Steam Atomizing Nozzle Assembly with Removable Inserts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Steam atomizing liquid spray nozzle assemblies face challenges in maintaining consistent droplet size and spray performance due to variables like water temperature, steam condensation, and wear, which can lead to costly repairs and inconsistent spraying across a wide temperature range.
Innovation Solution
A steam atomizing liquid spray nozzle assembly with removable nozzle inserts that optimize steam and liquid interaction, preventing condensation and allowing for easy modification and maintenance, ensuring consistent droplet size and efficient atomization across varying conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If steam is used for liquid spray atomization, then expensive air compressors and their costly operation and maintenance are eliminated, but steam condensation can occur which interferes with droplet size consistency and spray performance
Solution Approach 1:
A steam distribution manifold is introduced as an intermediary component between the steam source and the nozzle assembly. This manifold distributes steam uniformly to multiple nozzles and includes a heating element to maintain steam temperature, preventing condensation before the liquid spray atomization point, thus maintaining droplet size consistency while preserving cost effectiveness.
Solution Approach 2:
The system actively controls the temperature parameter of the steam by incorporating a heating element within the steam distribution manifold. By maintaining steam temperature above the dew point through continuous heating, condensation is prevented, ensuring consistent droplet size and spray performance throughout operation.
2Adaptability or versatility
If water temperature varies, then operational flexibility is improved, but droplet size consistency deteriorates
Solution Approach 1:
The system incorporates temperature sensors that monitor water temperature variations and provide feedback to a control system. When temperature changes are detected, the control system adjusts operational parameters such as steam flow rate and liquid flow rate to compensate, maintaining consistent droplet size across a wide temperature range.
Solution Approach 2:
The nozzle assembly is designed with dynamic adjustment capabilities where steam flow and liquid flow rates can be varied in response to temperature changes. This dynamic operation allows the system to adapt to different water temperatures while maintaining precise droplet size control through coordinated adjustment of multiple flow parameters.
3Productivity
If the spray nozzle assembly operates for extended periods, then productivity increases, but wear to discharge orifices occurs causing costly repair and replacement
Solution Approach 1:
The spray nozzle assembly is segmented into modular components, with discharge orifices designed as separate, removable inserts within the nozzle body. This segmentation allows individual orifice inserts to be quickly replaced when worn, without requiring replacement of the entire nozzle assembly, thereby reducing maintenance costs and downtime while maintaining high productivity.
Solution Approach 2:
The discharge orifices are designed as inexpensive, replaceable inserts that can be easily swapped out when worn. These simple orifice inserts are much cheaper than the complete nozzle assembly, allowing frequent replacement at minimal cost. The modular design enables quick exchange of worn orifices, maintaining continuous operation with minimal maintenance expenditure.
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 efficient and cost-effective generation of fine liquid particle sprays with controlled droplet size, maintaining consistency over a wide temperature range and facilitating easy maintenance, thus improving spray performance and reducing operational costs.
Implementation Method 1
a steam atomizing spray nozzle assembly having a nozzle body, a liquid supply communicating with said nozzle body, a steam supply communicating with said nozzle body, means for accelerating liquid through said nozzle body, means for accelerating steam through said nozzle body to a velocity sufficient to atomize the liquid
Implementation Method 2
means for accelerating steam through said nozzle body to a velocity sufficient to atomize the liquid
Data Source
AI summary
A steam atomizing liquid spraying system which in the preferred embodiment includes a spray nozzle assembly having a central liquid passageway for coupling to a liquid supply and a plurality of spray nozzles each removably mounted in the nozzle body and having a respective central steam passage communicating with a steam supply. The spray nozzles each further have a plurality of circumferentially spaced liquid accelerating passages that communicate with a respective angled passage of the nozzle body which in turn communicates with the central liquid supply passageway for directing liquid into the central steam passage of the spray nozzle for interaction with steam directed through the central steam passage and atomization of liquid discharging from the spray nozzle. In an alternative embodiment, a single spray nozzle insert is utilized.