A FLUID MIXER AND A METHOD FOR MIXING FLUIDS

Abstract

A fluid mixer for a reactor of a hydrocarbon processing plant includes a substantially cylindrical mixing chamber, at least one first inlet for conducting first fluid to the mixing chamber from above the mixing chamber and along a side wall of the mixing chamber to produce a spiral stream in the mixing chamber, at least one second inlet for conducting second fluid tangentially into the spiral stream, and an outlet channel for conducting the first and second fluids downwards out from the mixing chamber. The outlet channel is concentric to the mixing chamber and includes a mixing structure for enhancing mixing of the first and second fluids. At least a part of the mixing structure is located below an upper edge of the outlet channel and produces turbulence in a stream of the first and second fluids flowing in the outlet channel.

Claims

1. A fluid mixer comprising: a frame structure defining a mixing chamber and at least one first inlet configured for conducting a first fluid to the mixing chamber from above the mixing chamber, the mixing chamber being substantially cylindrical, and the at least one first inlet being shaped to conduct the first fluid along a side wall of the mixing chamber to produce a spiral stream in the mixing chamber; at least one second inlet configured for conducting a second fluid tangentially into the spiral stream, each opening of the at least one second inlet being inside the mixing chamber and a distance away from the side wall of the mixing chamber to reduce concentration of the second fluid at the side wall of the mixing chamber; and an outlet channel configured for conducting the first and second fluids downwards out from the mixing chamber, the outlet channel being concentric to the mixing chamber, wherein the outlet channel includes a mixing structure configured for producing turbulence in a stream of the first and second fluids when flowing in the outlet channel, at least a part of the mixing structure being located below an upper edge of the outlet channel.

2. A fluid mixer according to claim 1, wherein the mixing structure is located below a bottom of the mixing chamber.

3. A fluid mixer according to claim 1, wherein the mixing structure is configured to implement one or more stepwise reductions of a cross-sectional flow area of the outlet channel.

4. A fluid mixer according to claim 3, wherein a wall of the outlet channel is shaped to implement at least one stepwise reduction of the cross-sectional flow area of the outlet channel.

5. A fluid mixer according to claim 4, wherein the mixing structure comprises: a loop-shaped mixing ridge on an upwards facing surface of the outlet channel, the upwards facing surface being configured implementing the stepwise reduction of the cross-sectional flow area of the outlet channel.

6. A fluid mixer according to claim 1, wherein the mixing structure comprises: a mixing element mechanically supported inside the outlet channel and shaped to produce turbulence in the stream of the first and second fluids flowing in the outlet channel.

7. A fluid mixer according to claim 1, wherein the outlet channel comprises: a loop-shaped ridge on a bottom of the mixing chamber, the loop-shaped ridge constituting an upper portion of the outlet channel, and an upper rim of the loop-shaped ridge constituting the upper edge of the outlet channel.

8. A fluid mixer according to claim 1, wherein the outlet channel is substantially circularly symmetric with respect to a vertical geometric line.

9. A fluid mixer according to claim 1, wherein the at least one first inlet is shaped to descend to the mixing chamber in a form of a curved ramp.

10. A fluid mixer according to claims 1-9, wherein the at least one second inlet comprises: a tube protruding radially from the side wall of the mixing chamber towards a center of the mixing chamber and having one or more openings configured for passing the second fluid tangentially into the spiral stream.

11. A fluid mixer according to claim 10, wherein the tube is curved so that an end of the tube is tangential for passing the second fluid tangentially into the spiral stream.

12. A fluid mixer according to claim 10, wherein the tube has a closed end, and a side wall of the tube has the one or more openings for passing the second fluid tangentially into the spiral stream.

13. A fluid mixer according to claim 1, wherein the at least one second inlet comprises: one or more protrusions located on a bottom of the mixing chamber, each being provided with an opening configured for passing the second fluid tangentially into the spiral stream.

14. A fluid mixer according to claim 13, wherein the one or more protrusions are located at a place of the bottom of the mixing chamber where the at least one first inlet is configured to join the mixing chamber.

