Understanding Spray Technology to Optimize Sulfur Burning

Understanding Spray Technology

to Optimize Sulfur Burning
Chuck Munro
Dan Vidusek
Chuck Munro
Dan Vidusek
Understanding Spray Technology to Optimize Sulfur Burning
75yearoldnozzleengineering & manufacturing company
Leaderinspraytechnology
Globalmanufacturing,salesandsupport
Nozzles,headers,injectors, controlsandresearch&testing
About SprayingSystemsCo.
Understanding Spray Technology to Optimize Sulfur Burning
Nozzles101:TypesandPerformance
CommonProblemswithMoltenSulfurSpraying
Hydraulicvs.TwoFluidStudyusingComputationalFluid
Dynamics(CFD)
Agenda
Understanding Spray Technology to Optimize Sulfur Burning
ItALWAYSStartswiththeNozzle
Providesaspecificvolumeoffluidataspecifiedpressuredrop
Convertsfluidintoapredictabledropsizespectrumwitha
specificspraycoverage
Thenozzleistheheartoftheprocess asmallcomponentthat
greatlyaffectssystemperformance
Understanding Spray Technology to Optimize Sulfur Burning
HydraulicAtomizerTypes
FlatSpray Hollow Cone FullCone
Understanding Spray Technology to Optimize Sulfur Burning
FullConeSpray
Liquidisswirledwithinthenozzle
byavaneandexitstheorificein
aconicalpattern
Mediumtolargedropsize
Limitedfreepassage(duetovane)
Relativelylowresistanceto
clogging
Widedropsizespectrum
Understanding Spray Technology to Optimize Sulfur Burning
FlatSpray
Liquidpassesthroughanelliptical
orifice,formingaflatfanpattern
Widevarietyofspraycoverages
Mediumdropsizespectrum
Largefreepassage
Dropletsaremoreconcentrated
inasmallerarea
Understanding Spray Technology to Optimize Sulfur Burning
HollowConeSpray
Sprayisformedwithinthenozzle
byaninletthatistangentialtoa
whirlchamber
Theresultingwhirlingliquidforms
ahollowconeasitleavesthe
orifice
Largefree passagesforgoodclog
resistance
Understanding Spray Technology to Optimize Sulfur Burning
BAWhirlJetSulfurBurningNozzle
Hollowconespraypattern
Small tomediumsizeddroplets
Large, unobstructedflowpassagesto
minimizeclogging
Relatively lowcosttooperate
Understanding Spray Technology to Optimize Sulfur Burning
Areallnozzlescreatedequal?
Understanding Spray Technology to Optimize Sulfur Burning
Gasandliquidaremixedinaninternal
chamber;sprayexitsorificeinaflator
roundspraypattern
Smallestdropsize
Narrowdropsizespectrum
Sensitivetochangesinoperatingpressures
Largefreepassage
Relativelyhighresistancetoclogging
DualFluid AirAtomizing
Understanding Spray Technology to Optimize Sulfur Burning
DualFluidNozzle
Howitworks:
Understanding Spray Technology to Optimize Sulfur Burning
NozzleComparison
Issue Hydraulic
1/2BA309SS70
AirAtomizing
FM25A
FlowRate 38lpm @1.4bar
102lpm @10.3bar
19lpm @0.7bar
114lpm @5.3bar
(1.7m
3
/m constantair)
Turndown 2.7:1 6:1
FreePassage 9.5mm 6.4mm
DropSize(@ 28gpm) Dmax =1,087 mm
Dv0.90=754mm
D32=277mm
Dmax =375mm
Dv0.90=300mm
D32=185mm
Althoughthehydraulicnozzlehasalargerfreepassagearea,theairatomizing
nozzleprovidessmallerdropletsatagreaterturndownratio.
Understanding Spray Technology to Optimize Sulfur Burning
Atomization
Atomizationofaliquidinvolves
breakingtheliquidupintovery
smallpiecescalleddrops
Everyspraynozzleprovidesa
rangeofdropsizesratherthan
onesinglesize
Thedropsizerangevarieswith
Liquidproperties
Nozzletype
Capacity
Pressure
Sprayangle
Understanding Spray Technology to Optimize Sulfur Burning
Diameter
(m)
Numberof
Drops
Volume
(in
3
)
SurfaceArea
(in
2
)
Percentageincrease
inSurfaceArea
500 1 4x10
6
1.22x10
3

