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Industrial Sprays and Atomization

Industrial Sprays and Atomization - Springer978-1-4471-3816-7/1.pdfPreface Arguably, atomization and spray science and technology was established as an internationally important and

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Page 1: Industrial Sprays and Atomization - Springer978-1-4471-3816-7/1.pdfPreface Arguably, atomization and spray science and technology was established as an internationally important and

Industrial Sprays and Atomization

Page 2: Industrial Sprays and Atomization - Springer978-1-4471-3816-7/1.pdfPreface Arguably, atomization and spray science and technology was established as an internationally important and

Springer-Verlag London Ltd.

Page 3: Industrial Sprays and Atomization - Springer978-1-4471-3816-7/1.pdfPreface Arguably, atomization and spray science and technology was established as an internationally important and

G.G. NaSf, A.]. Yule and L. Bendig

Industrial Sprays and Atomization Design, Analysis and Applications

With 456 Figures

Springer

Page 4: Industrial Sprays and Atomization - Springer978-1-4471-3816-7/1.pdfPreface Arguably, atomization and spray science and technology was established as an internationally important and

G.G. Nasr, MSc, PGDip, PhD, MILASS University of Salford, School of Aeronautical, Civil and Mechanical Engineering, Salford, Greater Manchester, M5 4WT, UK

A.]. Yule, BSc, PhD, DSc, FRAeS Dept. ofMechanical Engineering, UMIST, PO Box 88, Manchester, M60 lQD, UK

L. Bendig, Diploma-Physiker Lechler GmbH & Co KG, D-72555 Metzingen, Germany

British Library Cataloguing in Publication Data Nasr, G. G.

Industrial sprays and atomization : design, analysis and applications 1.Atomization 2.Spraying I.Title H.Yule, Andrew J.lII.Bendig, L. 660.2'94515

Library of Congress Cataloging-in-Publication Data Nasr, G. G. (Ghasem G.), 1958-

Industrial sprays and atomization : design, analysis and applications 1 G.G. Nasr, A.J. Yule, and L. Bendig.

p.cm. Includes bibliographical references and index.

1. Spraying. 2. Atomization. 1. Yule, Andrew J. H. Bendig, L. (Lothar), 1943- III. Title. TP156.S6 N37 2002 660' .294515--dc21 2001049369

Apart from any fair dealing for the purposes of research or private study, or criticism or review, as permitted under the Copyright, Designs and Patents Act 1988, this publication may only be reproduced, stored or transmitted, in any form or by any means, with the prior permission in writing of the publishers, or in the case of reprographic reproduction in accordance with the terms oflicences issued by the Copyright Licensing Agency. Enquiries concerning reproduction outside those terms should be sent to the publishers.

http://www.springer.co.uk

© Springer-Verlag London 2002

Originally published by Springer-Verlag London Limited in 2002. Softcover reprint ofthe hardcover Ist edition 2002

The use of registered names, trademarks etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant laws and regulations and therefore free for general use.

The publisher makes no representation, express or implied, with regard to the accuracy of the information contained in this book and cannot accept any legal responsibility or liability for any errors or omissions that may be made.

Typesetting: Electronic text files prepared by authors

69/3830-543210 Printed on acid-free paper SPIN 10731904

ISBN 978-1-84996-875-1 ISBN 978-1-4471-3816-7 (eBook)DOI 10.1007/978-1-4471-3816-7

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Preface

Arguably, atomization and spray science and technology was established as an internationally important and cohesive field of research from the time of the first International Liquid Atomization and Sprays Conference, held in Tokyo in 1978. Of course, prior to that time, the subject of the production of sprays received the attention of some ofhistory's greatest scientists, and in particular the fundamental break-up theories of Raleigh, from the 19th century, continue to be applied. However a literature search would show that the considerable body of research carried out in the first three-quarters of the 20th century was very subject-oriented with, for example, workers involved in combustion applications being unaware of developments in agricultural spraying, and vice versa. Two great, rapid advances enabled and promoted the post-1970 growth in the subject as a more unified discipline. These advances were in instrumentation techniques, providing methods for the rapid, accurate and non-intrusive probing of sprays, and also in microprocessors. The latter enabled both the huge strides in computational modelling of sprays and turbulent flows, and also the rapid acquisition and processing of data from the new measurement techniques.

