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i

EFFECT OF LIQUID PROPERTIES (WATER AND LIME JUICE) ON

SPRAY CHARACTERISTICS OF DEFLECTED FLAT SPRAY NOZZLE

(AL-75)

MUHAMMAD FAQHRURRAZI BIN ABD RAHMAN

A thesis submitted in

fulfilment of the requirement for the award of the

Degree of Master of Mechanical Engineering

FACULTY OF MECHANICAL AND MANUFACTURING ENGINEERING

UNIVERSITI TUN HUSSEIN ONN MALAYSIA

AUGUST 2017

iii

SPECIAL GRATITUDE TO;

THE MOST BELOVED PARENTS,

Abd Rahman Bin Mohd Hasan and Fatimah Sham Binti Matt@Ahmad

For their support in whole of my life

MY HONOURED SUPERVISOR,

Assoc. Prof. Dr Norzelawati Binti Asmuin

For their advice, support and patience during completion this thesis

MY CO-SUPERVISOR

En. Mohamad Farid bin Sies

For their advice, support and patience during completion this thesis

SPECIAL THANK YOU FOR

All my friends

For their moral support, cooperation and assistance in this study

iv

ACKNOWLEDGEMENT

Alhamdulillah praises to Allah S.W.T due to His will and gift and blessing upon

Prophet Muhammad (p.b.u.h). By His grace, He places mankind on the friendly

earth, provide them all with the necessities for healthy living, permits them the

discovery of knowledge of science and application of technological skill for their

physical advancement in this temporary life. Ultimately, all shall return to Allah,

only the deed that pleases Him will remain on their credit for the internal life

hereafter.

There are no proper word to convey my deep gratitude and respect for my

supervisors, Assoc. Prof. Dr Norzelawati Binti Asmuin for guidance, encouragement

and also the advice throughout my time as student him. Also for my co-supervisor

Encik Mohammad Farid Bin Sies that always help me and assistance me until I finish

my work. Only Allah S.W.T shall repay all him kindness. Special thanks to my

parents Abd Rahman Bin Mohd Hasan and Fatimah Sham Binti Matt@Ahmad

whom had always supported me and gave encouragement and motivation me during

the course of this study.

My sincere thanks also goes to my friends who went through hard times

together, gave advice and also constructive discussion sessions. Last but not least, I

would like to thank those who have contributed directly or indirectly towards the

success of this study.

v

ABSTRACT

Nowadays, the application of the nozzle has been widely used in the industry. The

main factor that influences the spray is pressure of the liquid and air, type of nozzle,

type of spray and the viscosity of the liquid. The problem in this research is to

determine minimum liquid pressure used for atomization. This study is on

characteristic with different ratio of liquid properties which can affect the spray

behaviour for this spray such as spray angle, spray development and velocity. The

objective for this research is to get the best atomizer within 1 bar to 3 bar liquid

pressure for household piping. For this study, the pressure of liquid used was 1 bar, 2

bar and 3 bar, whereas the pressure of air used was 1 bar, 3 bar and 6 bar. Another

objective is to identify characteristic study of spray angle, spray development and

velocity of flat fan spray nozzle by using different liquid properties. 3 different fluids

were tested with deflected flat spray nozzle (AL-75); 100% water, L10W90 (consist

of 10% lime and 90% water) and L30W70 (consist of 30% lime and 70% water).

Final objective is to validate result for spray angle and velocity between experiment

and simulation using ANSYS CFX version 15.0. Based on the obtained results, the

duration of fully development for deflected flat spray nozzle (AL-75) operated at the

combination of 3 bar liquid pressure with 3 bar air pressure was 24ms, compared to

spray nozzle operated at the combination of 1 bar liquid pressure with 1 bar air

pressure with 32ms. This is because, an increase in pressure were decreases the

duration for spray pattern to be fully developed. Velocity of 100% water was the

highest compared to L10W90 and L30W70. This is due to the fact that as viscosity

increased, the velocity of spray decreases. Spray angle result shows that water have

wider angle compared to L10W90 and L30W70. As viscosity increased, the spray

angles become narrow and simultaneously reduce the spray angle.

vi

ABSTRAK

Pada masa kini, penggunaan muncung telah digunakan secara meluas dalam industri.

Masalah kajian ini adalah untuk menentukan penggunaan tekanan rendah cecair

untuk pengabusan. Kajian ini memberi tumpuan kepada ciri-ciri dengan nisbah cecair

berbeza yang boleh mempengaruhi tingkah laku semburan seperti sudut semburan,

perkembangan semburan dan halaju. Objektif kajian adalah mendapatkan

pengabusan yang terbaik dalam tekanan 1 bar hingga 3 bar cecair untuk paip rumah.

Untuk kajian ini, tekanan cecair yang digunakan adalah 1 bar, 2 bar dan 3 bar,

manakala tekanan udara yang digunakan adalah 1 bar, 3 bar dan 6 bar. Objektif

seterusnya adalah mengenal pasti ciri kajian sudut semburan, perkembangan

semburan dan halaju muncung semburan rata dengan menggunakan cecair yang

berbeza. 3 cecair yang berbeza telah diuji dengan muncung semburan kipas rata;

100% air, L10W90 (terdiri daripada 10% limau dan 90% air) dan L30W70 (terdiri

daripada 30% limau dan 70% air). Objektif terakhir adalah untuk mengesahkan

keputusan sudut semburan dan halaju daripada perbezaan eksperimen dan simulasi

menggunakan ANSYS CFX versi 15.0. Berdasarkan keputusan, tempoh

perkembangan sepenuhnya untuk muncung semburan rata (AL-75) pada kombinasi

tekanan cecair 3 bar dengan tekanan udara 3 bar adalah 24ms, berbanding semburan

muncung beroperasi pada gabungan 1 bar tekanan cecair dengan 1 bar tekanan udara

32ms. Ini kerana, peningkatan dalam tekanan mengurangkan tempoh untuk corak

semburan. Halaju 100% air adalah yang tertinggi berbanding L10W90 dan L30W70.

