Spray nozzles, pneumatic

Suitable feeds to a spray dryer are solutions or pumpable pastes and slurries. Such a material is atomized in a nozzle or spray wheel, contacted with heated air or flue gas and conveyed out of the equipment with a pneumatic or mechanical type of conveyor. Collection of fines with a cyclone separator or filter is a major aspect of spray dryer operation. Typical equipment arrangements and flow patterns are shown in Figure 9.14. 

Proper atomization of feed is the key to successful spray drying. The three devices of commercial value are pressure nozzles, pneumatic nozzles, and rotating wheels of various designs. Usual pressures employed in nozzles range from 300 to 4000 psi, and... 

The main variables in the operation of atomizers are feed pressure, orifice diameter, flow rate and motive pressure for nozzles and geometry and rotation speed of wheels. Enough is known about these factors to enable prediction of size distribution and throw of droplets in specific equipment. Effects of some atomizer characteristics and other operating variables on spray dryer performance are summarized in Table 9.18. A detailed survey of theory, design and performance of atomizers is made by Masters (1976), but the conclusion is that experience and pilot plant work still are essential guides to selection of atomizers. A clear choice between nozzles and spray wheels is rarely possible and may be arbitrary. Milk dryers in the United States, for example, are equipped with nozzles, but those in Europe usually with spray wheels. Pneumatic nozzles may be favored for polymeric solutions, although data for PVC emulsions in Table 9.16(a) show that spray wheels and pressure nozzles also are used. Both pressure nozzles and spray wheels are shown to be in use for several of the applications of Table 9.16(a). 

The negative exponent on the Reynolds number of -0.32 indicates that Re has a medium effect on the mean diameter. This result is about in accordance with those obtained by Gretzinger and Marshall [801 in their investigation on the external mixing pneumatic spray nozzles. 

Generally a very narrow droplet spectrum is obtained and the relative uniformity of the coating is improved accordingly. A further advantage of this method is that the gas flow rate is independent of the aerosol flow rate, which is not the case with pneumatic spraying. A modern spray deposition process can be described by relatively few parameters such as flow of carrier gas Q, concentration of the solution C, solution flow q, droplet radius r, distance between nozzle and substrate d, temperature of the gaseous environment Te, temperature of the substrates Ts and their speed... 

FIGURE 25.3 Microscopic images of carnauba wax microparticles produced by spray congealing under following conditions melt temperature 115°C, pneumatic spraying system with air pressure 1 bar, air nozzle internal diameter 1 mm (unpublished data). 

Antkowiak, W., and Heim, A., Investigation of Pneumatic Spray Nozzle for Wetting Granulate Fine Material, Inzynieria Chemiezna i Procesowa (Chem. Process Eng.), Vol. 8, No. 1, 1987, pp. 57-65 (in Polish). 

For proper use of the equations, the chamber shape must conform to the spray pattern. With cocurrent gas-spray flow, the angle of spread of single-fluid pressure nozzles and two-fluid pneumatic nozzles is such that wall impingement wiU occur at a distance approximately four chamber diameters below the nozzle therefore, chambers employing these atomizers should have vertical height-to-diameter ratios of at least 4 and, more usually, 5. The discharge cone below the vertical portion should have a slope of at least 60°, to minimize settling accumulations, and is used entirely to accelerate gas and solids for entty into the exit duct. 

Two-Fluid (Pneumatic) Atomizers This general category includes such diverse apphcations as venturi atomizers and reac tor-effluent quench systems in addition to two-fluid spray nozzles. Depending on the manner in which the two fluids meet, several of the breakup mechanisms may be apphcable, but the final one is high-level turbulent rupture. 

Optimum atomization is achieved by fine adjustment of the air cap and atomization air pressure measured at the nozzle. The binder solution is delivered to the nozzle port through a spray lance and tubing. The peristaltic- or positive-displacement pump is commonly used to pump the binder solution. The pneumatically controlled nozzle needle prevents the binder liquid from... 

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