Unity of the spray field is provided by a basic commonality of the main atomization techniques, whatever the field of application. More than this, the physics of the flows, the computational modelling methods (particularly CFD, i.e. Computational Fluid Dynamics), and the measurement techniques, are also similar, if not identical, for the different fields of application.

The three authors, whose backgrounds are outlined below, independently recognized that whilst there are academically orientated books available that address the fundamentals of spraying and measurement methods, and certain specialized texts addressing narrower areas of application, there is an absence of an industrially oriented book that covers, as far as possible, the utilization of sprays in industry as a whole. As described in Chapter 1, the term "industrial spray" is not easy to define, and can mean different things to different people. We include within the term, any unit manufacturing process that involves sprays, for example in the manufacture of foodstuffs, paper, metals (Section 3.1, 3.2, 7.1) but exclude sprays in domestic, medical and transport devices. On the other hand we, arguably, stretch the concept of a manufacturing process being involved, to cover areas such as fire suppression, agricultural spraying and printing (Section 4.1,5.1 and 5.4), and include fixed combustion devices utilized for power generation (Chapter 6).

Prior to commencing their cooperation on this book, AlY and LB cooperated for many years as committee members of ILASS-Europe (Institute of Liquid

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VI Preface

Atomization and Sprays Systems), helping to organize more than 15 conferences devoted to spraying, in various venues in Europe. Also GN and AJY had cooperated in research projects, particularly involving spray heat transfer and the UMIST short course on sprays. The incentive to cooperate and write the book came from the frequent requests from those in industry for a text that was suited to their applications-oriented needs and yet which covered a wide breadth of knowledge. Although, together, the authors have experience in a wide range of spray applications, the very large number of applications that ex ist in industry has meant that expertise has been sought from specialist companies and individuals. These specialists are thanked in a later section of this introduction.

Ghasem Nasr is Leader of the Postgraduate studies in Gas Engineering and Management at the School of Aeronautical, Civil and Mechanical Engineering at the University of Salford, Manchester, England. He has been involved with sprays and atornization and heat transfer for 18 years in both industry and academia, with a number of publications in his area of interest. He has also acted as a consultant in spray-related maUers for major companies in the Middle East, and Eastern and Western Europe.

Andrew Yule is Professor of Mechanical Engineering at UMIST, Manchester, England and he is the leader and founder of the Atomization and Sprays Research Group at UMIST. Graduating in Aeronautical Engineering (BSc) and Fluid Mechanics (PhD) at the University of Manchester, he moved into the combustion and chemical engineering fie1ds at the University of Sheffield before moving to UMIST in 1981. He has 25 years experience in research in many areas of spray production and utilization and is consultant for several companies. He was a founder of The Institute of Liquid Atomizations and Spray Systems-Europe, has authored 150 papers and was co-author of the book Atomization of Melts (OUP, 1994).

Lothar Bendig is Technical Director of the Research and Development Department of Lechler GmbH and CoKG, a leading German manufacturer of spray nozzles equipment. As a physicist he has 28 years experience in mechanics, fluid dynamics, acoustics, heat transfer and spray technology. He is chairman of ILASS-Europe.

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Acknowledgements

This book reflects a total of some 70 years experience of the authors in sprays and atomization systems in both industry and academia. The successful completion of the book, however, must be shared with those who provided the authors with invaluable advice and material. These are from a number of key companies involved in the field of industrial spraying. The authors are very grateful for the willing cooperation of these companies and individuals within them. Specifically these include the following, where the sections of the book particularly relevant to each company are given in brackets:

• Lechler GmbH, Metzingen, Germany (throughout the text and particularly Chapter 4,5, Section 5.2, and Chapter 7)

• Lurmark Ud, Cambridge, UK, IC Smith and S Waddelow (Section 3.1) • Nizo food research, Holland, REM Verdurmen (Section 3.1.1) and A

