Adjustable Spray Nozzle Geometry for Viscosity Control
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Solution Overview
Problem
Existing spray drying processes face challenges in maintaining optimal spray droplet size and efficiency due to fixed nozzle geometries that cannot adjust to changing product and process conditions, leading to issues like air-core break-downs, powder blockages, and fouling, especially when dealing with high viscosities and varying total solids content.
Innovation Solution
A method that continuously determines the shear viscosity, mass flow rate, spray pressure, and density of the product, using this data to adjust the spray nozzle geometry in real-time through a control device, ensuring stable droplet formation and preventing air-core break-downs, while also allowing for inline measurement of shear viscosity using a differential pressure drop method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If fixed geometry spray nozzles are used, then device complexity is reduced, but adaptability to changing product viscosity and process conditions deteriorates
Solution Approach 1:
The patent implements adjustable nozzle geometries that can be modified during operation to adapt to changing product viscosity and process conditions. The nozzle system transitions from fixed to dynamic configuration, allowing operators to optimize spray droplet size and distribution for different total solids content and viscosity levels without replacing the entire nozzle apparatus.
Solution Approach 2:
The invention changes physical parameters of the nozzle geometry (such as orifice size, angle, and shape) to accommodate varying product properties. By adjusting geometric parameters in response to viscosity changes and total solids content, the system maintains optimal spray characteristics across different operating conditions while avoiding air-core break-down.
2Manufacturing precision
If nozzle geometries are changed prior to production cycle, then manufacturing precision of spray droplet size is improved for specific conditions, but adaptability to varying process conditions deteriorates
Solution Approach 1:
The system enables inline adjustment of nozzle geometries during the production cycle rather than requiring shutdowns for configuration changes. This dynamic adjustment capability allows the spray droplet size distribution to be optimized for current process conditions while maintaining the precision benefits of tailored nozzle geometries.
Solution Approach 2:
The invention incorporates monitoring of process conditions (viscosity, total solids content) and uses this information to guide nozzle geometry adjustments. This feedback mechanism ensures that the nozzle configuration is continuously optimized for the actual product being processed, maintaining manufacturing precision across varying conditions.
3Productivity
If spray-drying is operated at higher total solids content, then productivity is improved, but reliability deteriorates due to air-core break-down
Solution Approach 1:
The system adjusts nozzle geometric parameters (orifice size, convergence angle, surface finish) to compensate for increased viscosity and total solids content. These parameter changes allow operation at higher productivity levels while preventing air-core break-down and maintaining stable droplet formation, thus preserving reliability.
Solution Approach 2:
The invention applies surface modifications (coatings, roughness control) and geometric optimizations in advance to prevent air-core break-down before it occurs. By pre-configuring the nozzle to handle high-viscosity, high-total-solids materials, the system cushions against the development of unstable spray patterns and maintains reliable operation at elevated productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables consistent powder agglomeration and quality, reduces fouling, minimizes downtime, and enhances process efficiency by maintaining optimal spray droplet size distribution and preventing blockages, thus improving the overall operation and economics of the spray drying process.
Implementation Method 1
Spray nozzles create droplets, which are dried in hot air by evaporating water
Implementation Method 2
droplets, which are dried in hot air by evaporating water
Data Source
AI summary
A method of controlling the spray droplet size of a spray nozzle apparatus, in particular for the manufacturing of food powders, delivered to the spray nozzle comprises the following steps: a) providing a paste of a product to be sprayed by a spray nozzle; b) continuously determining the shear viscosity (η) of the product paste delivered to the spray nozzle; c) determining the mass flow rate (Qrn) of the product paste delivered to the spray nozzle; d) determining the static pressure (P) of the product paste delivered to the spray nozzle; e) determining the density (p) of the product paste delivered to the spray nozzle; f) delivering the data obtained in steps b) to e) to a control device comprising a computer and a memory; g) calculating control data for adjusting the spray nozzle on the basis of the data obtained in steps b) to e) and on nozzle geometry parameters stored in the memory; h) sending the control data as control signals to a control means of the spray nozzle and adjusting the spray nozzle accordingly.