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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!


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