15. A fluid mixer according to claim 1, wherein the at least one first inlet is one of at least two first inlets placed substantially equidistantly on a periphery of the mixing chamber.

16. A fluid mixer according to claim 1, wherein the second inlet is one of at least two second inlets placed substantially equidistantly on a periphery of the mixing chamber.

17. A reactor for a hydrocarbon processing plant, the reactor comprising: a reactor vessel; catalytic beds inside the reactor vessel; and at least one fluid mixer inside the reactor vessel and between successive ones of the catalytic beds wherein the at least one fluid mixer includes: a frame structure defining a mixing chamber and at least one first inlet for conducting first fluid to the mixing chamber from above the mixing chamber, the mixing chamber being substantially cylindrical, and the at least one first inlet being shaped to conduct the first fluid along a side wall of the mixing chamber to produce a spiral stream in the mixing chamber; at least one second inlet for conducting second fluid tangentially into the spiral stream, each opening of the at least one second inlet being inside the mixing chamber and a distance away from the side wall of the mixing chamber to reduce concentration of the second fluid at the side wall of the mixing chamber; and an outlet channel for conducting the first and second fluids downwards out from the mixing chamber, the outlet channel being concentric to the mixing chamber and the outlet channel including a mixing structure for producing turbulence in a stream of the first and second fluids flowing in the outlet channel, at least a part of the mixing structure being located below an upper edge of the outlet channel.

18. A reactor according to claim 17, wherein the reactor is a hydrodeoxygenation reactor.

19. A method comprising: conducting a first fluid, via at least one first inlet, to a mixing chamber from above the mixing chamber, the mixing chamber being substantially cylindrical and the first fluid being conducted along a side wall of the mixing chamber to produce a spiral stream in the mixing chamber; conducting a second fluid, via at least one second inlet, tangentially into the spiral stream, each opening of the at least one second inlet being inside the mixing chamber and a distance away from the side wall of the mixing chamber to reduce concentration of the second fluid at the side wall of the mixing chamber; and conducting, via an outlet channel concentric to the mixing chamber, the first and second fluids downwards out from the mixing chamber wherein the outlet channel includes a mixing structure located at least partly below an upper edge of the outlet channel and producing turbulence in a stream of the first and second fluids flowing in the outlet channel.

20. A method according to claim 19, comprising: conducting the first fluid to the mixing chamber from a bottom of a first catalytic bed of a reactor, and conducting a mixture of the first and second fluids to a top of a second catalytic bed of the reactor.

21. A fluid mixer according to claim 2, wherein the mixing structure is configured to implement one or more stepwise reductions of a cross-sectional flow area of the outlet channel.

22. A fluid mixer according to claim 21, wherein a wall of the outlet channel is shaped to implement at least one stepwise reduction of the cross-sectional flow area of the outlet channel.

23. A fluid mixer according to claim 22, wherein the mixing structure comprises: a loop-shaped mixing ridge on an upwards facing surface of the outlet channel, the upwards facing surface implementing the stepwise reduction of the cross-sectional flow area of the outlet channel.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0023] Exemplifying and non-limiting embodiments of the invention and their advantages are explained in greater details below in the sense of examples and with reference to the accompanying drawings, in which:

[0024] FIG. 1 illustrates a reactor that comprises a fluid mixer according to an exemplifying and non-limiting embodiment,

[0025] FIGS. 2a and 2b illustrate a fluid mixer according to an exemplifying and non-limiting embodiment,

[0026] FIG. 3 illustrates a part of a fluid mixer according to an exemplifying and non-limiting embodiment,

[0027] FIGS. 4a and 4b illustrate of a fluid mixer according to an exemplifying and non-limiting embodiment,

[0028] FIGS. 5a, 5b, and 5c illustrate details of fluid mixers according to exemplifying and non-limiting embodiments, and

[0029] FIG. 6 shows a flowchart of a method according to an exemplifying and non-limiting embodiment for mixing fluids in a reactor of a hydrocarbon processing plant.