Heywood, Manchester, UK (Section 3.1.2) • Astra Zeneca, Macclesfield, Cheshire, UK, P Ben, M Hopkins,

P Merrick, S Hilton and M Blench (Section 3.2) • Academic Press, USA and CJ Biermann, Department of Forest Products,

Oregon, USA (Section 3.3) • Spray Systems Ud, Surrey, UK, T Canfie1d (Section 3.1,3.2 and 3.3) • Charles Thompson Ud, UK, G Lightowlers • Delavan Ud, Cheshire, UK (Section 3.1, 3.2 and 3.3) • Fogtec Brandschutz GmbH & Co KG, Cologne, Germany (Section 4.1) • Minimax GmbH, Bad Oldesloe, Germany (Section 4.1) • Stielow GmbH, Frankfurt, Germany (Section 4.2) • Luwa AG, Uster, Switzerland (Section 4.2) • AxAir AG, Pfaffikon, Switzerland (Section 4.2) • Dr Jörg Pape, Subl, Germany (Section 5.1) • Maschinenfabrik Rau GmbH, WeilheimlTeck, Germany (Section 5.1) • Gebr Holder GmbH, Metzingen, Germany (Section 5.1) • Cleanacres Machinery Ud, Hazleton, UK (§5.1) • TecnomaJAgrartechnik-Agentur, Altdorf, Germany (Section 5.1) • Alfred Kärcher GmbH & Co KG, Winnenden, Germany (Section 5.2) • Vauxhall Ud, Cheshire, UK, K Davies (Section 5.3) • Harnet Engineering Services, Cheshire, UK, S Starkey (Section 5.3) • Domino Inkjet Print Head, Manchester, UK, L Muffet and A Heywood

(Section 5.4)

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viii Acknowledgements

• Hamworthy Combustion Engineering Ltd, Poole, UK, B Foster (Section 6.1)

• AlT Combustion Technology Centre, Bumley, UK, A Irwin and A Wheatley (Section 6.2)

• Alstom Gas Turbine, Lincoln, UK, QP Zheng (Section 6.2) • MAN Band W Diesel Ltd, Stockport, UK, Dr A Poynton, P W ood and

N. HaITis (Section 6.3) • Bosch, Middlesex, UK, K Mcgregor (Section 6.3) • Corus Ltd (forrnerly B Steel Plc), Welsh Technology Centre, Wales, UK,

K Brown, D Loney and D Lewis (Section 7.1, 7.2) • SMS Demag AG, Düsseldorf, Germany (Section 7.3) • Osprey Metals, Neath, Wales, UK, A Leatham (Section 8.1) • Atomising Systems Ltd, Sheffield, UK, JJ Dunkley (Section 8.2) • Volvo AB, Gothenberg, Sweden, M-L Wahlhammer (Section 5.3)

Where illustrations have been reproduced with permission from other sources, this is acknowledged in the titles of the figures. Again, the authors express their thanks for kind agreement of the copyright holders. A number of individual industrial colleagues are also greatly thanked, who kindly used their expert knowledge in reviewing and commenting on the final manuscript of various chapters. They include Dr B Hewitt, Technical Director of Corus Ltd, Dr A W Poynton, Director of Research at MAN Band W Diesel Ltd, Alstom Engine Ltd, A Irwin, Senior Engineer at AlT Ltd, B Foster, Technical Research Manager of Hamworthy Combustion Engineering Ltd and J J Dunkley, Managing Director of Atomising Systems Ltd, Sheffield. The contribution of Mr M Williams of Stockport College in the preparation of CAD drawings is also acknowledged. Recognition and thanks are provided by the authors to Ms Melinda Curtis (UMIST, Manchester, UK) for her sustained effort in editing the drafts and preparing the final files for this book, over aperiod of two years. Finally we would also like to thank our families for coping with us during the long hours put into this time consuming but rewarding task. This is particularly the case for the long hours working at horne by GGN, who dedicates his efforts to Tara and Elica.

