Multi-nozzle for granulation with radial spray pattern
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Solution Overview
Problem
Conventional spout-fluid granulation methods face limitations in producing fine granules due to high pressure air requirements, leading to increased operating costs and inefficient droplet size, which restricts the throughput and scalability of the process.
Innovation Solution
A multi-nozzle design with cone-shaped nozzle ends arranged radially on a cone-shaped body, offering a spraying angle between 15° to 45° for each end and 30° to 60° for the whole nozzle, allowing for finer droplet formation without high pressure air, maintaining equivalent throughput to conventional designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high pressure air is introduced to an atomizing nozzle to spray the aqueous solution, then finer aqueous particles are formed with improved drying effect, but the power for pressurizing the air increases significantly, increasing operating cost
Solution Approach 1:
The invention divides a single nozzle into multiple nozzle ends (2-6 ends) arranged radially on a cone-shaped body. Each nozzle end operates at low pressure (0.6-1.2 MPa) but collectively they achieve the throughput equivalent to conventional single nozzles while producing finer droplets due to the smaller individual flow rate from each end.
Solution Approach 2:
The invention transitions from a single-point spray (0D/1D) to a multi-point radial spray pattern (3D distribution). The cone-shaped body with radially arranged nozzle ends creates a three-dimensional spray distribution that enhances droplet dispersion and drying effect without requiring high pressure.
2Manufacturing precision
If the spraying pressure of aqueous solution is increased to decrease droplet size with a single-fluid nozzle, then finer droplets are formed, but the apparatus for increasing the pressure becomes large and operating cost increases
Solution Approach 1:
The invention segments the spray function into multiple nozzle ends, each operating at conventional low pressure. This eliminates the need for large high-pressure apparatus while achieving fine droplet sizes through the combined effect of multiple low-pressure spray points.
3Manufacturing precision
If the throughput per single nozzle is decreased to form finer droplets, then droplet size is reduced, but the number of nozzles has to be increased, increasing the size of the granulator and air rate, thereby increasing operating cost
Solution Approach 1:
The invention merges multiple nozzle ends into a single multi-nozzle assembly that fits within one granulator unit. This consolidation achieves fine droplet formation through multiple spray points without increasing the overall granulator size or air rate requirements.
4Manufacturing precision
If more nozzles are arranged in the granulator to decrease throughput per nozzle, then droplet size is reduced, but the air rate to form the spout-fluid bed increases, increasing operating cost
Solution Approach 1:
The invention segments the spray function into multiple nozzle ends within a single nozzle assembly, achieving fine droplets without increasing the number of separate nozzle units. This maintains the original air rate requirements for spout-fluid bed formation.
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 enhances the drying effect, reduces water content, and increases particle loading strength, enabling efficient production of granules with lower water content and improved particle size distribution without altering the granulator structure or increasing operating costs.
Implementation Method 1
granulation, drying and cooling simultaneously proceed in the granulator
Implementation Method 2
a multi-nozzle mounted to a single nozzle, which multi-nozzle is structured by arranging a plurality of spray nozzle ends
Data Source
Figure 1(a)~2
Figure 3~4
AI summary
The present invention provides a granulation method with increased drying effect while assuring the pressure for spraying the aqueous solution and the necessary number of nozzles equivalent to those of conventional design. Specifically, the granulation method uses a granulator structured by a fluid bed which fluidizes the granulating-particles, an air feed pipe to introduce air, a nozzle for spraying the raw material aqueous solution being located at center part of the air feed pipe, and a perforated plate to feed a fluidization air to the fluid bed, thus granulating the raw material aqueous solution by spraying thereof from the nozzle into a granulation part, wherein a multi-nozzle in a specified shape having a plurality of nozzle ends thereon is used as the nozzle for spraying the raw material aqueous solution.