Sprayer Nozzle Shear-Mixing for Small Particle Granules
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Solution Overview
Problem
Existing spray-drying apparatuses are unable to produce small-particle-size granular powder materials due to limitations in the centrifugal atomization method, where the particle size is primarily affected by the rotating speed of the atomization disc.
Innovation Solution
A sprayer with a liquid material nozzle and gas nozzle that shear-mix the liquid material and gas to form micro mist droplets, which are then dried to produce small-diameter spherical granules, utilizing a dispersing member to create sub-channels for enhanced dispersion and a nozzle member for increased speed and uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If centrifugal atomization method is used with high-speed rotation of atomization disc, then granulation can be performed, but small-particle-size granular powder materials cannot be produced
Solution Approach 1:
The invention changes the atomization mechanism from centrifugal force to gas-liquid shear interaction. By adjusting gas flow rate, liquid flow rate, and nozzle structure parameters, the particle size can be precisely controlled across a wide range, solving the limitation of fixed particle size range in centrifugal atomization
Solution Approach 2:
The invention uses gas flow through the gas nozzle to shear and fragment the liquid material from the liquid nozzle. This pneumatic-hydraulic interaction creates micro mist droplets with controllable size, enabling production of small-particle-size granular materials that cannot be achieved by centrifugal atomization alone
2Manufacturing precision
If liquid material is sprayed to form micro liquid droplets, then granulation can be achieved, but the liquid material is not sufficiently fragmented to form micro mist droplets
Solution Approach 1:
The invention merges the liquid material nozzle and gas nozzle into a integrated nozzle assembly where gas flows through the gas nozzle to directly interact with liquid material from the liquid nozzle. This combined structure achieves sufficient fragmentation into micro mist droplets without requiring complex external fragmentation devices
Solution Approach 2:
The gas flow acts as an intermediary that mediates the fragmentation process. The gas nozzle delivers gas flow that shears and breaks up the liquid material into fine mist droplets, serving as an intermediate medium that enables controlled fragmentation without direct mechanical contact
3Manufacturing precision
If dispersing member is added to create sub-channels, then liquid material dispersion is enhanced, but device complexity increases
Solution Approach 1:
The dispersing member segments the liquid material channel into multiple sub-channels. This segmentation enhances liquid material dispersion by distributing flow through multiple pathways, improving atomization uniformity without requiring complex external dispersion mechanisms
Solution Approach 2:
The dispersing member with sub-channels is nested within the liquid material channel structure. This nested design enhances dispersion functionality while minimizing additional device complexity by integrating the dispersing function into the existing channel geometry
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 enables the production of small-diameter spherical granular powder materials by effectively fragmenting and drying the liquid material into mist droplets, overcoming the size limitations of traditional methods.
Implementation Method 1
a liquid material sprayed out of the liquid material nozzle and gas sprayed out of the gas nozzle are shear-mixed at the liquid material nozzle, such that the liquid material is physically fragmented and atomized by the gas to form micro mist droplets
Implementation Method 2
due to a quite large surface area of the mist droplet, moisture is quickly evaporated and dried under the action of hot gas flow
Implementation Method 3
The micro mist droplet forms a spherical shape under the action of surface tension
Data Source
AI summary
A sprayer includes a sprayer body. The sprayer body is provided with a liquid material inlet, a liquid material nozzle, a gas inlet, a gas nozzle, a liquid material channel, and a gas channel. The liquid material nozzle and the liquid material inlet both communicate with the liquid material channel, the gas nozzle and the gas inlet both communicate with the gas channel, and the gas nozzle is provided at the liquid material nozzle. A dispersing member is provided in the liquid material channel and disposed at the liquid material nozzle. The dispersing member divides the liquid material channel into multiple sub-channels communicating with the liquid material nozzle.