Sonic Speed Nozzle for Low Air Consumption Atomization
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Solution Overview
Problem
Existing atomization methods for liquids in fluid-bed granulators require high air consumption, leading to expensive and energy-intensive air feeding systems, which is a significant disadvantage in processes like urea granulation.
Innovation Solution
A spraying nozzle design that forms an emulsion of a gaseous phase into a liquid by mixing a fast gaseous jet with the liquid inside a mixing chamber, where the gaseous phase is accelerated to sonic or supersonic speeds, reducing the need for high air flow rates and allowing for efficient atomization with lower air consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large amount of air is used for atomization at high speed, then the liquid can be effectively atomized, but the air consumption and energy cost increase significantly
Solution Approach 1:
The patent changes the velocity parameter of the gas phase from subsonic to sonic/supersonic speeds. This parameter change allows effective atomization with much lower air consumption because the high-speed gas creates a stronger mixing and dispersion effect per unit volume, reducing the total air quantity needed from 50% of liquid flow rate to significantly lower amounts.
Solution Approach 2:
The patent employs periodic or pulsed gas injection through the swirling device, creating cyclic emulsion formation and breakdown. This periodic action enhances atomization efficiency by repeatedly disrupting the liquid film, achieving better dispersion with reduced overall air consumption compared to continuous low-speed airflow.
2Stability of the object's composition
If air flow rate is increased to achieve proper atomization, then droplet dispersion improves, but the air feeding system becomes more expensive and energy-intensive
Solution Approach 1:
By changing the gas velocity parameter to sonic/supersonic range, the patent achieves effective droplet dispersion with lower air flow rates. This reduces the complexity and cost of air feeding systems (compressors, piping, control equipment) while maintaining stable droplet dispersion through the enhanced mixing effect of high-speed gas-liquid interaction.
Solution Approach 2:
The swirling device creates rotational motion and vibration in the gas-liquid mixture, enhancing droplet breakup and dispersion. This mechanical vibration effect improves droplet distribution stability without requiring proportionally higher air flow rates, thereby reducing air feeding system complexity.
3Manufacturing precision
If high-speed air is used for atomization, then the liquid can be converted into fine spray, but the capital investment for compressors and air feeding equipment increases
Solution Approach 1:
The patent achieves fine spray quality by changing the gas velocity parameter to sonic/supersonic speeds rather than relying on high volumetric flow rates. This allows the use of smaller, less expensive compressors and air feeding equipment while maintaining the necessary kinetic energy for fine atomization, thereby reducing capital investment and equipment weight.
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 results in significantly reduced air consumption, lower energy costs, and a simpler nozzle design, achieving efficient atomization with minimal air usage, while maintaining high product purity and granule quality.
Implementation Method 1
The speed of the gaseous phase at an inlet region of the mixing chamber is around the speed of sound or greater, to form said emulsion
Implementation Method 2
the speed of the gaseous phase at an inlet region of the mixing chamber is around the speed of sound or greater
Implementation Method 3
an emulsion of the gas in the liquid is obtained, the emulsion being under pressure inside said chamber and formed by gas bubbles enveloped by the liquid in a film state
Implementation Method 4
said atomized flow is obtained by an expansion of said emulsion atomizing the liquid film at the outlet of said chamber
Data Source
AI summary
A method for atomizing a liquid (L) in a spraying nozzle (1), wherein a gaseous phase (G) and a liquid (L) are fed to a mixing chamber (30) inside a nozzle (1), obtaining an emulsion of the gas in the liquid, the emulsion being under pressure inside the chamber and formed by gas bubbles enveloped by the liquid in a film state. The speed of the gaseous phase at the inlet of the mixing chamber is around the speed of sound or greater. The atomized liquid is obtained by an expansion of the emulsion at the outlet of the chamber. A suitable nozzle (1) is also disclosed, comprising a mixing chamber (30) and a distribution device (D) adapted to provide appropriate gas and liquid feed to form an emulsion.