DESCRIPTION OF EXEMPLIFYING EMBODIMENTS

[0030] The specific examples provided in the description below should not be construed as limiting the scope and/or the applicability of the accompanied claims. Lists and groups of examples provided in the description are not exhaustive unless otherwise explicitly stated.

[0031] FIG. 1 shows a schematic section view of a reactor that comprises a fluid mixer 101 according to an exemplifying and non-limiting embodiment. The section plane is parallel with the xz-plane of a coordinate system 199. The reactor can be for example a hydrotreatment reactor such as e.g. a hydrodeoxygenation “HDO” reactor, a hydrodesulphurization “HDS” reactor, a hydrodenitrogenation “HDN” reactor, or a hydrodechlorination “HDCl” reactor. The reactor comprises a reactor vessel 117 that contains a first catalyst bed 118 and a second catalyst bed 119. The reactor comprises an inlet pipe 122 for receiving first fluid that enters a distribution tray 120 that distributes the first fluid evenly over the cross section of the first catalyst bed 118. The fluid mixer 101 is located below the first catalyst bed 118 and thus the fluid mixer 101 receives the first fluid that is processed within the first catalyst bed 118 and trickles through the first catalyst bed 118. The reactor comprises an inlet pipe 106 through which second fluid is fed to the fluid mixer 101. The first and second fluids are mixed in the fluid mixer 101 and the mixture of the first and second fluids enters a distribution tray 121 that distributes the mixture of the first and second fluids evenly over the cross section of the second catalyst bed 119. The reactor comprises an outlet pipe 123 through which product of the treatment process exits the reactor. In an exemplifying case where the reactor is a hydrodeoxygenation “HDO” reactor, the first fluid fed to the inlet pipe 122 may comprise a mixture of fresh feed substances and the product of the hydrodeoxygenation process so that a part of a material flow coming out from the outlet pipe 123 is fed back to the inlet pipe 122. The fresh feed substances may comprise e.g. plant oils, plant fats, animal oils, and/or animal fats. The second fluid that is fed to the inlet pipe 106 may comprise the fresh feed substances. The second fluid may also act as temperature control medium with the aid of which the temperature of the treatment process can be controlled at least partly. More than two catalyst beds may also be used so that there is a fluid mixer between successive ones of the catalyst beds. The number of fluid mixers is typically N−1 where N is the number of catalyst beds.

[0032] The fluid mixer 101 is illustrated in more details in FIGS. 2a and 2b. In this exemplifying case, the fluid mixer 101 comprises a frame structure that has an upper section 201 and a lower section 202. FIG. 2b shows the fluid mixer without the upper section 201. The frame structure defines a mixing chamber 203 and first inlets 204 and 205 for conducting the first fluid to the mixing chamber 203 from above the mixing chamber 203. As shown in FIG. 2b, the mixing chamber 203 is substantially cylindrical and the first inlets 204 and 205 are shaped to conduct the first fluid along a side wall of the mixing chamber 203 to produce a spiral stream in the mixing chamber 203. In this exemplifying case, the first inlets 204 and 205 are placed equidistantly on the periphery of the mixing chamber 203 so that the first inlets 204 and 205 are on opposite sides of the mixing chamber 203. The fluid mixer comprises second inlets 206 and 207 for conducting the second fluid tangentially into the spiral stream. The second inlets 206 and 297 are connected to inlet pipes shown in FIG. 1 so that e.g. the second inlet 206 is connected to the inlet pipe 106. As illustrated in FIG. 2b, each opening of the second inlets is a distance away from the side wall of the mixing chamber 203 to reduce concentration of the second fluid at the side wall of the mixing chamber. In FIG. 2b, one of the openings of the second inlets is denoted with a reference 216. In this exemplifying fluid mixer, the second inlets 206 and 207 are placed equidistantly on the periphery of the mixing chamber 203 so that the second inlets 206 and 207 are on opposite sides of the mixing chamber 203. In this exemplifying case, each of the second inlets 206 and 207 comprises a tube protruding radially from the side wall of the mixing chamber 203 towards the center of the mixing chamber 203, wherein the tube has a closed end and a side wall of the tube has the openings for passing the second fluid tangentially into the spiral stream occurring in the mixing chamber 203.

