Abstract:
A system for processing one or more materials includes a processor having a shell defining a chamber and a plurality of serially stacked pipe assemblies. Each pipe assembly includes a header having at least one substantially straight pipe section receiving a fluid; and a plurality of nozzles in fluid communication with and projecting downwardly from the header. The nozzles direct the fluid into the chamber of the processor.

Description:
BACKGROUND 
       [0001]    1. Field 
         [0002]    Embodiments described herein generally relate to systems and methods for processing materials. 
         [0003]    2. Description of the Related Art 
         [0004]    Fluidized bed reactors are representative of devices used to perform any number of chemical reactions. Conventionally, fluidized bed reactors include a shell or containment chamber in which a solid granular material (e.g., a catalyst) is deposited. A hot fluid, which can be a fluid, liquid, or mixtures thereof, and which can include entrained particles, is passed through the granular material at a sufficiently high velocity to cause the solids to behave as a fluid. 
         [0005]    There is a continuing need for new apparatus and methods for enhancing the fluid and solids interaction in fluidized bed reactors and other situations where fluides and one or more secondary materials are contacted with one another. 
       SUMMARY 
       [0006]    In aspects, the present disclosure provides a system for processing one or more materials. The system may include a processor having a shell defining a chamber. The system also includes a plurality of serially stacked pipe assemblies. Each pipe assembly may include a header having at least one substantially straight pipe section receiving a fluid; and a plurality of nozzles in fluid communication with and projecting downwardly from the header, the plurality of nozzles directing fluid into the chamber of the processor. In arrangements, the plurality of nozzles may be evenly circumferentially distributed around the shell. In further arrangements, the plurality of nozzles may be arranged to form a plurality of axially-spaced apart circumferential sets. In some embodiments, the system may include a dual layer refractory system associated with each of the pipe assemblies. 
         [0007]    It should be understood that examples of the more important features of the disclosure have been summarized rather broadly in order that the detailed description thereof that follows may be better understood, and in order that the contributions to the art may be appreciated. There are, of course, additional features of the disclosure that will be described hereinafter and which will in some cases form the subject of the claims appended thereto. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    For detailed understanding of the present disclosure, references should be made to the following detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings, in which like elements have been given like numerals and wherein: 
           [0009]      FIG. 1  depicts aside view of processor according to embodiment of the present disclosure; 
           [0010]      FIG. 2  depicts a top view of a first distributor according to the present disclosure; 
           [0011]      FIG. 3  depicts a top view of a second distributor according to the present disclosure; 
           [0012]      FIG. 4  depicts a top view of a third distributor according to the present disclosure; and 
           [0013]      FIG. 5  depicts a sectional view of a nozzle according to the present disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0014]    Referring to  FIG. 1 , there is shown a processor  10  for processing one or more materials. The processor  10  may include a shell  12  defining a chamber  14 . The chamber  14  may include one or more solids (not shown). The chamber  14  is substantially free of plates, metal baffles, or other structures that are positioned to obstruct fluid flow and to promote mixing. Thus, as used herein, the phrase “substantially open” refers to a chamber  14  that does not include mixing structures principally dimensioned, sized, and positioned to cause mixing of fluids and/or solids contained therein. Thus, while structures may project into the chamber  14 , these structures do not have a principal purpose of causing mixing. 
         [0015]    In accordance with one embodiment of the present disclosure, the processor  10  includes a multi-inlet fluid distributor  20  in order to evenly distribute a high temperature, high velocity fluid into the solids (not shown). The fluid may be a gas having entrained solid particles. In aspects, the fluid has a temperature of at least 1,200 degrees F. In some applications, the fluid has a temperature of at least 2,000 degrees F. In other applications, the fluid as a temperature of at least 3,000 degrees F. The distributor  20  includes a plurality of inlets  22  that distributes the fluid circumferentially and axially into the shell  12 . By axially, it is meant that there are inlets  22  are two or more discrete elevations. In some applications, the fluid has a velocity of at least forty feet per second. In other applications, the fluid may have a velocity of at least two hundred feet per second or at least three hundred feet per second. 
         [0016]    In one arrangement, the distributor  20  includes a plurality of pipe assemblies  30 ,  32 ,  34 . Since the pipe assemblies  30 ,  32 ,  34  share common features, only pipe assembly  30  will be described. Referring to  FIG. 2 , pipe assembly  30  includes a supply inlet  40 , a header  42 , and inlets formed as a plurality of nozzles  44   a - h.  The header  42  may be formed in a “pin-wheel” or hexagonal shape and forms the flow channel through which the fluid flows from the supply inlet  40  to the nozzles  44   a - h.    
