Refinery spray technology for petroleum production
SPRAYING Systems Co., the world’s leading manufacturer of spray nozzles, injectors and related systems, represented in Southern Africa by Monitor Engineering since 1975, plays a crucial role in the petroleum refining industry. Their products are engineered to handle harsh environments, ensuring efficient fluid dispersion, cooling, and chemical injection. In refineries, these spray solutions optimise processes, reduce maintenance, and enhance safety. From crude distillation to pollution control, their technology addresses key operational challenges like corrosion, temperature control, and emission reduction.
One primary area of application is in the Crude Distillation Unit (CDU), where spray injectors facilitate water wash operations. Here, water is sprayed to prevent salt build-up and corrosion in distillation columns. This involves hydraulic spray nozzles that distribute water evenly, minimising downtime and extending equipment life. Similarly, in the Fluid Catalytic Cracking Unit (FCCU), spray products are used for overhead water washes to combat corrosion from ammonia and cyanide. FCCU feed injection atomises feedstock into catalyst-laden gas streams, improving cracking efficiency with precise drop size control via two-fluid nozzles.
In Cokers, spray systems handle off-gas cooling through steam atomisation, using clog-resistant spray nozzles to quench hot gases and prevent fouling. Hydrotreaters benefit from chemical injection, where injectors deliver neutralising amines or inhibitors to reduce corrosiveness in fractionators. These lances, often made from corrosion-resistant alloys like Hastelloy, ensure uniform spray patterns even under high pressure and temperature.
Beyond unit-specific uses, Spraying Systems Co. products support broader refinery processes. For instance, in heat exchangers, inhibitors are injected to prevent corrosion, while additive injection enhances product quality. Steam quenching in cracking heaters controls temperatures, and slurry backflush clears hydrocarbons with catalysts using wear-resistant nozzles. Pollution control applications include flue gas desulfurization (FGD) with clog-resistant spray nozzles and Selective Catalytic Reduction (SCR) for NOx control via ammonia injection.
The company’s injectors, such as the OptiMax® series, mix steam with oil to provide a uniform spray pattern and quick evaporation. We also offer Computational Fluid Dynamics (CFD) modelling for optimal placement and performance. This addresses challenges like flow profiles, erosion, and vibration, ensuring dependable operation in co-current or counter-current setups. Benefits include reduced maintenance—many injectors last years without service—improved efficiency, and compliance with ASME standards for safety.
“It’s easy to assume what’s happening at every stage of your processes,” says Monitor Engineering MD Grant Orsmond, “but the systems are enclosed. We therefore offer our expertise, working with you to model your spray operations and provide new insight into areas that could be improved. We can also help you select better nozzles, optimise injector placement within a vessel, or design and fabricate an injector to deliver the performance you need, complete with testing and documentation. Injectors can be built to comply with ASME® Boiler & Pressure Vessel Code (BPVC), ASME U-Stamp Vessel Manufacturing, ASME B31.1, ASME B31.3, ASME BPVC Section IX and PED 2014/68/EU.”
For more information contact grant@monitorspray.co.za or visit www.spray.co.za