GG Nasr, AJ Yule Manchester,

England

L Bendig Metzingen,

Gerrnany

March 2002

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Contents

Nomenclature ....................................................................................................... xv

1. Introduction to Industrial Sprays .................................................................. 1 1.1 Why Use a Spray? .................................................................................... 1 1.2 Scope of this Book ................................................................................... 3

1.2.1 Brief Glossary ofTerms ................................................................ 3 1.2.2 When is a Spray an "Industrial Spray"? ........................................ 3 1.2.3 Layout of this Book ....................................................................... 3 1.2.4 The Approach to Information Provision on Each Process ............. 4

1.3 Scope and Scale ofIndustrial Spraying .................................................... 5

2. Background on Sprays and Their Production .............................................. 7 2.1 Fundamentals of Sprays ........................................................................... 7

2.1.1 Pattemation .................................................................................... 7 2.1.2 Drop Size Distributions and Mean Diameters ............................... 8 2.1.3 Atomization ................................................................................. 12 2.1.4 Droplets and Their Dynamics ...................................................... 14 2.1.5 Deposition and Impact ofDrops .................................................. 15 2.1.6 Non-Newtonian Multi-Component Liquids and Slurries ............. 16

2.2 Basic Atomizer Designs ......................................................................... 17 2.2.1 Overview ..................................................................................... 17 2.2.2 Pressure Jet .................................................................................. 17 2.2.3 Two-Fluid Atomizers .................................................................. 23 2.2.4 Other Designs .............................................................................. 25

2.3 Measurement Techniques ....................................................................... 28 2.3.1 Light Scattering: Laser Diffraction and PDA .............................. 28 2.3.2 Flow Visualization and Sheet Lighting ....................................... 30

2.4 Computer Modelling (CFD) ................................................................... 31 References ....................................................................................................... 32

3. Sprays in Industrial Production Processes .................................................. 35 3.1 F ood Processing ..................................................................................... 35

3.1.1 Introduction ................................................................................. 35 3.1.2 Manufacturing Process Description ............................................. 36 3.1.3 Atomizer Types, Design and Operating Parameters .................... 44 3.1.4 Measurement Techniques and Performance Analysis ................. 58 3.1.5 Problems and Future Challenges ................................................. 64

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x Contents

3.2 Pharmaceutical Manufacturing ............................................................... 67 3.2.1 Introduction ................................................................................. 67 3.2.2 Pharmaceutical Manufacturing Processes ................................... 68 3.2.3 Nozzle Types, Design and Operating Parameters ........................ 75 3.2.4 Measurement Techniques and Performance Analysis ................. 82 3.2.5 Problems and Future Challenges ................................................. 83

3.3 Sprays in Pulp and Paper Manufacturing ............................................... 85 3.3.1 Introduction ................................................................................. 85 3.3.2 Process Description ..................................................................... 85 3.3.3 Spray Properties ......................................................................... 106

3.3.3.1 Atomizer types, Design and Operating Parameters ..... 106 3.3.3.2 Measurement Techniques and Performance Analysis. 108

3.3.4 Problems and Future Challenges ............................................... 111 3.4 Miscellaneous Applications ................................................................. 112

3.4.1 Introduction ............................................................................... 112 3.4.2 Bonding ..................................................................................... 112 3.4.3 Polymers .................................................................................... 112 3.4.4 Aerosol Cans ............................................................................. 113 3.4.5 Future Developments ................................................................. 115

References ..................................................................................................... 116

4. Processes Involving Vaporization, Cooling or Cleaning of Gases ........... 119 4.1 Fire Suppression ................................................................................... 119

4.1.1 Introduction ............................................................................... 119 4.1.2 Process Description ................................................................... 121

4.1.2.1 Conventiona1 Fire Fighting with Low-Pressure Nozzles ........................................................................ 123

4.1.2.2 Fire Suppression with High-Pressure Water Fog ......... 126 4.1.3 Spray Properties ......................................................................... 131

4.1.3.1 Atomizer Types and Designs ....................................... 131 4.1.3.2 Measurement Techniques and Data Analysis .............. 135

4.1.4 Problems and Future Challenges ............................................... 137 4.2 Air Humidification ............................................................................... 138

4.2.1 Introduction ............................................................................... 138 4.2.2 Process Description ................................................................... 139

