Movable Stem Spray Nozzle for Independent Flow and Droplet Control
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Solution Overview
Problem
Existing spray nozzles face challenges in independently controlling flow rate and droplet size, leading to sub-optimal performance, increased energy and capital costs, and inefficient use of resources, particularly at turndown conditions where the pump flow increases despite reduced process requirements.
Innovation Solution
A spray nozzle design featuring a movable stem and nozzle body that creates a variable orifice gap, allowing independent control of flow rate and droplet size through motor-actuated movement, which reduces pump energy consumption and eliminates the need for expensive high-pressure control valves and recirculation systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If spillback systems are used to reduce process injection flow, then flow rate control is achieved, but total pump flow increases leading to wasted pumping power
Solution Approach 1:
The invention extracts and eliminates the spillback recirculation loop from the system. Instead of diverting flow through a return line to a storage tank, the nozzle directly controls the process injection flow by varying the orifice area, thereby removing the wasteful recirculation path and associated energy consumption.
Solution Approach 2:
The invention employs a dynamically adjustable orifice area within the nozzle body, controlled by a positioning mechanism that responds to process demands. This dynamic adjustment allows the nozzle to precisely control flow rate without requiring external spillback valves or recirculation systems, optimizing pumping power at all operating points.
2Adaptability or versatility
If spillback systems are used to achieve turndown, then flow rate variation is possible, but larger and more expensive pumps are required
Solution Approach 1:
The invention changes the orifice area parameter dynamically through mechanical positioning of the nozzle internal components. This allows a single pump sized for maximum flow to operate efficiently across the entire turndown range by adjusting the effective orifice area, eliminating the need for oversized pumps required by spillback systems.
3Ease of operation
If fixed-orifice nozzles vary liquid supply pressure to control flow rate, then flow rate control is achieved, but droplet size cannot be controlled independently
Solution Approach 1:
The invention segments the flow control and droplet size control functions into two independent mechanisms: orifice area adjustment controls flow rate, while orifice geometry and liquid pressure independently control droplet size. This segmentation allows both parameters to be optimized separately without the coupling inherent in fixed-orifice pressure-based control.
4Ease of operation
If spillback systems are used for flow control, then turndown is achieved, but expensive high pressure control valves and return piping are required
Solution Approach 1:
The invention merges the flow control function directly into the nozzle body by integrating a movable orifice mechanism within the nozzle. This eliminates the need for separate high-pressure control valves, return piping, and storage tanks, simplifying the overall system while maintaining precise flow control capability.
Data Source
AI summary
A spray nozzle has a nozzle portion at an outlet or downstream end that includes a nozzle body defining an opening therethrough, and a movable stem or pintle at least partially within the opening of the nozzle body. The stem and nozzle body define a gap therebetween to define a fluid passageway for fluid in the nozzle to flow through the nozzle portion and out of the nozzle throughout a range of relative movement between the stem and the nozzle body. The relative movement and the size of the gap may be controllable independently of fluid pressure of fluid within the nozzle. The nozzle body and the stem may define geometries so that the flow area between the stem and the nozzle body does not increase, and may decrease, in the downstream direction. The axis of the spray may be at an angle to the nozzle.