Gas Needle Atomizer for Viscous Fuel Spray
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Solution Overview
Problem
Existing atomization technologies are inefficient in handling a variety of fuel types, particularly viscous fuels, and lack the capability to atomize liquids using gaseous media effectively, leading to limited performance and increased energy consumption.
Innovation Solution
An apparatus and method utilizing a gas needle to create a reduced pressure area behind a nozzle tip, combining with a longitudinal tube and fuel channel to produce a spray cone with an angle of at least 24°, allowing for efficient atomization of liquids and fuels, including viscous ones, using compressed gas or air, and enabling flexible operation across different fuel types and engine sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional nozzles are used for atomizing viscous fuels, then the nozzle structure is simple, but the atomization efficiency is poor and the nozzle capacity is limited
Solution Approach 1:
The nozzle is divided into multiple functional sections: a gas needle channel for compressed gas, a liquid fuel channel for viscous fuel, and a mixing chamber where the two fluids interact. This segmentation allows each channel to be optimized for its specific fluid type, enabling effective atomization of viscous fuels while maintaining structural organization
Solution Approach 2:
The gas needle is positioned concentrically within the nozzle structure, with the liquid fuel channel surrounding it. The gas needle extends into the liquid fuel stream, creating a nested configuration where compressed gas is injected directly into the viscous fuel flow, enhancing atomization without requiring a completely separate atomization system
2Adaptability or versatility
If air atomizing nozzles are used for fuel injection, then the nozzle can handle some fuel types, but the capacity to handle heavier and more viscous fuel grades is limited
Solution Approach 1:
The invention uses compressed gas (pneumatic principle) injected through the gas needle to atomize the viscous liquid fuel. The high-velocity gas stream breaks up the viscous fuel into fine droplets, providing effective atomization of heavy fuel grades without requiring mechanical moving parts or complex hydraulic systems
Solution Approach 2:
The nozzle design allows adjustment of gas-to-fuel ratio, gas pressure, and nozzle geometry parameters to optimize performance for different fuel viscosities. By changing these parameters, the same nozzle can effectively handle a wide range of fuel types from light to heavy viscous grades
3Productivity
If high pressure pumping is used for fuel injection, then fuel can be delivered to the nozzle, but energy consumption increases and the system becomes less efficient
Solution Approach 1:
The compressed gas serves dual purposes: it provides the atomization force and simultaneously draws the liquid fuel through the nozzle via the ejector effect created by the gas flow. This self-service mechanism eliminates the need for separate high-pressure fuel pumping systems, reducing energy consumption while maintaining effective fuel injection
4Adaptability or versatility
If conventional nozzle designs are used, then the nozzle can be optimized for specific fuel types, but the ability to handle a variety of different fuel types and qualities is limited
Solution Approach 1:
The nozzle design with concentric gas and liquid channels can handle multiple fuel types by adjusting operating parameters such as gas pressure, gas flow rate, and needle position. The same basic structure effectively atomizes everything from light fuels to heavy viscous grades, providing universal applicability while maintaining consistent atomization quality through parameter optimization
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 solution achieves significantly higher atomization efficiency, reducing energy consumption, and allows for the use of high-viscosity fuels without preheating, with the ability to handle acidic and non-lubricating fuels, and adapt to various combustion systems, including internal combustion engines.
Implementation Method 1
setting the speed of the compressed gas and the liquid so that the flow of compressed gas forms an area of reduced pressure behind the tip of the gas needle producing an ejector effect
Implementation Method 2
the nozzle hole is configured to produce a spray cone having at least 24° angle between the central axis of the nozzle tip and the mantle of the cone
Data Source
Figure 1~3
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Figure 5
AI summary
According to an example aspect of the present invention, there is provided a method and apparatus for atomizing liquids and burning liquid fuels, comprising a body (1), a longitudinal cavity (2) within the body (1), having a first end (3) and second end (4), a longitudinal tube (5) within the longitudinal cavity (2), having a first end (6) and a second end (7). There is a gas needle (8) in flow connection with the longitudinal tube (5) and extending from the second end (7) of the longitudinal tube (5) and ending to a tip (9). A liquid channel (10) is formed between the longitudinal cavity (2) and the longitudinal tube (5), a nozzle hole (11) is extending from the second end (7) of the longitudinal cavity (2) and ending as a nozzle tip (12). The liquid channel (10) opens behind the tip (9) of the gas needle (8) without extending past the tip (9) in direction towards the nozzle hole (11) and the nozzle hole (11) is configured to produce a spray cone having at least 24° angle between the central axis of the nozzle tip (12) and the mantle of the cone.