100 121 4x10
6
5.89x10
3
484%
IncreaseinSurfaceArea
100m
Masstransferisproportionaltothedropletsurfacearea!
SurfaceArea=4r
2
Volume=4/3r
3
150m 200m 250m
300m 400m 500m
Understanding Spray Technology to Optimize Sulfur Burning
AtomizationMechanics
Primarybreakup
conicalsheet
Understanding Spray Technology to Optimize Sulfur Burning
AtomizationMechanics
Secondarybreakup
dropletbreakup
Airflow
directions
Dropflattened
byairpressure
Cupforms
(bubbleexpands)
Bubblebursts,
thickrimremains
Rimbreaksintoligaments,
bubblefragmentsremain
Understanding Spray Technology to Optimize Sulfur Burning
CommonFactorsAffectingMoltenSulfur
Atomization
Pluggednozzles
Sprayatomization
Sulfurcarryover
Turndown
Gundesign
Sulfurtemperatureconsistency
Steammigrationintosulfurline
Understanding Spray Technology to Optimize Sulfur Burning
NozzlePluggage
Carsulorothercontaminantsinthemoltensulfurcanplug
nozzleorifices
Particlescanbedifferentsizessomaximizingthefree
passageofanozzleiscritical
Pluggage canoccurwhengunpressurereducedorgunsare
turnedoff
Withairatomizingnozzles,airpurgesthesulfur
Comparisonofahydraulicandairatomizingnozzle@14gpm
flowrate:
1/2BA309SS70 FM25A
0.375(9.5mm) 0.250 (6.4mm)
Understanding Spray Technology to Optimize Sulfur Burning
SprayAtomization
Ifthemoltensulfurdroplets
aretoolarge,theydonot
combustintimeandcancarry
overandcausefires
downstream
Itisimportanttohavethe
sprayeddropletdistribution
sizedcorrectlytooptimize
burneroperation
Understanding Spray Technology to Optimize Sulfur Burning
Turndown
Alargeturndownofthenozzle(s)flowrateisrequiredforstartup,
lowproductiontimesandtoaccommodatepeakproduction
Canbeachievedby:
Addingorremovingguns
Adjustingoperatingpressureoftheguns/nozzles
Understanding Spray Technology to Optimize Sulfur Burning
Turndown
Understanding Spray Technology to Optimize Sulfur Burning
GunDesign
Allowforthermalexpansionandtowithstandtemperature
loadingwithoutbending
Steamrecirculationfortightcontrolofmoltensulfur
temperatureandassociatedphysicalproperties
Designcriteriashouldstipulate:
Propertestingmustbeconducted
Validationisperformed
Weldersareproperlytrained
Criticalthateachpathway(moltensulfur,atomizingmedium,
jacketingsteam)areisolatedfromeachother
Understanding Spray Technology to Optimize Sulfur Burning
InjectorDesign:HydraulicSulfurGun
Understanding Spray Technology to Optimize Sulfur Burning
InjectorDesign:TwoFluidSulfurGun
Understanding Spray Technology to Optimize Sulfur Burning
FurnaceCFDSetup
TopView
SideView
Main Inlet
Air
Q=308,000Nm
3
/hr
=113.9kg/s
T =122C
P
operating
=11barg
Outlet
T
out
~1160C
Injections
(6x)53686001injectorswith1/2BA309SS70
WhirlJet

