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Type of Nozzle for Sulphur Spraying.
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Understanding Spray Technology to Optimize Sulfur Burning
Understanding Spray Technology to Optimize Sulfur Burning
Chuck MunroDan VidusekChuck MunroDan Vidusek
Understanding Spray Technology to Optimize Sulfur Burning
75yearoldnozzleengineering & manufacturing company Leaderinspraytechnology Globalmanufacturing,salesandsupport Nozzles,headers,injectors, controlsandresearch&testing
About SprayingSystemsCo.
Understanding Spray Technology to Optimize Sulfur Burning
Nozzles101:TypesandPerformance CommonProblemswithMoltenSulfurSpraying Hydraulicvs.TwoFluidStudyusingComputationalFluidDynamics(CFD)
Agenda
Understanding Spray Technology to Optimize Sulfur Burning
ItALWAYSStartswiththeNozzle
Providesaspecificvolumeoffluidataspecifiedpressuredrop Convertsfluidintoapredictabledropsizespectrumwithaspecificspraycoverage
Thenozzleistheheartoftheprocess asmallcomponentthatgreatlyaffectssystemperformance
Understanding Spray Technology to Optimize Sulfur Burning
HydraulicAtomizerTypes
FlatSpray Hollow ConeFullCone
Understanding Spray Technology to Optimize Sulfur Burning
FullConeSpray Liquidisswirledwithinthenozzle
byavaneandexitstheorificeinaconicalpattern
Mediumtolargedropsize Limitedfreepassage(duetovane) Relativelylowresistanceto
clogging Widedropsizespectrum
Understanding Spray Technology to Optimize Sulfur Burning
FlatSpray Liquidpassesthroughanelliptical
orifice,formingaflatfanpattern Widevarietyofspraycoverages Mediumdropsizespectrum Largefreepassage Dropletsaremoreconcentrated
inasmallerarea
Understanding Spray Technology to Optimize Sulfur Burning
HollowConeSpraySprayisformedwithinthenozzlebyaninletthatistangentialtoawhirlchamber
Theresultingwhirlingliquidformsahollowconeasitleavestheorifice
Largefree passagesforgoodclogresistance
Understanding Spray Technology to Optimize Sulfur Burning
BAWhirlJetSulfurBurningNozzleHollowconespraypatternSmall tomediumsizeddropletsLarge, unobstructedflowpassagestominimizeclogging
Relatively lowcosttooperate
Understanding Spray Technology to Optimize Sulfur Burning
Areallnozzlescreatedequal?
Understanding Spray Technology to Optimize Sulfur Burning
Gasandliquidaremixedinaninternalchamber;sprayexitsorificeinaflatorroundspraypattern
Smallestdropsize Narrowdropsizespectrum Sensitivetochangesinoperatingpressures Largefreepassage Relativelyhighresistancetoclogging
DualFluid AirAtomizing
Understanding Spray Technology to Optimize Sulfur Burning
DualFluidNozzleHowitworks:
Understanding Spray Technology to Optimize Sulfur Burning
NozzleComparison
Issue Hydraulic1/2BA309SS70
AirAtomizingFM25A
FlowRate [email protected]@10.3bar
[email protected]@5.3bar(1.7m3/m constantair)
Turndown 2.7:1 6:1FreePassage 9.5mm 6.4mmDropSize(@ 28gpm) Dmax =1,087mm
Dv0.90=754mmD32=277mm
Dmax =375mmDv0.90=300mmD32=185mm
Althoughthehydraulicnozzlehasalargerfreepassagearea,theairatomizingnozzleprovidessmallerdropletsatagreaterturndownratio.
Understanding Spray Technology to Optimize Sulfur Burning
AtomizationAtomizationofaliquidinvolvesbreakingtheliquidupintoverysmallpiecescalleddrops
Everyspraynozzleprovidesarangeofdropsizesratherthanonesinglesize
Thedropsizerangevarieswith Liquidproperties Nozzletype Capacity Pressure Sprayangle
Understanding Spray Technology to Optimize Sulfur Burning
Diameter(m)
NumberofDrops
Volume(in3)
SurfaceArea(in2)
PercentageincreaseinSurfaceArea
500 1 4x106 1.22x103
100 121 4x106 5.89x103 484%
IncreaseinSurfaceArea
100m
Masstransferisproportionaltothedropletsurfacearea!
