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Understanding Spray Technology to Optimize Sulfur Burning
Understanding Spray Technology to Optimize Sulfur Burning
Chuck MunroDan VidusekChuck MunroDan Vidusek
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Understanding Spray Technology to Optimize Sulfur Burning
75yearoldnozzleengineering & manufacturing company Leaderinspraytechnology Globalmanufacturing,salesandsupport Nozzles,headers,injectors, controlsandresearch&testing
About SprayingSystemsCo.
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Understanding Spray Technology to Optimize Sulfur Burning
Nozzles101:TypesandPerformance CommonProblemswithMoltenSulfurSpraying Hydraulicvs.TwoFluidStudyusingComputationalFluidDynamics(CFD)
Agenda
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Understanding Spray Technology to Optimize Sulfur Burning
ItALWAYSStartswiththeNozzle
Providesaspecificvolumeoffluidataspecifiedpressuredrop Convertsfluidintoapredictabledropsizespectrumwithaspecificspraycoverage
Thenozzleistheheartoftheprocess asmallcomponentthatgreatlyaffectssystemperformance
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Understanding Spray Technology to Optimize Sulfur Burning
HydraulicAtomizerTypes
FlatSpray Hollow ConeFullCone
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Understanding Spray Technology to Optimize Sulfur Burning
FullConeSpray Liquidisswirledwithinthenozzle
byavaneandexitstheorificeinaconicalpattern
Mediumtolargedropsize Limitedfreepassage(duetovane) Relativelylowresistanceto
clogging Widedropsizespectrum
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Understanding Spray Technology to Optimize Sulfur Burning
FlatSpray Liquidpassesthroughanelliptical
orifice,formingaflatfanpattern Widevarietyofspraycoverages Mediumdropsizespectrum Largefreepassage Dropletsaremoreconcentrated
inasmallerarea
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Understanding Spray Technology to Optimize Sulfur Burning
HollowConeSpraySprayisformedwithinthenozzlebyaninletthatistangentialtoawhirlchamber
Theresultingwhirlingliquidformsahollowconeasitleavestheorifice
Largefree passagesforgoodclogresistance
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Understanding Spray Technology to Optimize Sulfur Burning
BAWhirlJetSulfurBurningNozzleHollowconespraypatternSmall tomediumsizeddropletsLarge, unobstructedflowpassagestominimizeclogging
Relatively lowcosttooperate
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Understanding Spray Technology to Optimize Sulfur Burning
Areallnozzlescreatedequal?
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Understanding Spray Technology to Optimize Sulfur Burning
Gasandliquidaremixedinaninternalchamber;sprayexitsorificeinaflatorroundspraypattern
Smallestdropsize Narrowdropsizespectrum Sensitivetochangesinoperatingpressures Largefreepassage Relativelyhighresistancetoclogging
DualFluid AirAtomizing
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Understanding Spray Technology to Optimize Sulfur Burning
DualFluidNozzleHowitworks:
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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.
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Understanding Spray Technology to Optimize Sulfur Burning
AtomizationAtomizationofaliquidinvolvesbreakingtheliquidupintoverysmallpiecescalleddrops
Everyspraynozzleprovidesarangeofdropsizesratherthanonesinglesize
Thedropsizerangevarieswith Liquidproperties Nozzletype Capacity Pressure Sprayangle
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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
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Understanding Spray Technology to Optimize Sulfur Burning
AtomizationMechanicsPrimarybreakup
conicalsheet
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Understanding Spray Technology to Optimize Sulfur Burning
AtomizationMechanicsSecondarybreakup
dropletbreakup
Airflowdirections
Dropflattenedbyairpressure
Cupforms(bubbleexpands)
Bubblebursts,thickrimremains
Rimbreaksintoligaments,bubblefragmentsremain
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Understanding Spray Technology to Optimize Sulfur Burning
CommonFactorsAffectingMoltenSulfurAtomizationPluggednozzlesSprayatomization
SulfurcarryoverTurndownGundesign
Sulfurtemperatureconsistency Steammigrationintosulfurline
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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)
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Understanding Spray Technology to Optimize Sulfur Burning
SprayAtomizationIfthemoltensulfurdropletsaretoolarge,theydonotcombustintimeandcancarryoverandcausefiresdownstream
Itisimportanttohavethesprayeddropletdistributionsizedcorrectlytooptimizeburneroperation