[0033] The fluid mixer 101 comprises an outlet channel 208 that is substantially concentric to the mixing chamber 203 and conducts the first and second fluids downwards out from the mixing chamber 203. The outlet channel 208 comprises a mixing structure 209 that is located below the upper edge of the outlet channel 208 and that produces turbulence in a stream of the first and second fluids flowing in the outlet channel 208. In this exemplifying case, the mixing structure 209 is a stepwise reduction of the cross-sectional flow area of the outlet channel so that the stepwise reduction is located below the bottom of the mixing chamber 203. According to computer simulations, the stepwise reduction of the cross-sectional flow area improves the mixing effect so that the maximum local concentration of the second fluid is about 10% less than when using a corresponding fluid mixer without the stepwise reduction of the cross-sectional flow area in an exemplifying test case where the amount of the second fluid is about 15 weight-% of the mixture of the first and second fluids i.e. in ideal mixing the concentration of the second fluid would be about 15 weight-% all over the mixture.

[0034] FIG. 3 illustrates a part of a fluid mixer according to an exemplifying and non-limiting embodiment. The fluid mixer comprises a mixing chamber 303 and a first inlet 304 for conducting first fluid to the mixing chamber 303 from above the mixing chamber. The mixing chamber 303 is substantially cylindrical and the first inlet 304 is shaped to conduct the first fluid along a side wall of the mixing chamber 303 to produce a spiral stream in the mixing chamber 303. The fluid mixer comprises a second inlet 306 for conducting second fluid tangentially into the spiral stream. As shown in FIG. 3, an opening 316 of the second inlet 306 is a distance away from the side wall of the mixing chamber 303 to reduce concentration of the second fluid at the side wall of the mixing chamber 303. In this exemplifying case, the second inlet 306 comprises a tube protruding radially from the side wall of the mixing chamber 303 towards the center of the mixing chamber 303, wherein the tube is curved so that an end of the tube is tangential for passing the second fluid tangentially into the spiral stream occurring in the mixing chamber 303.

[0035] The fluid mixer comprises an outlet channel 308 that is substantially concentric to the mixing chamber 303 and conducts the first and second fluids downwards out from the mixing chamber 303. The outlet channel 308 comprises a mixing structure 309 that is located below the upper edge of the outlet channel 308 and that produces turbulence in a stream of the first and second fluids flowing in the outlet channel 308. In this exemplifying case, the mixing structure 309 is a stepwise reduction of the cross-sectional flow area of the outlet channel so that the stepwise reduction is located substantially in flush with the bottom of the mixing chamber 303. In this exemplifying case, the outlet channel 308 comprises a loop-shaped ridge 310 on the bottom of the mixing chamber 303. The loop-shaped ridge 310 constitutes an upper portion of the outlet channel 308 and thus the upper rim of the loop-shaped ridge 310 constitutes the upper edge of the outlet channel 308.

[0036] FIG. 4 illustrates a part of a fluid mixer according to an exemplifying and non-limiting embodiment. The fluid mixer comprises a mixing chamber 403 and a first inlet 404 for conducting first fluid to the mixing chamber 403 from above the mixing chamber 403. The mixing chamber 403 is substantially cylindrical and the first inlet 404 is shaped to conduct the first fluid along a side wall of the mixing chamber 403 to produce a spiral stream in the mixing chamber 403. The fluid mixer comprises a second inlet 406 for conducting second fluid tangentially into the spiral stream. In this exemplifying fluid mixer, the second inlet 406 comprises protrusions on the bottom of the mixing chamber 403. Each of the protrusions is provided with an opening for passing the second fluid tangentially into the spiral stream. In this exemplifying case, the protrusions are located at a place of the bottom of the mixing chamber 403 where the first inlet 404 joins the mixing chamber 403. FIG. 4 shows a magnified section view of one of the protrusions. The section plane is parallel with the xz-plane of a coordinate system 499.