Ini disebabkan kelikatan meningkat, halaju semburan berkurangan. Sudut semburan

menunjukkan bahawa air mempunyai sudut yang lebih luas berbanding L10W90 dan

L30W70. Kelikatan meningkat, sudut semburan menjadi sempit dan pada masa yang

sama mengurangkan sudut semburan.

vii

CONTENT

TITLE i

DECLARATION ii

DEDICATION iii

ACKNOWLEDGEMENT iv

ABSTRACT v

ABSTRAK vi

TABLE OF CONTENT vii

LIST OF FIGURES xii

LIST OF TABLES xvii

LIST OF SYMBOLS AND ABBREVIATIONS xix

LIST OF APPENDICES xx

LIST OF PUBLICATIONS xxi

CHAPTER 1 INTRODUCTION 1

1.1 Background study 1

1.2 Problem statement 2

1.3 Objectives 3

1.4 Scope of study 3

1.5 Outline of the thesis 4

viii

CHAPTER 2 LITERATURE REVIEW 5

2.1 Introduction 5

2.2 Atomization 5

2.2.1 Droplet size 6

2.3 Spray nozzle 7

2.3.1 Two fluid nozzle 9

2.3.1.1 Internal mixing nozzle 9

2.3.1.2 Flow principle for spray nozzle 10

2.4 Types of spray nozzle 12

2.4.1 Standard flat fan spray nozzle 12

2.4.2 Full cone spray nozzle 13

2.4.3 Hollow cone spray nozzle 13

2.4.4 Deflected flat spray nozzle 14

2.5 Spray nozzle performance 15

2.5.1 Spray angle affected by viscosity

and pressure 16

2.5.2 Velocity affected by viscosity and pressure 20

2.6 Image capture 22

2.6.1 High speed camera 23

2.6.2 Tracker software 25

2.6.3 ImageJ 27

2.7 Computational fluid dynamics (CFD) 30

2.7.1 Turbulence modelling 31

2.8 Lime juice 32

2.9 Flow rate 32

2.10 Summary 33

ix

CHAPTER 3 METHODOLOGY 34

3.1 Introduction 34

3.2 Flow chart experimental and simulation on

deflected flat spray nozzle 35

3.3 Spray nozzle 37

3.3.1 Deflected flat spray nozzle 38

3.4 Lime and water as liquid for deflected flat

spray nozzle 39

3.4.1 Density and viscosity for the lime 39

3.4.2 Liquid and air pressure for deflected

flat spray nozzle 41

3.4.3 Flow rate for water, L10W90 and L30W70 41

3.5 Experimental setup procedure 45

3.5.1 Apparatus and equipment 47

3.6 Phantom camera control software (PCC) 53

3.7 Velocity trace by tracker software 56

3.8 Spray angle trace by imageJ 59

3.9 Calculation of molar mass and density of

citric acid and water 61

3.10 Choosing simulation on deflected flat spray nozzle 63

3.10.1 Geometry for deflected flat spray nozzle 64

3.10.2 Meshing for deflected flat spray nozzle 65

3.10.3 Mesh quality: skewness and orthogonal 66

3.10.4 Parameter setup for ANSYS CFX 67

CHAPTER 4 RESULTS AND DISCUSSIONS 68

4.1 Introduction 68

4.2 Spray development for deflected flat spray nozzle 68

4.2.1 Spray development for 1 bar liquid 1 bar air 69

x






4.2.7 Tulip and distorted pencil condition 75

4.3 Calculation of boundary condition in simulation 77

4.3.1 Setup for deflected flat spray nozzle 79

4.4 Calculation of velocity for simulation and experiment 83

4.5 Validation on the simulation 86

4.5.1 3 bar liquid 3 bar air using

water as the working fluid 87


L10W90 as the working fluid 89



4.6 Validation of the simulation using experimental data 93

4.6.1 Spray angle for 3 bar liquid 3 bar air

using water as the working fluid 93


using L10W90 as the working fluid 95


using L30W70 as the working fluid 96

4.7 Discussions 98

4.7.1 Effects on velocity by varying

operating pressure (experiment) 98

4.7.2 Effects on spray angle by varying

operating pressure (experiment) 99

xi

4.7.3 Effect on velocity by varying operating

pressure (simulation and experiment) 100

4.7.4 Effect on spray angle by varying operating

pressure (simulation and experiment) 101

CHAPTER 5 CONCLUSION AND RECOMMENDATION 102

5.1 Conclusion 102

5.2 Recommendation 103

REFERENCES 104

APPENDICES 108

xii

LIST OF FIGURES

Figure 2.1 Atomization phases 6

Figure 2.2 Categories of droplet size in micron 7

Figure 2.3 Properties of sprays and examples of their uses 8

Figure 2.4 Spray nozzle 9

Figure 2.5 Internal mixing nozzle 10

Figure 2.6 Flow principle of the spray nozzle 11

Figure 2.7 Standard flat-fan nozzle 12

Figure 2.8 Full cone spray nozzle 13

Figure 2.9 Hollow cone nozzle 14

Figure 2.10 Deflected flat spray nozzle 15

Figure 2.11 Fluid viscosity against cone angle 18

Figure 2.12 Schematic of experimental Rig for Cold Flow Test 19

Figure 2.13 Effect of injection pressure and the number of inlet

slot on spray cone angle 20

Figure 2.14 Velocity against viscosity bar chart 21

Figure 2.15 Geometry model of the jet flow field 21

Figure 2.16 Effect of nozzle pressure drop on nozzle

outlet velocity 22

Figure 2.17 The experimental section in operation, reacting

flow condition 23

Figure 2.18 Bubble emerging from flush-mounted nozzle 24

Figure 2.19 Experimental setup for visual observation of

electrospray 24

Figure 2.20 Camera snapshot of the electrospray of the

pure water 25

Figure 2.21 Analysis using the tracker program 26

xiii

Figure 2.22 Analysis of time dependence for the position (square)