nozzle
Liquidsulfur
Q
total
=29m
3
/hr

total
=14.6kg/s(2.4kg/spernozzle)
T =132C
SecondaryInlets
Air

total
=1kg/s
T=122C
Understanding Spray Technology to Optimize Sulfur Burning
TemperatureProfiles
Temperature
(C)
2000
1075
150
T
OUT
=1434(C)
InjectionPlanes
Understanding Spray Technology to Optimize Sulfur Burning
SpeciesContent(Sulfur)
MassFractionSulfur
.063
.032
.000
SulfurCombustionPrior
toBaffleWall
FullCombustionPriorto
Outlet
Understanding Spray Technology to Optimize Sulfur Burning
SpeciesContent(Oxygen)
MassFractionOxygen
.063
.032
.000
OxygenDepletedPriorto
BaffleWall
Understanding Spray Technology to Optimize Sulfur Burning
SprayVisualization
Understanding Spray Technology to Optimize Sulfur Burning
FurnaceCFDwithFloMaxnozzles
InjectionParameters Liquid:MoltenSulfur
Pernozzle units Flomax

FM5A
LiquidFlowRate lpm 80.5
LiquidMassFlowRate kg/s 2.44
LiquidTemperature C 132
DropletVelocity m/s 35
SprayAngle 55
D
V0.01
Minimum m 11
D
V0.50
Average m 66
D
V0.99
Maximum m 144
N(RRspreadparameter) 2.4
2.5m
Understanding Spray Technology to Optimize Sulfur Burning
Temperatureprofile
Temperature
(C)
2000
1075
150
T
OUT
=1547(C)
Understanding Spray Technology to Optimize Sulfur Burning
SpeciesContent(Sulfur)
MassFractionSulfur
.063
.032
.000
Sulfurcombustionnot
completepriortobafflewall
FullCombustionPriorto
Outlet
Understanding Spray Technology to Optimize Sulfur Burning
SpeciesContent(Oxygen)
MassFraction
Oxygen
.063
.032
.000
OxygenDepletedPriorto
BaffleWall
SecondaryAirImbalance
inOxygen
Understanding Spray Technology to Optimize Sulfur Burning
SprayVisualization
Understanding Spray Technology to Optimize Sulfur Burning
CFDConclusions
Velocity
Goodalignmentwithvelocitycontours
ofinletair hydraulic
Pooralignmentwithvelocitycontours
ofinletair hydraulic
WallImpingement
Impingementwithbaseofcombustion
chamber hydraulic
Noimpingementwithbaseof
combustionchamber dualfluid
Understanding Spray Technology to Optimize Sulfur Burning
NewHybridSulfurGun
Hydraulicandairatomizingina
singlegun
Quickchangeoverfromhydraulic
nozzlestoair
atomizingnozzles
Compressedairmustbedryto
eliminateunwantedmoisture
Allowsusertotryair
atomizingandconvert
backtohydraulicwhile
resultsarereviewed
Understanding Spray Technology to Optimize Sulfur Burning
NewHybridSulfurGunwithHydraulicNozzle
Understanding Spray Technology to Optimize Sulfur Burning
NewHybridSulfurGunwithDualFluidNozzle
Understanding Spray Technology to Optimize Sulfur Burning
HybridSulfurGunDemo
Understanding Spray Technology to Optimize Sulfur Burning
AirAtomizing NotforEveryone
Positive
Smallerdropsize better
combustion
Smallerdropsizedistribution:
moreefficientcontrolof
process
Constantairflowkeepnozzle
purged
Negative
Moltensulfurcanhavesolids
thatclogthenozzle
Requiresmoreprocesspiping
Compressedairuseaddscost
Understanding Spray Technology to Optimize Sulfur Burning
InSummary
Beginwiththeendinmind!
Thinkintermsofdropsizerequirements
UseCFDwhenmanyfactorsinfluencethespray
ContactSprayingSystemsCo.earlytohelpsolve
yoursprayapplication
Understanding Spray Technology to Optimize Sulfur Burning
ThankYou!