         [0017]    The header  42  may include one or more substantially straight pipe segments  46  from which the nozzles  44   a - h  may project downwards and join at a non-perpendicular juncture  49  with the chamber  14 . The angle at the juncture  49  is selected to allow material to flow downward due to gravity into the chamber  14 . The downward orientation forces solids to overcome gravity in order to enter the header  42 . The header  42  may also include caps  48  that may be removed to allow cleaning implements to be inserted into the straight pipe segments  46 . Thus, when needed, devices such as rods may be used to clean clogged pipes. 
         [0018]    In embodiments, the distributor  20  may include a dual layer insulating and wear-resistant refractory lining  50  ( FIG. 5 ). The lining  50  may be formed by a first layer of lightweight refractory that is protected on the surface by a second layer of dense refractory. Such a dual layer refractory system may be used to contain the high heat from the fluid in the piping. 
         [0019]    The pipe assemblies  32  ( FIGS. 3 ) and  34  ( FIG. 4 ) are similar to pipe assembly  20  except for having fewer nozzles. 
         [0020]    In one mode of operation, a fluid is supplied to each of the pipe assemblies  30 ,  32 ,  34 . In each pipe assembly  30 ,  32 ,  34 , the fluid flows in a circular fashion prior to be flowing downward through the nozzles (e.g., nozzles  44   a - h ) into the processor  10 . As noted above, the nozzles are evenly distributed both axially (vertically) and circumferentially. When the fluid velocity is sufficiently high, the force of the fluid on the solids counter-balances the weight of the solid material. At this point, the contents of the processor bed expand and swirl to form a fluidized bed. 
         [0021]    It should be appreciated that these distributed nozzles promote mixing without the use of metal distributors positioned in the chamber  14  of the processor  10 . Thus, the fluid may be supplied at temperatures that would otherwise be too hot for such metal distributors. 
         [0022]    In contrast to processors that use structures inside the chamber  14  to redirect flow and promote mixing, embodiments of the present disclosure using multiple flow streams, each having different flow directions in order to generate uniform mixing inside the chamber  14 . As shown, the nozzles  44   a - h  are sloped so that the flow is not perpendicular to the vertical axis of the chamber  14 . Further, the nozzles  44   a - h  are all directed radially inward to the vertical axis of the chamber  14 . However, in other embodiments, the nozzles  44   a - h  may induce flow that is perpendicular to this vertical axis. In still other embodiments, the nozzles  44   a - h  may induce a tangential component to the fluid flow. In still other embodiments, the nozzles  44   a - h  may point into two or more different directions. 
         [0023]    As shown, the  FIG. 3  and  FIG. 4  pipe assemblies have successively fewer nozzles. However, in some arrangements, they could have the same number of nozzles. Also, the number and orientation of the nozzles can vary among the pipe assemblies  30 ,  32 ,  34 . 
         [0024]    Referring now to  FIG. 5 , there is sectionally shown an illustrative nozzle  44  that is connected to the chamber  14  at a juncture  48 . As noted previously, the internal surfaces of the chamber  14  and the distributor  30  may be lined with a multi-layer refractory  50 . A first, outer layer  52  is formed of materials that are suitable for containing heat. A second inner layer  54  is formed of materials that are erosion-resistant. Thus, the inner layer  54  provides a physical shield and prevents direct contact between the high-velocity abrasive fluids and the heat-containing outer later  52 . 
         [0025]    In some embodiments, the nozzle  44  includes a venturi-type of flow restrictor  60 . The flow restrictor  60  generates a pressure drop of the fluid flowing into the chamber  14 . The magnitude of the pressure drop may be selected to circumferentially and axially equalize the flow of fluid into the chamber  14 . As illustrated in  FIGS. 1 and 2 , the nozzles  44   a - h  are distributed around the circumference of the chamber  14  and along three discrete elevations. Uncontrolled flow into the chamber  14  could result in uneven flow at these locations. Therefore, some or all of the nozzles  44   a - h  include the flow restrictor  60  ( FIG. 5 ) in order to generate sufficient back pressure to ensure at least a minimum flow at all of the nozzles  44   a - h.    
         [0026]    Referring to  FIG. 5 , in one arrangement, the flow restrictor  60  is cast into the refractory  50 . The refractory  50  may have a first flow passage  62 , a second flow passage  64 , and a third flow passage  66 . The venturi effect may be obtained by making the cross-sectional flow area of the second flow passage  64  smaller than the cross-sectional flow area of the first flow passage  62  for a specified axial distance. The third flow passage  66  may have a larger cross-sectional flow area than that of the second flow passage  64 . The changes in the cross-sectional area of the flow passages  62 ,  64 ,  66  may be obtained by varying the thickness of the inner layer  54  as shown. A similar effect may be obtained by varying the thickness of the outer layer  52 . 
         [0027]    While the foregoing is directed to embodiments of the present disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.