and velocity (circle) of a metal ball, exploring the

mathematical operations of integrations and derivation 27

Figure 2.23 Schematic diagram of newly designed atomizer 28

Figure 2.24 Binary conversion 29

Figure 2.25 Angle measurements using the angle tools in imageJ 29

Figure 2.26 Streamline of velocity distribution in a

nozzle geometry 31

Figure 2.27 The effects of pressure on nozzle mass flow rates 33

Figure 3.1 Flow chart for experimental and simulation 35

Figure 3.2 Deflected flat spray nozzle (AL-75) from

Delavan spray 37

Figure 3.3 Dimension for the AL-75 nozzle 38

Figure 3.4 Deflected Flat spray nozzle 38

Figure 3.5 Experimental setup 45

Figure 3.6 Schematic diagram of the experimental setup 45

Figure 3.7 High Speed Camera 48

Figure 3.8 Air compressor 49

Figure 3.9 Water pressure tank 49

Figure 3.10 Air flow meter 49

Figure 3.11 Water flow meter 50

Figure 3.12 Nikon DSLR D7000 Camera 51

Figure 3.13 50 mm F2 Carl Zeiss lens 51

Figure 3.14 Spotlight Arrilite 1000 52

Figure 3.15 Spotlight stand 52

Figure 3.16 Pressure gauge 52

Figure 3.17 An example of PCC image of AL-75 spray nozzle 53

Figure 3.18 Fully developed spray captured by using Phantom

Camera Control (PCC) for 1 bar liquid 1 bar air with


Figure 3.19 Fully developed spray captured by using Phantom

Camera Control (PCC) for 3 bar liquid 3 bar air

using water as the working fluid 55

xiv

Figure 3.20 Image of fully developed spray for 3 bar liquid

3 bar air in Tracker software 56

Figure 3.21 Graph and table for 3 bar liquid 3 bar air using

water as working fluid in Tracker software 57

Figure 3.22 ImageJ software 59

Figure 3.23 The image from Nikon DSLR D7000 camera

Transferred into imageJ 59

Figure 3.24 The spray image after being invert 60

Figure 3.25 Image of spray angle after measurement 60

Figure 3.26 ANSYS Software 63

Figure 3.27 Geometry of deflected flat spray nozzle (AL-75) 64

Figure 3.28 Meshing of deflected flat spray nozzle (AL-75) 65

Figure 3.29 Skewness value and orthogonal value 66

Figure 4.1 Stage of spray development for water, L10W90 and

L30W70 for (8000 fps) for 1 bar liquid 1 bar

air pressure 69



air pressure 70



air pressure 71

Figure 4.4 Stage of spray development for 3 bar liquid 1 bar air

using water, L10W90 and L30W70 as working fluid

at 8000 fps 72



at 10000 fps 73



at 10000 fps 74

Figure 4.7 Tulip condition in (a) 1 bar liquid 1 bar air, (b) 2 bar

liquid 1 bar air, (c) 2 bar liquid 3 bar air and (d) 3 bar

liquid 1 bar air 75

xv

Figure 4.8 Distorted pencil condition for deflected flat spray

nozzle for 3 bar liquid 1 bar air 76

Figure 4.9 Tulip condition for deflected flat spray nozzle

for 3 bar liquid 1 bar air 77

Figure 4.10 Geometry of AL-75 spray nozzle for this simulation 80

Figure 4.11 Air inlet for AL-75 spray nozzle 81

Figure 4.12 Water/Lime inlet for AL-75 spray nozzle 82

Figure 4.13 Water velocity contour for 3 bar liquid 3 bar air

using water as working fluid 82

Figure 4.14 Trigonometry method used in the tracker for

the experiment 83

Figure 4.15 The position of probe for zero gradients 85

Figure 4.16 The point for the final velocity 86

Figure 4.17 Experiment result for 3 bar liquid 3 bar air using


Figure 4.18 Simulation result for 3 bar liquid 3 bar air using


Figure 4.19 Experimental result for 3 bar liquid 3 bar air using


Figure 4.20 Simulation result for 3 bar liquid 3 bar air using


Figure 4.21 Experimental result for 3 bar liquid 3 bar air using


Figrue 4.22 Simulation result for 3 bar liquid 3 bar air using


Figure 4.23 The spray angle from the experiment for 3 bar liquid

3 bar air using water as the working fluid 94

Figure 4.24 The spray angle from the simulation for 3 bar liquid

3 bar air using water as the working fluid 94

Figure 4.25 The spray angle from the experiment result for 3 bar

liquid 3 bar air using L10W90 as the working fluid 95

Figure 4.26 The spray angle from the simulation result for 3 bar


xvi

Figure 4.27 The spray angle from the experiment result for 3 bar


Figure 4.28 The spray angle from the simulation result for 3 bar


xvii

LIST OF TABLES

Table 2.1 Summaries for the various factors that affect the

spray performance 15

Table 2.2 Suggested minimum spray heights 16

Table 2.3 Viscosities of water glycerol mixture fluids at 23.3oC 17

Table 2.4 Volume ratio of glycerol with cone angle 17

Table 2.5 Viscosity of mixture distilled water with different

percentage of Glycerine 20

Table 3.1 Properties of lime and water mixing used in the

simulation obtained by experiment 39

Table 3.2 Density of lime juice + raw water 39

Table 3.3 Viscosity rate for lime juice + distilled water 40

Table 3.4 Pressure of both liquid and air for 6 different cases 41

Table 3.5 Flow rate for water 43

Table 3.6 Flow rate for L10W90 43

Table 3.7 Flow rate for L30W70 44

Table 3.8 Specification for Phantom Camera Control V710 47

Table 3.9 Specification for Nikon DSLR D7000 50

Table 3.10 Average velocity value for 3 bar liquid 3 bar air

using water as working fluid using Microsoft Excel 57

Table 3.11 Element of Citric Acid properties 61

Table 3.12 Element of Water properties 61

Table 3.13 Meshing properties in ANSYS CFX for Flat spray

nozzle (AL-75) 65

Table 3.14 Skewness and Orthogonal for flat spray nozzle

(AL-75) 66

Table 3.15 Parameter setup for deflected flat spray nozzle 67

xviii

Table 4.1 Flow rate for Water, L10W90 and L30W70 in

pressure 3 bar liquid 3 bar air 77

Table 4.2 The velocity calculated for all working fluid 79

Table 4.3 Reynolds number for Deflected flat spray

