Pressure Atomisers

Pressure atomisers are used in a wide range of applications. In this type of atomiser, pressure energy is converted into kinetic energy in order to speed up the liquid to a high velocity relative to surrounding atmosphere (Liu, 2000). A high relative velocity enhances the liquid jet disintegration into a well-atomised spray. Depending on its design and geometry, the corresponding sprays could have different patternations (see Section 5.3 and Figure 5.6). There are several types of pressure atomisers which are briefly discussed below:

5.4.2.4.1 Plain orifice atomiser

The plain-orifice atomiser (see Figure 5.17) is the simplest type of pressure atomiser and is widely used for injecting liquids into a flow stream of air or gas. A circular orifice is used to inject a round jet of liquid into the surrounding air at high velocity under the action of high pressure. The best known of this type of application is possibly diesel injectors. They are widely used for spraying liquids into a flow stream of air or gas. In this type of atomiser, a small orifice size (usually < 0.3mm) and high pressure (>100MPa) are needed to produce a fine spray (Nasr et al., 2002).

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Figure 5.17: Typical plain orifice pressure atomiser

5.4.2.4.2 Fan jets atomiser

Fan jets or flat sprays atomisers use the simple orifice variation, in which the flow of liquid convergence shape of the orifice and the elliptically shaped exit hole combine to diverge the liquid streamlines as they leave the exit orifice (Nasr et al., 2002). Fan jets atomisers generally produce a triangular liquid sheet, the angle (0o- 110o) of which is determined by the orifice shape and the upstream convergence of the orifice. Figure 5.18 shows a typical Vee Jet atomiser.

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5.4.2.4.3 Features and performance of pressure swirl atomiser

The useful features of the pressure swirl atomiser include simplicity of construction, ease of manufacture, reliability, good atomisation quality, low congestion propensities, and low pumping power needs. These benefits have resulted in the widespread use of pressure swirl atomisers (Ibrahim and Jog, 2006). Figure 5.19 shows the various designs of the pressure swirl atomiser.

Figure 5.19: Various designs of pressure swirl atomiser

This type of atomiser is classified as the most competent atomiser in producing a fine spray using pressurised liquid. A minimum supply pressure is necessary to provide a particular drop size (Nasr et al., 2002). In this type of atomiser, swirling motion is imparted to the liquid inside the atomiser. It spreads out as a conical sheet once it leaves

104 the orifice under the action of centrifugal force. The atomiser consists of a cylindrical swirl chamber with arrangements of inlet and exit orifices.

Swirl atomisers differ from other atomisers in the quality of atomisation, and in the simplicity of construction and the reliability of operation (Khavkin, 2004). There are two major types of the swirl atomiser: the hollow-cone spray atomiser and the full-cone

spray atomiser.

In the hollow-cone atomiser, most of the drops are concentrated at the outer edge of the conical spray pattern, while in the full-cone spray atomiser the drops are distributed across the spray.

In comparison, the hollow-cone atomisers provide better atomisation than solid-cone as solid-cone atomisers provide relatively coarse atomisation. Moreover, hollow-cone atomisers are preferred for many industrial applications due to their radial liquid distribution.

Horvay and Leuckel (1984) and Bayvel and Orzechowski (1993) accredit the swirl atomiser invention to Korting in 1902. Its applications include: aerosol products, oil fired combustors, agriculture, fire suppression, spray drying, fuel injection systems and many chemical processes.

Typically, solid- or full-cone atomisers have a larger drop size compared with hollow- cone atomisers. The aim of the experimental work in this study was to produce fine droplets (≤ 5 μm) by using a spraying and atomisation techniques; therefore, a hollow- cone atomiser has been selected in this research because it produces smaller drop sizes compared with the full cone atomiser (Nasr et al., 2002 and Lefebvre, 1989).

105 The characteristics of the spray produced by hollow-cone spray atomisers have been studied by a number of investigators. Rizk and Lefebvre (1984) reported that the mean drop sizes are relatively large close to the atomiser but decrease with the increase in downstream distance. Tokuoka et al. (1991) studied the radial distribution of the drop size, velocity and volume flux of the spray and they reported that the spray produced from hollow-cone atomisers contain, in general, large drops at the fringe and smaller drops entrained towards the central region. The important performance characteristic of this atomiser reinforced the selection that was made at the design stage of the present study, because the hollow-cone atomiser is capable of producing fine drops.

The effects of injection pressure and atomiser characteristics on hollow-cone sprays have also been studied by Zhang et al. (1991). They reported that the boundary between the sheath region and the central part of spray became clearer and the thickness of the sheath region decreased with increasing injection pressure.

The operating pressure is the major factor that affects the flow rate through an atomiser, which may be calculated by using the following relationship:

( ⁄ ) (5.22)

Where P1 is the calculated pressure for the desired spray discharge flow rate, Q1, P2 and Q2 are the known pressure and the spraying flow rate. This relationship is acceptable for most industrial applications and was used in the design of the atomiser in this research.

The relative velocity between the fluid and the air affects the droplet sizes. The fluid’s velocity is created by pressure in the atomiser. Velocity increases as the fluid pressure

106 increases, and the average droplet size decreases. Figure 5.20 illustrates the development stages of the spray as the liquid injection pressure is increased.

The next chapter presents the design, construction and set-up of the experimental apparatus used in this research, in addition to the experimental procedure.

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CHAPTER - 6: DESIGN OF A FINE SPRAY ATOMISER DEVICE, EXPERIMENTAL SET-UP AND PROCEDURE

6.1 Introduction

This chapter presents the design, construction and set-up of the experimental apparatus of the second method used in this research, in addition to the experimental procedure. The first method of this work (previously mentioned in Chapter Four) was a theoretical investigation of partial oxidation of natural gas (mainly methane) to produce syngas. The second method is the generation of Single-Walled Carbon Nanotubes (SWCNT) from the excess natural gas that was previously flared in oil industry activity.

The second method is divided into two phases: Phase-I was implemented at the University of Salford, Spray Research Group Laboratory, to develop sprays and atomisation techniques to produce fine droplets that have a number mean diameter (Dn0.50) of less than or equal 5 μm. Phase-II was implemented at the University of Oxford, in which a furnace was installed at the bottom of the Phase-I rig and the droplet particles’ stream of methane and a catalyst solution was passed through the furnace (400 – 800o

C). These reacted within the furnace to form C + 2H2. The carbon, after

dissolving in the iron (Fe) metal, will reorganise to form the Single-Walled Carbon Nanotubes material and the hydrogen may be stored for other use. The following sections describe in detail the design of the spray device, in addition to the construction and set-up of the experimental apparatus and the experimental procedure.

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