SurfaceArea=4r2 Volume=4/3r3150m 200m 250m 300m 400m 500m
Understanding Spray Technology to Optimize Sulfur Burning
AtomizationMechanicsPrimarybreakup
conicalsheet
Understanding Spray Technology to Optimize Sulfur Burning
AtomizationMechanicsSecondarybreakup
dropletbreakup
Airflowdirections
Dropflattenedbyairpressure
Cupforms(bubbleexpands)
Bubblebursts,thickrimremains
Rimbreaksintoligaments,bubblefragmentsremain
Understanding Spray Technology to Optimize Sulfur Burning
CommonFactorsAffectingMoltenSulfurAtomizationPluggednozzlesSprayatomization
SulfurcarryoverTurndownGundesign
Sulfurtemperatureconsistency Steammigrationintosulfurline
Understanding Spray Technology to Optimize Sulfur Burning
NozzlePluggageCarsulorothercontaminantsinthemoltensulfurcanplugnozzleorifices Particlescanbedifferentsizessomaximizingthefree
passageofanozzleiscriticalPluggage canoccurwhengunpressurereducedorgunsareturnedoff Withairatomizingnozzles,airpurgesthesulfur
Comparisonofahydraulicandairatomizingnozzle@14gpmflowrate:
1/2BA309SS70 FM25A0.375(9.5mm) 0.250 (6.4mm)
Understanding Spray Technology to Optimize Sulfur Burning
SprayAtomizationIfthemoltensulfurdropletsaretoolarge,theydonotcombustintimeandcancarryoverandcausefiresdownstream
Itisimportanttohavethesprayeddropletdistributionsizedcorrectlytooptimizeburneroperation
Understanding Spray Technology to Optimize Sulfur Burning
Turndown
Alargeturndownofthenozzle(s)flowrateisrequiredforstartup,lowproductiontimesandtoaccommodatepeakproduction
Canbeachievedby: Addingorremovingguns Adjustingoperatingpressureoftheguns/nozzles
Understanding Spray Technology to Optimize Sulfur Burning
Turndown
Understanding Spray Technology to Optimize Sulfur Burning
GunDesign
Allowforthermalexpansionandtowithstandtemperatureloadingwithoutbending
Steamrecirculationfortightcontrolofmoltensulfurtemperatureandassociatedphysicalproperties
Designcriteriashouldstipulate:PropertestingmustbeconductedValidationisperformedWeldersareproperlytrained
Criticalthateachpathway(moltensulfur,atomizingmedium,jacketingsteam)areisolatedfromeachother
Understanding Spray Technology to Optimize Sulfur Burning
InjectorDesign:HydraulicSulfurGun
Understanding Spray Technology to Optimize Sulfur Burning
InjectorDesign:TwoFluidSulfurGun
Understanding Spray Technology to Optimize Sulfur Burning
FurnaceCFDSetup
TopView
SideView
Main Inlet Air Q=308,000Nm3/hr =113.9kg/s T =122C Poperating =11barg
OutletTout ~1160C
Injections (6x)53686001injectorswith1/2BA309SS70WhirlJet nozzle
Liquidsulfur Qtotal =29m3/hr total =14.6kg/s(2.4kg/spernozzle) T =132C
SecondaryInlets Air total =1kg/s T=122C
Understanding Spray Technology to Optimize Sulfur Burning
TemperatureProfilesTemperature(C)
2000
1075
150
TOUT=1434(C)
InjectionPlanes
Understanding Spray Technology to Optimize Sulfur Burning
SpeciesContent(Sulfur)MassFractionSulfur
.063
.032
.000
SulfurCombustionPriortoBaffleWall
FullCombustionPriortoOutlet
Understanding Spray Technology to Optimize Sulfur Burning
SpeciesContent(Oxygen)
MassFractionOxygen
.063
.032
.000
OxygenDepletedPriortoBaffleWall
Understanding Spray Technology to Optimize Sulfur Burning
SprayVisualization
Understanding Spray Technology to Optimize Sulfur Burning
FurnaceCFDwithFloMaxnozzles
InjectionParameters Liquid:MoltenSulfurPernozzle units Flomax FM5A
LiquidFlowRate lpm 80.5
LiquidMassFlowRate kg/s 2.44
LiquidTemperature C 132
DropletVelocity m/s 35
SprayAngle 55
DV0.01 Minimum m 11
DV0.50 Average m 66
DV0.99 Maximum m 144
N(RRspreadparameter) 2.4
2.5m
Understanding Spray Technology to Optimize Sulfur Burning
TemperatureprofileTemperature(C)
2000
1075
150
TOUT=1547(C)
Understanding Spray Technology to Optimize Sulfur Burning
SpeciesContent(Sulfur)MassFractionSulfur
.063
.032
.000Sulfurcombustionnotcompletepriortobafflewall
FullCombustionPriortoOutlet
Understanding Spray Technology to Optimize Sulfur Burning
SpeciesContent(Oxygen)MassFractionOxygen
.063
.032
.000
OxygenDepletedPriortoBaffleWall
SecondaryAirImbalanceinOxygen
Understanding Spray Technology to Optimize Sulfur Burning
SprayVisualization
Understanding Spray Technology to Optimize Sulfur Burning
CFDConclusions
Velocity
Goodalignmentwithvelocitycontoursofinletair hydraulic
Pooralignmentwithvelocitycontoursofinletair hydraulic
WallImpingement
Impingementwithbaseofcombustionchamber hydraulic
Noimpingementwithbaseofcombustionchamber dualfluid
Understanding Spray Technology to Optimize Sulfur Burning
NewHybridSulfurGunHydraulicandairatomizinginasinglegun
Quickchangeoverfromhydraulicnozzlestoairatomizingnozzles
Compressedairmustbedrytoeliminateunwantedmoisture
Allowsusertotryairatomizingandconvertbacktohydraulicwhileresultsarereviewed
Understanding Spray Technology to Optimize Sulfur Burning
NewHybridSulfurGunwithHydraulicNozzle
Understanding Spray Technology to Optimize Sulfur Burning
NewHybridSulfurGunwithDualFluidNozzle
Understanding Spray Technology to Optimize Sulfur Burning
HybridSulfurGunDemo
Understanding Spray Technology to Optimize Sulfur Burning
AirAtomizing NotforEveryone
PositiveSmallerdropsize bettercombustion
Smallerdropsizedistribution:moreefficientcontrolofprocess
Constantairflowkeepnozzlepurged
NegativeMoltensulfurcanhavesolidsthatclogthenozzle
RequiresmoreprocesspipingCompressedairuseaddscost
Understanding Spray Technology to Optimize Sulfur Burning
InSummaryBeginwiththeendinmind!Thinkintermsofdropsizerequirements
UseCFDwhenmanyfactorsinfluencethespray
ContactSprayingSystemsCo.earlytohelpsolveyoursprayapplication
Understanding Spray Technology to Optimize Sulfur Burning
ThankYou!