nozzle (AL-75) 80

Table 4.4 Material properties in ANSYS CFX Simulation 81

Table 4.5 The average velocity value for 3 bar liquid 3 bar

air using water as the working fluid 88

Table 4.6 The average velocity value for 3 bar liquid 3 bars

air using L10W90 as the working fluid 90

Table 4.7 The average velocity value for 3 bar liquid 3 bars

air using L30W70 as the working fluid 92

Table 4.8 Experiment velocity for 3 bar liquid 3 bar air and

3 bar liquid 6 bar air 98

Table 4.9 Experiment spray angle for 3 bar liquid 3 bar air and

3 bar liquid 6 bar air 99

Table 4.10 Comparison velocity between experiment and

simulation for 3 bar liquid 3 bar air 100

Table 4.11 Comparison spray angle between experiment and

simulation for 3 bar liquid 3 bar air 101

xix

LIST OF SYMBOLS AND ABBREVIATIONS

CFD - Computational Flow Dynamics

3D - 3 Dimensional

ρ - Density

D - Diameter

μ - Dynamic Viscosity

v - Velocity

VOC - Volatile Organic Compounds

KH2PO4 - Monopotassium Phosphate

COD - Chemical Oxygen Demand

RO - Reverse Osmosis

La(NO3)3.6H2O - Lanthanum (II) Nitrate Hexahydrate

Mn (NO3)2.4H2O - Manganese (II) Nitrate Tetrahydrate

Co(NO3)2.6H2 - Cobaltous Nitrate Hexahydrate

LaMnO3 - Lanthanum Manganate

LaCoO3 - Lanthanum Silicate Oxypatite

H - Hydrogen

O - Oxygen

xx

LIST OF APPENDICES

Publications 107

xxi

LIST OF PUBLICATIONS

1. Analysis mist spray development with Al-75 nozzle by using high speed

camera. AIP Conference Proceedings 1831, 020023 (2017); doi:

http://dx.doi.org/10.1063/1.4981164

1

CHAPTER 1

INTRODUCTION

1.1 Background study

In the 20th century, the demand of mist spray nozzle is very high in various

companies especially which involve with cleaning process. Multiphase flow is

described as any fluid consisting of more than one phase or component. There are

two types of nozzle that had been widely used in the industry, namely deflected flat

spray nozzle and jet nozzle. The jet nozzle performs quite well compared to flat

spray nozzle. However, it uses more water. Most industry wanted to reduce the usage

of water to cut the cost incurred during production. As for deflected flat spray nozzle,

only a small amount of water mixed with lime was used. The main objective of using

the deflected flat spray nozzle in kitchen hood is to clean the grease and at the same

time act as surface cooler.

In spraying system, nozzles break the liquid into the droplets. Droplet size

refers to the size of the individual drops that comprise a nozzle spray pattern. There

are many factors that affecting the fluid properties of the spray such as surface

tension, viscosity and density (Graco, 1995). For the surface tension, it is important

to stabilize a fluid and the higher the surface tension can produce the larger average

droplet size upon the atomization. The viscosity can cause the fluid to resist agitation

and tending to prevent its breakup. The increase viscosity produces the slower

velocity for the spray nozzle and the larger droplets were produce. For the spray

angle, the higher the viscosity, the narrow the spray angle was produced. The density

2

can cause the fluid to resist acceleration. Higher density tends to result in a larger

average droplet size (Nuyttensa et al., 2007)

The nozzle used for this study is deflected flat spray nozzle (AL-75). This

nozzle was used because the lower pressure for air and water can be applied into it.

These nozzles are used to clean up the filter by using water; however, the cleanliness

quality of the filter is not satisfactory because water is not good cleaning agent to

clean the oil and grease in the filter. Therefore, the organic citric acid mix with water

was suggested for another alternative as a cleaning agent. Organic citric acid is good

agents to kill bacteria, mold and mildew for great general disinfecting and safety

cleaning agent. The operation pressure used for this experiment is 1 bar, 2 bar and 3

bar for liquid pressure and 1 bar, 3 bar and 6 bar for air pressure.

The software that was used in this research was ANSYS software. ANSYS

software is widely used in variety of industry involving engineering projects because

it can design the process. For this research, the ANSYS software can predict the

simulation in the nozzle. The simulations using ANSYS software provide prediction

on flow behaviour of the nozzle.

1.2 Problem statement

Nowadays the spray nozzle is often used for industry such as spraying in painting,

filtering and cleaning. Most of pressure use to atomize the liquid are above 6 bar for

example jet nozzle atomized above 150 bar (Tamaki & Shimizu, 2002) while macro

spray nozzle and single point nozzle atomized at 34 bar (Hannifin, 2013) and

pressure swirl nozzle atomized at 6 bar liquid pressure (Schuchmann & Gaukel,

2015). The problem in this research is to determine minimum liquid pressure used

for best atomization in household piping system. According to this research also

focus on characteristic study with different ratio of liquid properties which can affect

the spray behaviour such as spray angle, spray development and velocity.

3

1.3 Objectives

The objectives of this study are:

i. To obtain the best atomizer configuration within 1 bar to 3 bar liquid

pressure for household piping and 1 bar, 3 bar and 6 bar for air pressure.

ii. To identify characteristic study by using different liquid properties.

iii. To validate the Computational Fluid Dynamic (CFD) result using ANSYS

CFX with experimental for spray angle and velocity.