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Understanding Spray Technology to Optimize Sulfur Burning
Turndown
Alargeturndownofthenozzle(s)flowrateisrequiredforstartup,lowproductiontimesandtoaccommodatepeakproduction
Canbeachievedby: Addingorremovingguns Adjustingoperatingpressureoftheguns/nozzles
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Understanding Spray Technology to Optimize Sulfur Burning
Turndown
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Understanding Spray Technology to Optimize Sulfur Burning
GunDesign
Allowforthermalexpansionandtowithstandtemperatureloadingwithoutbending
Steamrecirculationfortightcontrolofmoltensulfurtemperatureandassociatedphysicalproperties
Designcriteriashouldstipulate:PropertestingmustbeconductedValidationisperformedWeldersareproperlytrained
Criticalthateachpathway(moltensulfur,atomizingmedium,jacketingsteam)areisolatedfromeachother
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Understanding Spray Technology to Optimize Sulfur Burning
InjectorDesign:HydraulicSulfurGun
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Understanding Spray Technology to Optimize Sulfur Burning
InjectorDesign:TwoFluidSulfurGun
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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
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Understanding Spray Technology to Optimize Sulfur Burning
TemperatureProfilesTemperature(C)
2000
1075
150
TOUT=1434(C)
InjectionPlanes
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Understanding Spray Technology to Optimize Sulfur Burning
SpeciesContent(Sulfur)MassFractionSulfur
.063
.032
.000
SulfurCombustionPriortoBaffleWall
FullCombustionPriortoOutlet
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Understanding Spray Technology to Optimize Sulfur Burning
SpeciesContent(Oxygen)
MassFractionOxygen
.063
.032
.000
OxygenDepletedPriortoBaffleWall
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Understanding Spray Technology to Optimize Sulfur Burning
SprayVisualization
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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
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Understanding Spray Technology to Optimize Sulfur Burning
TemperatureprofileTemperature(C)
2000
1075
150
TOUT=1547(C)
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Understanding Spray Technology to Optimize Sulfur Burning
SpeciesContent(Sulfur)MassFractionSulfur
.063
.032
.000Sulfurcombustionnotcompletepriortobafflewall
FullCombustionPriortoOutlet
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Understanding Spray Technology to Optimize Sulfur Burning
SpeciesContent(Oxygen)MassFractionOxygen
.063
.032
.000
OxygenDepletedPriortoBaffleWall
SecondaryAirImbalanceinOxygen
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Understanding Spray Technology to Optimize Sulfur Burning
SprayVisualization
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Understanding Spray Technology to Optimize Sulfur Burning
CFDConclusions
Velocity
Goodalignmentwithvelocitycontoursofinletair hydraulic
Pooralignmentwithvelocitycontoursofinletair hydraulic
WallImpingement
Impingementwithbaseofcombustionchamber hydraulic
Noimpingementwithbaseofcombustionchamber dualfluid
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Understanding Spray Technology to Optimize Sulfur Burning
NewHybridSulfurGunHydraulicandairatomizinginasinglegun
Quickchangeoverfromhydraulicnozzlestoairatomizingnozzles
Compressedairmustbedrytoeliminateunwantedmoisture
Allowsusertotryairatomizingandconvertbacktohydraulicwhileresultsarereviewed
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Understanding Spray Technology to Optimize Sulfur Burning
NewHybridSulfurGunwithHydraulicNozzle
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Understanding Spray Technology to Optimize Sulfur Burning
NewHybridSulfurGunwithDualFluidNozzle
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Understanding Spray Technology to Optimize Sulfur Burning
HybridSulfurGunDemo
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Understanding Spray Technology to Optimize Sulfur Burning
AirAtomizing NotforEveryone
PositiveSmallerdropsize bettercombustion
Smallerdropsizedistribution:moreefficientcontrolofprocess
Constantairflowkeepnozzlepurged
NegativeMoltensulfurcanhavesolidsthatclogthenozzle
RequiresmoreprocesspipingCompressedairuseaddscost
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Understanding Spray Technology to Optimize Sulfur Burning
InSummaryBeginwiththeendinmind!Thinkintermsofdropsizerequirements
UseCFDwhenmanyfactorsinfluencethespray
ContactSprayingSystemsCo.earlytohelpsolveyoursprayapplication
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Understanding Spray Technology to Optimize Sulfur Burning
ThankYou!
