molecular parafinic and
aeromatic materials. These components go through a phase change
above normal ambient temperatures causing a substantial change in
the viscosity of residual fuel. Depending on the characteristics of
the fuel the change occurs for typical residual or No. 6 fuel oil
at temperatures above 400.degree. F. In some instances it was found
that excellent atomization of the fuel could be obtained simply by
pressurizing and heating without adding water providing the oil was
heated above the transition temperature of the bulk of the long
chain molecules or high molecular weight materials and pressurized
sufficiently to avoid vaporization of the lighter constituents
prior to passing through the atomization nozzle. The lower
temperature limit is, therefore, established by:
1. The water distribution in the emulsion (size of water droplets
and dispersion);
2. The quantity of water used;
3. The furnace pressure;
4. The characteristics of the nozzle;
5. The characteristics of the fuel (transition or phase change
temperatures of the long chain molecules); and
6. The delivery pressure of the emulsion to the fuel nozzle. In
practice, temperatures of 500.degree.F and above have been found to
work well with 5 percent to 10 percent water and a furnace at
atmospheric pressure, burning No. 6 residual oil having the
analysis set forth above. It is believed that at temperatures in
the order of 550.degree.F and above, a phase change from liquid to
vapor occurs not only in the water but also in the lighter
constituents of the fuel. This facilitates the atomization process
and indicates that under appropriate temperature and pressure
conditions, at least some atomization probably could be achieved
without the use of water.
Atomization, in varying degrees, can be achieved over a range of
parameters such as, for example, a temperature range of about
450.degree. - 700.degree. F, a pressure range of about 2,000-10,000
psi and a fuel to water ratio of about 5:1 to 25:1.
Again referring to FIG. 2, which is the partial enthalpy entropy
diagram of water/steam, reference numeral 100 represents the pump
discharge conditions shown at a pressure somewhat above the heater
inlet conditions represented by reference numeral 101, to account
for the pressure drop in the system between the pump 40 and the
heater 20. Heat is added in the heater 20 essentially at constant
pressure. The emulsion, containing the water, is then delivered to
the nozzle at the selected temperature point represented by
reference numeral 102 and the water-fuel mixture expands to the
choking point of nozzle 11 and the water approaches the isentropic
curve or constant entropy. Assuming a temperature of 700.degree. F
and a pressure of 3,500 psi water, the pressure at the choking
point in the nozzle would be approximately 2,000 psi with about 50
percent of the water converted to steam at the point represented by
reference numeral 103. As the expanding oil droplets leave the
nozzle 11, the action is not fully understood, however, it is
believed that initially the process will be polytropic with some
heat being rejected to the surroundings, dropping the temperature
to a point represented by reference numeral 104 in FIG. 2. As the
process continues and the steam continues to expand, heat will be
absorbed from the surroundings in the case of a furnace until point
105 is reached wherein the process becomes essentially constant
pressure at the partial pressure of the water vapor in the furnace,
which is approximately 2 psia for the conditions previously
described. The temperature of the vapor will continue to rise
reaching the combustion temperature of the furnace 106. The bulk of
the secondary atomizing is believed to occur between points 103 and
104 in FIG. 2 where a rapid expansion of the steam shatters the oil
droplets.
An alternate embodiment of the invention is shown in FIG. 3 wherein
the water and fuel emulsion is delivered to the fuel nozzles 130 of
a gas turbine, not shown. While the gas turbine may include ten or
more such nozzles, only three are illustrated for the sake of
simplicity. The fuel and water delivery circuits 14 and 15, of FIG.
3, are substantially the same as that shown in FIG. 1. A heater 131
may be disposed in fuel delivery conduit 27 of the dispersator 16.
The heater 131, which may be electrical, for example, elevates the
temperature of the oil from fuel source 28 to approximately
150.degree. - 250.degree.F. In addition, a pressure relief valve
132 may be provided downstream of the heater 131 so that in the
event of deposits or a failure, for example, the valve 132 will
dump the oil flow into the return conduit 67. A pressure regulating
valve 134 may also be provided downstream of the heater 131 to
prevent excess pressure from damaging the dispersator 16 and the
suction seals of the high pressure pump 18. Normally, fuel flows
from the discharge of heater 132 through the pressure regulating
valve 134 and the flow meter 47 to the dispersator 16. The emulsion
is pressurized and metered by pump 18 and passes through heater 20
in the manner described with respect to the embodiment of FIG. 1,
prior to passage to a flow divider 136 where the flow is divided
equally between the combustion chamber fuel nozzles 130 of the gas
turbine. The flow divider 136 may be any well-known type, such as
the electric motor driven flow divider manufactured by General
Electric Company for stationary gas turbines.
While the apparatus of FIGS. 1 and 3 have been discussed in
relation to variable metering pumps and orifices, it will be
appreciated that the system is also operative with fixed flows and
settings.
It will be appreciated that the process and apparatus discussed
with respect to FIGS. 1-3 facilitates the atomization of liquids,
such as residual fuels, that cannot readily be vaporized for the
purpose of accelerating chemical reactions or carrying such
reactions closer to completion in a shorter time interval. The
fluid is finely atomized to a sufficiently small droplet size so as
to insure thorough mixing with a gas, or in the case of a
combustion process, a mixture of air and carbon dioxide or simply
air. In a combustion process such as a mixture of gases, vapor and
finely atomized fuel will burn in a manner which is substantially
equivalent to a completely vaporized fuel with combustion
supporting gases. Such mixing of the atomized fuel with air and
perhaps carbon dioxide as well as other products of hydrocarbon
combustion and air may occur prior to the introduction of the
mixture into the furnace zone. That portion of the fuel which is
not vaporized is so finely atomized as to be easily suspended in
the premixing gas. By providing relatively smaller droplets which
are further subdivided by the water vaporization, the combustion
reaction volume of the furnace is reduced by allowing the
combustion process of finely divided fluid droplets to be so rapid
that a flame can behave as if the fuel was prevaporized allowing a
substantial reduction in furnace volume. Further, by reducing the
droplet size, the size of long chain carbon particles formed in
liquid reactions are minimized thus reducing the dwell time
necessary for the resulting particles to be oxidized. In addition,
the use of a water emulsion in the early stages of combustion
promotes the further reduction of carbon particulate in the
effluent from the combustion process by the well-known reaction of
carbon and water which provides carbon monoxide and hydrogen. It
will additionally be appreciated that the need for a separate
auxiliary atomizing fluid such as air or steam as employed in
conventional fluid atomizers is eliminated since the pressurized
emulsion contains sufficient energy for atomization when the fluid
is released from the nozzle 11.
While the atomization method and apparatus have been discussed in
relation to a combustion process, it will be appreciated that it
also has application to other processes wherein fine atomization of
liquids is required. For example, in the production of manufactured
gas from heavy liquid fuel, such as No. 6 oil, fuel, steam and
oxygen are initially passed through a reactor which may contain a
suitable catalyst to form CO, H.sub.2, CH.sub.4, other
hydrocarbons, residual carbon particles and other gases. Such
processes are accelerated and the quantity of carbon particulate
produced is reduced if the oil is finely atomized in the manner
described with respect to the combustion process depicted by FIGS.
1-3. Also, while the invention is described in relation to the use
of an emulsion of water and oil for the purpose of atomizing the
oil, it will be appreciated that many fluids could be substituted
for water and oil to achieve these results.
While only a few embodiments of the invention have been illustrated
and described, it is not intended to be limited thereby but only by
the scope of the appended claims.
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