1.4 Scope of study

The scope of study is limited to:

i. Liquid pressure used in experiment are 1 bar, 2 bar and 3 bar, and air

pressure from 1 bar, 3 bar and 6 bar.

ii. Percentage ratio of water and limes as liquids

a) 10% lime juice and 90% water (L10W90)

b) 30% lime juice and 70% water (L30W70)

c) 100% of water (L0W100)

iii. Deflected flat spray nozzle (AL-75) was used in the experiment.

iv. High speed camera (Phantom V710) used for detected spray development

with the following specifications; maximum resolution of 1280x800 at

7500 fps, minimum resolution of 128x8 at 1400000 fps (optional) and

685800 fps (standard). Image sensor of MOS sensor having 20 μm pixel

size. Phantom Camera Control (PCC) with speed of 7.5 Gpx/Sec and

recording time of 2.97s at maximum frame rate.

v. Nikon D7000 Camera used to capture the spray angle with 16.9 million

effective pixels and the speed of 1/8000. The flash sync or frame rate of

this camera is 1/250 per seconds. CMOS Image sensor of 23.6x15.6 mm.

4

vi. Software used in experiment:

a) ImageJ

b) Tracker

c) Phantom Camera Control

d) Adobe Photoshop CS5 Extended

vii. Software used in simulation:

a) Computational Fluid Dynamics (CFD) ANSYS CFX version 15.0 for

simulation

b) Turbulence model used for simulation is K-epsilon

1.5 Outline of the thesis

This outline provides a summary of the contents of each chapter in this research and

it is given as below:

CHAPTER 1 has introduced the alternative used for the spray nozzle, the

pressure and liquid properties were used for this study.

CHAPTER 2 explains the necessary background for the deflected flat spray

nozzle, the theory for spray nozzle and tools that were used for this experiment and

simulation that are involved in this thesis.

CHAPTER 3 discussed the procedures for the experimental and simulation

set up as well, including experimental tools and parameter setup for ANSYS

software.

CHAPTER 4 present all the experiment result and the validation simulation

result by ANSYS software. Discussed the result get from the experiment and

simulation.

CHAPTER 5 conclude the result from entire thesis and suggest the

recommendation for the future studies.

5

CHAPTER 2

LITERATURE REVIEW

2.1 Introduction

Water consumed each day is continuously increasing and this has become a serious

issue to the environment. In the industry, water involved in several activities such as

power generation, manufacturing, landscaping and also cleaning. In this study, the

water consumed can be reduced by replacing and mixing the water with lime juice

for the cleaning purpose. Lime juice is a Non-Volatile Organic Compound (non-

VOC) that acts as a cleaning agent.

2.2 Atomization

Atomization is the process of generating droplets and the process begun when a

liquid was forced through a nozzle. The liquid potential along the geometry which is

usually being measured as liquid pressure for hydraulic nozzles or liquid and air

pressure for two-fluid nozzles can cause the liquid to emerge as ligaments. The

ligaments were then broken into very small pieces called droplets, drop or liquid

particles (Rudolf.J, 2006). The atomization process is shown in Figure 2.1.

6

Figure 2.1: Atomization process (Rudolf.J, 2006)

Different spray for example, hollow cone nozzle and full cone nozzle produces

different range of droplet sizes. Various spray patterns produced due to various shape

of the orifice for each nozzle. Droplet size distribution was influenced by types of

nozzle, liquid properties, nozzle capacity, spray angle and also spray-operating

pressure (Air Atomizing Nozzles, 2011).

2.2.1 Droplet size

Droplet size is usually expressed in microns (micrometres, 10-6m). There are four

major criteria that affect droplet size of a nozzle namely capacity, spray pattern type,

spray tip style and spraying pressures. Larger droplet sizes were produced when

lower spraying operating pressure was adopted. In contrast, higher spraying pressure

produced smaller droplet sizes. The smallest droplet size was achieved by using

nozzle with air atomizing spray tips. Wide angle spray tips and flat hydraulic spray

tips produced large spray droplets when injected. For the hydraulic spray tip series,

the hollow-cone spray tips can also produce by the small droplets sizes (Peterson,

2013). The droplet size categories in micron show in Figure 2.2.

7

Figure 2.2: Categories of droplet size in micron (Peterson, 2013)

2.3 Spray nozzle

Spray is often being stated as the primary reason for the breaking up of liquids into

droplets. The word “spray” is referred to a droplet-laden flow of a gas. It is also

known as droplets moving through the ambient gas. To gain the advantage in various

processes, the surface area of the liquid can be increased. The utilization of sprays is

often used in the combustion of liquid fuels and spray painting, due to the formation

of an even surface coating produced by the advantages of dispersion droplets. Those

fields include spray measurement technique as well as Computational Fluid

Dynamics (CFD). With this combination, the industrial spray system can be

improved and the measurement of droplet sizes, diagnostic techniques and computer-

aided design can be achieved using CFD computer modelling codes (Yule, 2015).

The properties of sprays and a few examples of their usage are shows in Figure 2.3.

8

Figure 2.3: Properties of sprays and examples of their uses (Yule, 2015)

Nozzles were commonly used in cleaning, removing dirt as well as spraying.

The difference in each specific mode of the atomization can be classified as

ultrasonic, hydraulic, electrostatic nozzle and the most commonly used is swirl

nozzle. Spray nozzle can be categorized according to droplet size, spray angle, liquid

mass distribution, mass flow rate and spray impact. Higher feed pressure can produce

larger spray angles which also depends on the area needed to be covered by the

spray. Higher spray angle must be applied to reduce the impact of the nozzle (Xie et

al., 2013). The spray nozzle image shows in Figure 2.4.