[0037] The fluid mixer comprises an outlet channel 408 that is substantially concentric to the mixing chamber 403 and conducts the first and second fluids downwards out from the mixing chamber 403. The outlet channel 408 comprises a mixing structure 409 that is located below the upper edge of the outlet channel and that produces turbulence in a stream of the first and second fluids flowing in the outlet channel 408. In this exemplifying case, the outlet channel 408 is like the outlet channel 208 of the fluid mixer 101 shown in FIGS. 2a and 2b.

[0038] In the exemplifying fluid mixers illustrated in FIGS. 2a, 2b, 3, and 4, the outlet channels are substantially circularly symmetric with respect to a vertical geometric line. It is however also possible that an outlet channel of a fluid mixer according to an exemplifying and non-limiting embodiment has a non-circular cross-sectional shape, e.g. oval, polygon, etc. In the exemplifying fluid mixers illustrated in FIGS. 2a, 2b, 3, and 4, each first inlet is shaped to descend to the mixing chamber in a form of a curved ramp. It is however also possible that each first inlet of a fluid mixer according to an exemplifying and non-limiting embodiment is implemented with a curved tube for producing a spiral stream in a mixing chamber. The exemplifying fluid mixer illustrated in FIGS. 2a and 2b comprises two first inlets and two second inlets, whereas the exemplifying fluid mixer illustrated in FIG. 3 comprises one first inlet and one second inlet. It is also possible that a fluid mixer according to an exemplifying and non-limiting embodiment comprises three or more first inlets and/or three of more second inlets.

[0039] FIGS. 5a, 5b, and 5c show section views of outlet channels of fluid mixers according to exemplifying and non-limiting embodiments. The section plane is parallel with the yz-plane of a coordinate system 599. FIG. 5a shows an outlet channel 508a that comprises a mixing structure 509a that is located below the upper edge of the outlet channel 508a and produces turbulence in a stream of fluids flowing in the outlet channel 508a. The mixing structure 509a comprises a loop-shaped mixing ridge 514 on an upwards facing surface 515 of the outlet channel 508a, where the upwards facing surface 515 implements a stepwise reduction of the cross-sectional flow area of the outlet channel 508a. FIG. 5b shows an outlet channel 508b that comprises a mixing structure 509b that is located below the upper edge of the outlet channel 508b and produces turbulence in a stream of fluids flowing in the outlet channel 508b. The mixing structure 509b comprises loop-shaped mixing ridges 511 on a vertical surface of the outlet channel 508b. The loop-shaped mixing ridges 511 implement two stepwise reductions and two stepwise expansions of the cross-sectional flow area of the outlet channel 508b. FIG. 5c shows an outlet channel 508c that comprises a mixing structure 509c that produces turbulence in a stream of fluids flowing in the outlet channel 508c. The mixing structure 509c comprises a mixing element 512 mechanically supported inside the outlet channel 508c and implementing at least one stepwise reduction of the cross-sectional flow area of the outlet channel 508c. In this exemplifying case, the mixing element 512 is located below the upper edge of the outlet channel 508c. It is however also possible that only a part of the mixing element is below the upper edge of the outlet channel 508c. As shown in FIG. 5c, there are bar-shaped support elements in the outlet channel 508c so that the support elements mechanically support the mixing element 512. One of the support elements is denoted with a reference 513. The support elements may also improve the mixing.

[0040] It is to be noted that the above-presented mixing structures are non-limiting examples only, and many different mechanical shapes and arrangements can be used for producing turbulence in a stream of fluids flowing in an outlet channel of a fluid mixer. For example, it is possible to implement a combination of one or more of the above-presented mixing structures.

