Static Reactors

Cavitation Units for High-Impact Treatment of Liquid Fuels

Overview

Static Reactor is specific unit which is designed for the high energy impact on oil-based and other liquids. It uses a cavitation for breaking long molecular chains into a smaller ones and intensifying mixing process.

Functions

Static reactors are designed for improving oil and oil-based products by the decrease of viscosity, flash point and pour point.
Being a very effective unit for the mixing it amplifies an impact of additives which are normally used for improving the quality of oil, Heavy Fuel Oil (HFO, mazut) and other products.
Another function of static reactor is an improved mixing process of liquids and gases. For example, ozone is added to a water or other liquid is well mixed with with bubbles size below micrometers.
Oil, passed through the static reactor, has higher output of light fractions like benzin and diesel. Oil and oil-based fuels becoming uniform what improves combustion characteristics.

Applications

Static reactors are effective for improving Heavy Fuels Oils (HFO), mazut, oil wastes, etc. Watered oil is becoming homogeneous (uniform). Major applications are:

  • In oil-refineries – for increasing light oil fractions output, reducing consumption of catalysts, dissolving liquid and gazeous additives, etc.
  • In combustion systems – for improving combustion characteristics, reducing sledging, etc.
  • Special applications – dissolving liquid additives and gases in oil, micromilling of solid particles which may exist in oil, especially in heavy fuel oil, other applications.

Depending on oil characteristics static reactor may reduce oil viscosity up to 30%, reduces pour point from -6 deg C till -16 deg C, increases output of light fractions on 2…3% or more for different types of oil. Watered oil processed in DEWA-OIL becomes uniform and does not include “water lenes”, produced water-oil emulsion is stable for a long period.

How it Works

Oil is pumped with a certain pressure into the Static Reactor which produces a myriads of bubbles (caverns). These caverns are collapsing immediately after they are produced. This process (cavitation) creates a local pressure inside a bubble up to hundreds bars (locally) and destructs long molecular chains. As the result all components (oil, water, additives, ..) are properly mixed in a form of stable emulsion.

Multi-stage turbulent sections are designed inside the reactor in order to create conditions for the cavitation. Due to media viscosity&density are different, static reactors for non-standard liquids are designed individually.

Normal working pressure for static reactor is 12…20 bars depending on oil or other media type.

Modelling of processes insde the static reactor

Effects & Results

Static Reactor makes a remarkable own impact on oil (FO, HFO) pour point, viscosity and flash point. Based on results of our customers static reactor amplifies an impact of catalysts significantly reduces its’ total consumption.

Results of processing HFO and FO in a static reactor with and without catalyst show change in parameters up to 30%:

 Flash PointPour PointViscosity
FO14513181
FO after Reactor1308169
FO+Catalyst+Reactor95-4154
HFO22024240
HFO after Reactor21116224
HFO+catalyst+reactor180-2198

Model Range and Configurations

Static reactor can be provided either as a stand alone unit or as a part of fully functioning complex (skid). 
If static reactor is provided as a stand-alone unit it is typically connected inline the existing system. Then Customer is responsible for controlling pressure, throughput, temperature, etc.
Skids, which are using  static reactor as a core device, include next components:
  • static reactor,
  • pump with control system for providing proper pressure,
  • single frame,
  • piping and valves, 
  • tank(s) for original and/or final product.
Single units are available in a range of 0.5…100 m3 per hr.

Interested?

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