9

Figure 2.4: Spray nozzle (Xie et al., 2013)

2.3.1 Two fluid nozzle

The concepts that had been used in two fluid nozzle systems are to generate mixing

between two fluids such as gas and liquid in the nozzle. The mixing between two

fluids produced a fine spray with a high velocity. It can also produce smaller droplet

size compared to single fluid nozzle. The common design being used to connect

between gas and liquid phase is located at the outlet of the nozzle. This process is

known as external mixing. For two fluids nozzle, the internal mixing has also been

used for discrete jet (Gottlieb et al., 2004).

2.3.1.1 Internal mixing nozzle

Internal mixing nozzle is commonly used because of its flexibility. By adjusting the

liquid and air operating pressures, a wide range of flow rates, spray patterns and also

droplet sizes can be produced. Liquid and air operating pressure needs to be defined

to allow interaction of both fluids in the nozzle. The impacts between high speed

gases with low pressure liquid atomization produced a high velocity flow compared

to the external mixing nozzle. These nozzles do not require high-pressure gas for

highly concentrated liquid. The internal of mixing nozzle are shows in Figure 2.5

(Bete.F, 2013).

10

Figure 2.5: Internal mixing nozzle (Bete.F, 2013)

The internal mixing type can be classified into three types, inner air types,

outer air type and Pre-mix type. For inner air type, the air flows were compressed in

the centre of the nozzle while liquid flows along its circumference. The benefit for

these type it provides larger free passage diameter which minimizes clogging. For

outer air type, the liquid flows in the centre of the nozzle while the air flows were

compressed along its circumference. This nozzle selected for wide range

applications. Pre-mix types are where the low air-water ratio can increase velocity of

droplet resulting in a strong impact force (Keuchi, 2013).

2.3.1.2 Flow principle for spray nozzle

High efficiency of nozzles was controlled by both droplet size and spray

convergence. First, at the inlet port, the pressurized liquid entered the nozzle. Then,

the liquid flows out through the holes before entering several numbers of annular

helicoidal slots and swirl in the swirl chamber. Finally, the swirling liquids were

discharged through a small orifice (Hussein.A et al., 2012). The flow principle of

spray nozzle obtained through this multi-stage process is shown in Figure 2.6.

11

Figure 2.6: Flow principle of spray nozzle (Bete.F, 2013)

There are three stages principle operation for the nozzle:

i. Stage one: Primary Fluid Breakup

The air and liquid was combined behind the air guide. The primary

atomization of the liquid stream was achieved when the pressure drops across

the air guide orifice.

ii. Stage two: Secondary Fluid Breakup

The impact were target both for the focused stream if the forcing of the

additional mechanical breakup.

iii. Stage three: Final Mixing

At the final mixing chamber, the air caps were produced and as liquid cross

the multiple orifices; the pressure drops to prepare for the final atomization

process.

12

2.4 Types of spray nozzle

In the spraying systems, nozzles break the liquid into droplets and form the spray

pattern. The volume of the nozzles can be determined by given operating pressure,

velocity and spacing. There are plenty of nozzles available on the market such as

standard flat fan spray nozzle, full cone spray nozzle, hollow cone spray nozzle and

deflected flat spray nozzle. This nozzle has different ability but have same concept,

for cleaning purposes.

2.4.1 Standard flat fan spray nozzle

A standard flat-fan nozzle can operate between 30 to 60 psi where the ideal range for

this type of nozzle is 30-40 psi. It can produce droplet sizes ranging from coarser to

finer, depending on the operating pressure, which makes it suitable for most

agrochemical applications.

This nozzle also has high impact and extra wide angle of spray. The flat fan

nozzle produce spray angle between 15o to 145

o. The standard flat-fan nozzles are

shows in Figure 2.7 (Robert et al., 2013).

Figure 2.7: Standard flat-fan nozzle (Robert et al., 2013)

13

2.4.2 Full cone spray nozzle

The wide-angle, full-cone nozzles produce large droplets. Full-cone nozzles, which

always recommended for soil-incorporated herbicides, have an operating pressure

between 15 psi to 40 psi. Optimum uniformity can be achieved by setting up the

nozzles to angle of 30o and 150

o, which also overlap the spray coverage by 100%.

The full cone nozzle can be shaped by using the tangential whirl nozzles. The full

cone nozzle is shows in Figure 2.8 (Robert et al., 2013).

Figure 2.8: Full cone nozzle (Robert et al., 2013).

2.4.3 Hollow cone spray nozzle

Hollow cone nozzles are generally used to apply insecticides or fungicides at field

crops when foliage penetration and complete coverage of leaf surfaces are required.

These nozzles have an operating pressure ranging from 40 psi to 100 psi. The

potential of spray-drift potential is for hollow cone nozzles compared to other

nozzles due to smaller droplets produced. Hollow cone spray nozzle also has wide

spray angle between 30o and 155

o. The Hollow cone nozzle is shows in Figure 2.9

(Robert et al., 2013).

14

Figure 2.9: Hollow cone nozzle (Robert et al., 2013).

2.4.4 Deflected flat spray nozzle

Deflected flat spray nozzle was used for spray cooling, mineral washing, general

product washing, air cleaning and cooling, gas cleaning and cooling, dust control,

crop washing, scrubbers, degreasing and rinsing, fire protection (L.Durdina et al.,

2014). The spray pattern for flat spray is tapered edges and it is necessary to make

uniform fluid coverage possible when there are overlapping sprays one adjacent to

the other. This nozzle also has the high functional impact upon the basic angle, flow

rate and operating pressures (Sayinci, 2015). Flat spray pattern have a higher impact

compared to full or hollow cone spray patterns. This type of nozzle produced larger

droplet sized compared to cone nozzles. Some of the fine droplets were also

produced by air atomization in flat spray nozzles (Yao et al., 2015). The pattern for

this pray is formed by liquid flowing over the deflector surface from around orifice.

The spray angle for flat spray nozzle is between 15o to 165

o.