[0041] FIG. 6 shows a flowchart of a method according to an exemplifying and non-limiting embodiment for mixing fluids in a reactor of a hydrocarbon processing plant. The method comprises: [0042] action 601: conducting first fluid, via at least one first inlet, to a mixing chamber from above the mixing chamber, the mixing chamber being substantially cylindrical and the first fluid being conducted along a side wall of the mixing chamber to produce a spiral stream in the mixing chamber, [0043] action 602: conducting second fluid, via at least one second inlet, tangentially into the spiral stream, each opening of the second inlet being a distance away from the side wall of the mixing chamber to reduce concentration of the second fluid at the side wall of the mixing chamber, and [0044] action 603: conducting, via an outlet channel concentric to the mixing chamber, the first and second fluids downwards out from the mixing chamber, wherein the outlet channel comprises a mixing structure located at least partly below the upper edge of the outlet channel and producing turbulence in a stream of the first and second fluids flowing in the outlet channel.

[0045] In a method according to an exemplifying and non-limiting embodiment, the first fluid flows to the mixing chamber from a bottom of a first catalytic bed of the reactor and a mixture of the first and second fluids is conducted to a top of a second catalytic bed of the reactor. In an exemplifying case where the reactor comprises three or more catalytic beds, the above-mentioned first and second catalytic beds can be any two successive catalytic beds of the reactor. Furthermore, the method can be carried out between each successive two of the catalytic beds.

[0046] In a method according to an exemplifying and non-limiting embodiment, the mixing structure is located below the bottom of the mixing chamber.

[0047] In a method according to an exemplifying and non-limiting embodiment, the mixing structure implements one or more stepwise reductions of the cross-sectional flow area of the outlet channel.

[0048] In a method according to an exemplifying and non-limiting embodiment, a wall of the outlet channel is shaped to implement at least one stepwise reduction of the cross-sectional flow area of the outlet channel.

[0049] In a method according to an exemplifying and non-limiting embodiment, the mixing structure comprises a loop-shaped mixing ridge on an upwards facing surface of the outlet channel, where the upwards facing surface implements a stepwise reduction of the cross-sectional flow area of the outlet channel.

[0050] In a method according to an exemplifying and non-limiting embodiment, the mixing structure comprises a mixing element mechanically supported inside the outlet channel and implementing at least one stepwise reduction of the cross-sectional flow area of the outlet channel.

[0051] In a method according to an exemplifying and non-limiting embodiment, the outlet channel comprises a loop-shaped ridge on the bottom of the mixing chamber, where the loop-shaped ridge constitutes an upper portion of the outlet channel and the upper rim of the loop-shaped ridge constitutes the upper edge of the outlet channel.

[0052] In a method according to an exemplifying and non-limiting embodiment, the outlet channel is substantially circularly symmetric with respect to a vertical geometric line.

[0053] In a method according to an exemplifying and non-limiting embodiment, the first inlet is shaped to descend to the mixing chamber in a form of a curved ramp.

[0054] In a method according to an exemplifying and non-limiting embodiment, the second inlet comprises a tube protruding radially from the side wall of the mixing chamber towards the center of the mixing chamber and having one or more openings for passing the second fluid tangentially into the spiral stream. The tube can be for example curved so that an end of the tube is tangential for passing the second fluid tangentially into the spiral stream. For another example, the tube can have a closed end and a side wall of the tube can have one or more openings for passing the second fluid tangentially into the spiral stream.

[0055] In a method according to an exemplifying and non-limiting embodiment, the second inlet comprises one or more protrusions located on the bottom of the mixing chamber and each being provided with an opening for passing the second fluid tangentially into the spiral stream. The one or more protrusions can be located for example at a place of the bottom of the mixing chamber where the first inlet joins the mixing chamber.

[0056] In a method according to an exemplifying and non-limiting embodiment, the first inlet is one of at least two first inlets placed substantially equidistantly on the periphery of the mixing chamber.

[0057] In a method according to an exemplifying and non-limiting embodiment, the second inlet is one of at least two second inlets placed substantially equidistantly on the periphery of the mixing chamber.

[0058] The specific examples provided in the description given above should not be construed as limiting. Therefore, the invention is not limited merely to the exemplifying and non-limiting embodiments described above. Lists and groups of examples provided in the description are not exhaustive unless otherwise explicitly stated.