Atomizing Nozzle with Converging Air Header for Micronized Droplets
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Solution Overview
Problem
Current atomization technologies are inefficient in producing small droplets for applications like Furnace Sorbent Injection methods and spray drying, leading to suboptimal pollutant capture and processing efficiency in combustion processes, and lack flexibility in adapting to different applications.
Innovation Solution
A single-step atomizing device with an adjustable liquid nozzle and converging air header design that produces micronized droplets by optimizing the air-to-liquid ratio and nozzle geometry, allowing for co-flow or counter-flow injection of sorbent materials into combustion furnaces, enhancing droplet formation and reaction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional atomization technologies are used, then device complexity is reduced, but droplet size is too large and throughput is insufficient
Solution Approach 1:
The atomizing device is divided into distinct functional segments: a liquid nozzle for fluid delivery, a converging air header with transition cone for air flow control, and an atomizing section where droplet formation occurs. This segmentation allows each component to be optimized independently for its specific function while maintaining overall system efficiency.
Solution Approach 2:
The device incorporates adjustable parameters including liquid flow rate, air flow rate, nozzle geometry, and air-to-liquid ratio. These dynamic adjustments enable optimization of droplet size and distribution for different applications, transitioning from fixed conventional designs to adaptable systems that can achieve micronized droplets.
2Adaptability or versatility
If conventional atomization is used, then device simplicity is maintained, but application versatility is limited
Solution Approach 1:
The atomizing device is designed with universal applicability across multiple industries including agriculture (crop protection, fertilization), fire-fighting, combustion processes (pollutant removal), spray drying, and coating applications. The adjustable air-to-liquid ratio and configurable nozzle geometry enable a single device design to serve diverse functions that previously required multiple specialized systems.
3Productivity
If larger droplets are produced, then energy consumption is reduced, but pollutant capture efficiency decreases
Solution Approach 1:
The device optimizes the air-to-liquid ratio as a critical parameter to achieve the desired droplet size distribution. By carefully controlling this ratio along with air and liquid flow rates, the system produces micronized droplets that maximize pollutant capture surface area while maintaining energy efficiency through optimized airflow patterns in the converging air header.
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
The device achieves smaller droplet sizes and increased throughput, improving pollutant capture and process efficiency in combustion processes, and is adaptable for various applications, including Furnace Sorbent Injection and spray drying.
Implementation Method 1
a converging air header with an air transition cone
Implementation Method 2
atomizing device with an adjustable liquid nozzle and converging air header design that produces micronized droplets
Implementation Method 3
optimizing the air-to-liquid ratio and nozzle geometry, allowing for co-flow or counter-flow injection
Data Source
AI summary
The invention relates to a new atomizing device with improved droplet formation. Smaller droplets are formed with increased micronized volume throughput, wherein high volumes of air are fed to a liquid sprayed from a liquid nozzle (2). High volume ratios result in mean free path between droplets being conveyed so as to minimize collisions and to prevent aggregation of the droplet.