15

The higher impact can produce a narrow spray angle while for the lower impact, the

wider spray angle was produced (Monte P. et al., 2014). The deflected flat spray

nozzle images were shows in Figure 2.10.

Figure 2.10: Deflected flat spray nozzle (Monte P. et al., 2014)

2.5 Spray nozzle performance

There are various factors that affect spray performance. The spray performance

considered nozzle characteristics such as spray angle, droplet size and velocity. The

summary of various factors that affect spray performance are shows in Table 2.1.

Table 2.1: Summary of various factors that affect spray performance (Bete.F, 2013).

Nozzle

Characteristic

Increase in

Specific

Gravity

Increase in

Operating

Pressure

Increase in

Viscosity

Increase in

Surface

Tension

Spray angle Negligible Increases then

Decreases

Decreases Decreases

Velocity Decreases Increases Decreases Negligible

Droplet Size Negligible Decreases Increases Increases

16

Firstly, for spray performance based on the spray angle, an increase in

operating pressure increases the spray angle. When the pressure remains constant, the

spray angles decreases. The increase in viscosity resulted in the decrease of the spray

angle. As for the surface tension, an increase of the surface tensions decreases the

spray angle. On the other hand, velocity decreases, specific gravity increases. In

contrast, velocity increased simultaneously resulted in an increase of operating

pressure and reduction of viscosity. Lastly, from the summary, droplet size decreases

when operating pressure increases. On the contrary, an increase of droplet size

resulted in increases of viscosity and surface tension.

2.5.1 Spray angle affected by viscosity and pressure

The spray angles for deflected flat spray nozzle nozzles are 65 degrees, 80 degrees

and 110 degrees. The heights recommended for this nozzle during the broadcast

application is given in Table 2.2.

Table 2.2: Suggested minimum spray heights (Robert et al., 2013)

Spray Height ( Inches)

Spray Angle (Degrees) 20 Spacing Overlap 30 Spacing Overlap

50% 100% 50% 100%

65 22-24 NR NR NR

80 17-19 26-28 26-28 37- 39

110 10-12 15-17 14-18 25-27

NR: Not recommended

To measure the correct nozzle height from the target, the top of the ground,

stubble or growing canopy can be used. The 30 inches of height can be used if the

nozzle is in 110-degrees. When the booms are higher, nozzle with spray angles of 80

degrees can be used. This resulted in wide angle of nozzles to produces smaller

droplets (Robert et al., 2013).

The experiment setup by (Yao et al., 2012) was done to observe the viscosity

effects on spray angle. The experiment used different working fluids with different

viscosities, prepared by mixing distilled water and glycerol with different volume

17

ratios from 0% to 90% with a step of 10%. For the wave frequency analysis, 60% to

74% water–glycerol mixtures with a step- size of 2% were used, because preliminary

experiments by (Yao et al., 2012) shows that it was difficult to calculate the wave

frequency of fluids with glycerol less than 60%. The viscosities of water–glycerol

mixture at 23.3oC are shows in Table 2.3.

Table 2.3: Viscosities of water glycerol mixture at 23.3oC (Yao et al., 2012)

Vol.

ratio of

glycerol

0% 10% 20% 30% 40% 50% 60% 70% 80% 90%

Viscosity

(mPa-s)

0.937 1.310 1.888 2.849 4.533 7.828 13.874 29.944 79.488 251.84

The result shows that, when the liquid viscosity increases from 0% to 50% of

water-glycerol mixture, the spray angle decreases. The spray angle reduced

dramatically with fluids having higher viscosity such as from 60% to 70% glycerol

compared to less viscous fluid. For 80% water-glycerol mixture, the spray angle

keeps decreasing because the angle is only about half of that of pure water. The

relationship between volumes ratios of glycerol with cone angle are shown in Table

2.4. The graph for fluid viscosity against cone angle is shows in Figure 2.11 (Yao et

al., 2012).

Table 2.4: Volume ratio of glycerol with cone angle (Yao et al., 2012)

Vol. ratio of glycerol (%) Cone angle (o)

0 59.67

10 56.39

20 55.70

30 55.17

40 54.35

50 50.74

60 42.46

70 40.98

80 35.57

18

Figure 2.11: Fluid viscosity against cone angle (Yao et al., 2012)

The experiment conducted by (Syazwan et al., 2012) was done to determine

the pressure effects on spray angle. An experimental test rig was constructed to

measure that characteristic of sprays. All atomizers were tested using water at room

temperature as the simulation fluid to investigate the spray cone angle and the

discharge coefficient at different injection pressure 2 bar, 4 bar, 6 bar and 8 bar. The

supply water pressure is controlled via a ball valve. The water flow rate (Q) and

supply pressure is measured by a digital flow meter and a Bourdon-type pressure

gauge respectively. The digital flow meter was pre-calibrated by the manufacturer

with an accuracy of ±2 % of full scale. The atomizer is located downward on vertical

plane at the end of the hoses and the spray is directly injected into the water tank.

The schematic of experimental Rig for Cold Flow Test is shown in Figure 2.12.

19

Figure 2.12: Schematic of experimental Rig for Cold Flow Test (Syazwan et al.,

2012)

The result shows that higher injection pressures leads to wider spray cone

angle. The spray cone angle increases by only 5.4% as the inlet slot number

increased from 2 to 5 for an injection pressure of 2 bar, but increases by 10.7% for an

injection pressure of 8 bar. Furthermore, the variation of spray cone angle with

respect to injection pressure shows an almost linear trend for all atomizers at an

injection pressure below 6 bar. The graph also shows that an increasing injection

pressure leads to wider spray formation for each atomizer tested. The effect of

injection pressure and the number of inlet slot on spray cone angle graph is shown in

Figure 2.13 (Syazwan et al., 2012)

Figure 2.13: Effect of injection pressure and the number of inlet slot on spray cone

angle (Syazwan et al., 2012)

20

2.5.2 Velocity affected by viscosity and pressure

The experiment conducted by (Raman et al., 2013) to observe the viscosity effects on

velocity. The formula to measure droplet velocity can be estimated by using the

droplet`s displacement over time. The droplet velocity was then calculated by using

the following simple formula:

(2.1)

The fluids used in this experiment were distilled water added with certain

percentage of Glycerine to achieve the desired viscosity, 54% of distilled water was

added with 46% of Glycerine and 52.5% of distilled water was added with 47.5% of

Glycerine. The viscosity of mixtures used in this experiment is shown in Table 2.5.

