effect of liquid properties (water and lime juice)...
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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
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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
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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.
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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.
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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.
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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
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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
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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
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4.2.2 Spray development for 2 bar liquid 1 bar air 70
4.2.3 Spray development for 2 bar liquid 3 bar air 71
4.2.4 Spray development for 3 bar liquid 1 bar air 72
4.2.5 Spray development for 3 bar liquid 3 bar air 73
4.2.6 Spray development for 3 bar liquid 6 bar air 74
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
4.5.2 3 bar liquid 3 bar air using
L10W90 as the working fluid 89
4.5.3 3 bar liquid 3 bar air using
L30W70 as the working fluid 91
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
4.6.2 Spray angle for 3 bar liquid 3 bar air
using L10W90 as the working fluid 95
4.6.3 Spray angle for 3 bar liquid 3 bar air
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
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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
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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
water as the working fluid 54
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
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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
Figure 4.2 Stage of spray development for water, L10W90 and
L30W70 for (8000 fps) for 2 bar liquid 1 bar
air pressure 70
Figure 4.3 Stage of spray development for water, L10W90 and
L30W70 for (10000 fps) for 2 bar liquid 3 bar
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
Figure 4.5 Stage of spray development for 3 bar liquid 3 bar air
using water, L10W90 and L30W70 as working fluid
at 10000 fps 73
Figure 4.6 Stage of spray development for 3 bar liquid 6 bar air
using water, L10W90 and L30W70 as working fluid
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
water as the working fluid 87
Figure 4.18 Simulation result for 3 bar liquid 3 bar air using
water as the working fluid 88
Figure 4.19 Experimental result for 3 bar liquid 3 bar air using
L10W90 as the working fluid 89
Figure 4.20 Simulation result for 3 bar liquid 3 bar air using
L10W90 as the working fluid 90
Figure 4.21 Experimental result for 3 bar liquid 3 bar air using
L30W70 as the working fluid 91
Figrue 4.22 Simulation result for 3 bar liquid 3 bar air using
L30W70 as the working fluid 92
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
liquid 3 bar air using L10W90 as the working fluid 96
xvi
Figure 4.27 The spray angle from the experiment result for 3 bar
liquid 3 bar air using L30W70 as the working fluid 97
Figure 4.28 The spray angle from the simulation result for 3 bar
liquid 3 bar air using L30W70 as the working fluid 97
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
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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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