FIG. 14-86 Sheet breakup. (a) By perforation. [After Fraser et al., Am. Inst. Chem. Eng. J., 8(5), 672 (1962).] (b) By sinusoidal wave growth. [After Dom-browski and Johns, Chem. Eng. Sci., 18, 203 (1963).]

NWe cnt for low-viscosity fluids commonly ranges from 10 to 20, with the larger value for a free-fall condition and the smaller for a sudden acceleration. High liquid viscosity also increases NWe crit.

Droplet breakup via impingement appears to follow a similar relationship, but much less data is available. This type of breakup can result from impingement on equipment walls or compressor blades. In general, there is less tendency to shatter on wetted surfaces.

Droplet Size Distribution Instead of the single droplet size implied by the discussion above, a spectrum of droplet sizes is produced. The most common ways to characterize this spectrum are:

• Volume median (mass median) Dvm. This has no fundamental meaning but is easy to determine since it is at the midpoint of a cumulative-volume plot.

• Sauter mean D32. This has the same ratio of surface to volume as the total drop population. It is typically 70 to 90 percent of Dvm. It is frequently used in transport processes and is used here to characterize drop size.

• Maximum Dmax. This is the largest-sized particle in the population. It is typically 3 to 4 times D32 in turbulent breakup processes, per Walzel [International Chemical Engineering, 33, 46, (1993)]. It is the size directly calculated from the power/mass relationship. D32 is estimated from Dmax by

and Dvm is estimated from it by

However, any average drop size is fictitious, and none is completely satisfactory. For example, there is no way in which the high surface and transfer coefficients in small drops can be made available to the larger drops. Hence, a process calculation based on a given droplet size describes only what happens to that size and gives at best an approximation to the total mass.

There are a variety of ways to describe the droplet population. Figures 14-88 and 14-90 illustrate one of the most common methods, the plot of cumulative volume against droplet size on log-normal graph paper. This satisfies the restraint of not extrapolating to a negative drop size. Its other advantages are that it is easy to plot, the results are easy to visualize, and it yields a nearly straight line at lower drop sizes.

Cumulative volume over the range of 1 to 50 percent can also be shown to vary approximately as D2. This is equivalent to finding that the number of droplets of a given size is inversely proportional to the droplet area or the surface energy of the droplet.

Atomizers The common need to disperse a liquid into a gas has spawned a large variety of mechanical devices. The different designs emphasize different advantages such as freedom from plugging, pattern of spray, small droplet size, uniformity of spray, high turndown ratio, and low power consumption.

As shown in Table 14-19, most atomizers fall into three categories:

1. Pressure nozzles (hydraulic)

2. Two-fluid nozzles (pneumatic)

3. Rotary devices (spinning cups, disks, or vaned wheels)

These share certain features such as relatively low efficiency and low cost relative to most process equipment. The energy required to produce the increase in area is typically less than 0.1 percent of the total energy consumption. This is because atomization is a secondary process resulting from high interfacial shear or turbulence. As droplet sizes decrease, this efficiency drops lower.

Other types are available that use sonic energy (from gas streams), ultrasonic energy (electronic), and electrostatic energy, but they are less commonly used in process industries. See Table 14-19 for a summary of the advantages/disadvantages of the different type units. An expanded discussion is given by Masters [Spray Drying Handbook, Wiley, New York (1991)];

Special requirements such as size uniformity in prilling towers can dictate still other approaches to dispersion. Here plates are drilled with many holes to develop nearly uniform columns.

Commonly, the most important feature of a nozzle is the size of droplet it produces. Since the heat or mass transfer that a given dispersion can produce is often proportional to (1/Dd)2, fine drops are usually favored. On the other extreme, drops that are too fine will not settle, and a concern is the amount of liquid that will be entrained from a given spray operation. For example, if sprays are used to contact atmospheric air flowing at 1.5 m/s, drops smaller than 350 mm [terminal velocity = 1.5 m/s (4.92 ft/s)] will be entrained. Even for the relative coarse spray of the hollow-cone nozzle shown in Fig. 14-88, 7.5 percent of the total liquid mass will be entrained.

Hydraulic (Pressure) Nozzles Manufacturers' data such as shown by Fig. 14-88 are available for most nozzles for the air-water system. In Fig. 14-88, note the much coarser solid-cone spray. The coarseness results from the less uniform discharge.

Effect of Physical Properties on Drop Size Because of the extreme variety of available geometries, no attempt to encompass this variable is made here. The suggested predictive route starts with air-water droplet size data from the manufacturer at the chosen flow rate. This drop size is then corrected by Eq. (14-195) for different viscosity and surface tension:

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