Table 2.5: Viscosity of mixture containing distilled water with different percentage

of Glycerine (Raman et al., 2013)

Fluids Viscosity

DW 1.16 mPas

G1 (46%) + DW (54%) 9.52 mPas

G2 (47.5%) + DW (52.5%) 10.2 mPas

The result shows that, viscosity increases as the amount of Glycerine added

into the mixture increased. Viscosity of distilled water was 1.16 mPas, and increased

to 9.52 mPas for mixture of 46% Glycerine with 54% distilled water. The highest

viscosity was obtained by mixing 47.5% of Glycerine with 52.5% distilled water.

Higher viscosity resulted in lower velocity produced. Velocity against viscosity bar

chart is shows in Figure 2.14.

21

Figure 2.14: Velocity against viscosity bar chart (Raman et al., 2013)

The other experiment conducted by (C.Cai et al., 2017) to determine the

pressure effects on the velocity. A two-dimensional geometry model of the liquid

nitrogen jet flow field made up of the internal space of the nozzle and the jet region

(external space of the nozzle) was built as shown in Fig. 1. The axial symmetric

nozzle was generated by the jet flow field. During the jetting process, the high-

pressure fluid flows through the nozzle and then it is accelerated to a high speed. In

this simulation model, the nozzle inlet was set as pressure inlet boundary and the

flow domain outlet was set as pressure outlet boundary. The wall boundary

orthogonal and nozzle outlet distance to the nozzle axis was 600 mm, wall boundary

parallel and nozzle outlet distance to the nozzle axis is 300 mm. Geometry model of

the jet flow field graph is shown in Figure 2.15.

Figure 2.15: Geometry model of the jet flow field (C.Cai et al., 2017)

22

The result shows for instance, this velocity was increased by 73.3% (from

151.06 m/s to 261.72 m/s) with an increase in the nozzle pressure drop from 10 MPa

to 30 MPa. This was because with the growth of nozzle pressure drop, the kinetic

energy was increased accordingly. The nozzle outlet velocity of liquid nitrogen jet

was obviously increased by increasing nozzle pressure drop but was also hardly

influenced by the confining pressure. Effect of nozzle pressure drop on nozzle outlet

velocity graph is shown in Figure 2.16 (C.Cai et al., 2017).

Figure 2.16: Effect of nozzle pressure drop on nozzle outlet velocity (C.Cai et al.,

2017)

2.6 Image capture

Image captured by using a few tools such as High speed camera, Tracker software

and imageJ. High speed camera was used to observe the spray development for the

deflected spray nozzle. Tracker software was used to analysis the data including

manual or automatic curve fitting of all or any selected subset of the data, the time

dependencies for the position, velocities and acceleration can be conducted. To find

the spray angle for the deflected spray nozzle, the imageJ software was used in this

experiment.

23

2.6.1 High speed camera

High speed camera is commonly used imaging tools which is capable of capturing

images more than one hundred frames per second (fps). It enables the user to observe

flow that is too fast for the naked eyes. High speed camera can be used in various

fields such as sports training, engineering measurement and entertainment. The

issues of the high speed camera is when the pixels decrease, the fps also increases

(Nogami et al., 2015).

Better result of the image captured was obtained by using the high speed

camera. In previous experiment of reacting flow condition, when the combustor and

mixing chamber were in operation, the high speed camera was not clearly visible to

capture the image as it only showed the water as white fog. The operation of reacting

flow condition shown in Figure 2.17 (Linck et al., 2013).

Figure 2.17: The experimental section in operation reacting flow condition (Linck et

al., 2013).

To observe the gas stream from the exhaust nozzle, Photron Ultima 1024

high-speed camera was used to capture series of distinct bubbles or gas slugs

emerged. The regular frequency was between 0.8 Hz to 1.0 Hz. The high-speed

camera was linked to a high-performance desktop via an IEEE 1394 connection.

Monochrome image of the gas stream was captured using 500 frames per second

(fps). The resolution for the image was 480x360 pixels. The emerging and detaching

image of bubbles is shown in Figure 2.18 (Linck et al., 2013).

24

Figure 2.18: Bubble emerging from flush-mounted nozzle (Linck et al., 2013)

There was another experiment that used high speed camera to capture the

image of an electrospray. The experiment was conducted by using glass syringe (100

ml). High voltage of electrode was exerted at the needle. 20 cm stainless-steel dish

was used to counter the grounded-electrode. Three different inner types of nozzle

(0.2, 0.3 and 0.4 mm) and three different outer diameters (0.3, 0.5 and 1.0 mm) were

used in this experiment. The experimental setup for visual observation of

electrospray is shown in Figure 2.19 (Kim.H et al., 2011).

Figure 2.19: Experimental setup for visual observation of electrospray (Kim.H et al.,

2011)

The high-speed camera (Photron Co; FASTCAM-SA 1, Model 675K-M2), is

capable of capturing maximum of 1,000,000 (fps) and was used to capture the

images of the electrospray. The high-speed camera was attached with the zoom lens

to enlarge the images of the spray nozzles pattern captured. The image of the

dripping mode at 0kV, 10kV, 12kV and 14kV are shown in Figure 2.20 below.

104

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Download - EFFECT OF LIQUID PROPERTIES (WATER AND LIME JUICE) …eprints.uthm.edu.my/id/eprint/9870/1/Muhammad_Faqhrurrazi_Abd_Rahman.pdftekanan cecair 3 bar dengan tekanan udara 3 bar adalah

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