4.2.2.1 Direct Air Humidification with Spray Nozz1es .......... 144 4.2.2.2 Air Scrubbers and Humidifiers .................................... 147

4.2.3 Spray Properties ......................................................................... 153 4.2.3.1 Atomizer Types and Designs ....................................... 153 4.2.3.2 Measurement Techniques and Data Analysis .............. 156

4.2.4 Problems and Future Challenges ............................................... 159 4.3 Gas C1eaning and Conditioning Processes ........................................... 159

4.3.1 Introduction ............................................................................... 159 4.3.2 Process Description ................................................................... 160

4.3.2.1 Gas Cooling ................................................................. 161 4.3.2.2 De-dusting ofGases ..................................................... 162 4.3.2.3 De-noxification ofExhaust Gases ............................... 163 4.3.2.4 Flue Gas De-sulphurization ......................................... 165

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Contents xi

4.3.3 Spray Properties ......................................................................... 168 4.3.3.1 Atomizer Types and Designs ....................................... 169 4.3.3.2 Measurement Techniques and Data Analysis .............. 174

4.3.4 Problems and Future Challenges ............................................... 179 References ..................................................................................................... 180

5. Processes Involving Spray Surface Impact ..... .......................................... 185 5.1 Agricultural Sprays .............................................................................. 185

5.1.1 Introduction ............................................................................... 185 5.1.2 Process Description ................................................................... 185

5.1.2.1 Principles of Agricultural Spraying ............................. 185 5.1.2.2 Spray Drift and Biological Efficiency ......................... 191 5.1.2.3 Spraying from Aircraft ................................................ 192 5.1.2.4 Electrostatic Spraying ofPesticides ............................. 195

5.1.3 Spray Properties ......................................................................... 197 5.1.3.1 Atomizer Types and Designs ....................................... 197 5.1.3.2 Measurement Techniques and Data Analysis .............. 204

5.1.4 Problems and Future Challenges ............................................... 208 5.2 Surface Cleaning and Treatment .......................................................... 209

5.2.1 Introduction ............................................................................... 209 5.2.2 Process Description ................................................................... 211

5.2.2.1 Tank Washing .............................................................. 212 5.2.2.2 Surface Treatment ....................................................... 216 5.2.2.3 High -pressure Cleaning .............................................. 220

5.2.3 Spray Properties ......................................................................... 224 5.2.3.1 Atomizer Types and Designs ....................................... 226 5.2.3.2 Measurement Techniques and Data Analysis .............. 233

5.2.4 Problems and Future Challenges ............................................... 235 5.3 Spray Painting and Coating .................................................................. 236

5.3.1 Introduction ............................................................................... 236 5.3.2 Spray Painting and Coating in the Automotive

Manufacturing Industry ............................................................. 237 5.3.3 Spray Painting and Coating Atomizer Systems ......................... 242 5.3.4 Measurement Techniques and Performance Analysis ............... 255 5.3.5 Problems and Future Challenges ............................................... 257

5.4 Printing Processes ................................................................................ 261 5.4.1 Introduction ............................................................................... 261 5.4.2 Inkjet Print Head Designs and Operating Parameters ................ 263 5.4.3 Measurement Techniques and Performance Analysis ............... 275 5.4.4 Problems and Future Challenges ............................................... 282

References ..................................................................................................... 289

6. Fuel Sprays for Fixed Plant ........................................................................ 293 6.1 Bumers, Boilers and Fumaces .............................................................. 293

6.1.1 Introduction ............................................................................... 293 6.1.2 Description ofProcesses ............................................................ 295

6.1.2.1 Power Generation ........................................................ 295 6.1.2.2 Process Heat Generation .............................................. 297

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Xli Contents

6.1.2.3 Hot Water or Steam Generation .................................. 300 6.1.3 Atomizer Types and Operating Conditions ............................... 303

6.1.3.1 Introduction ................................................................. 303 6.1.3.2 Operation ofDifferent Atomizers ................................ 305

6.1.4 Measurement Techniques and Performance Analysis ............... 315 6.1.4.1 Measurement Techniques ............................................ 315 6.1.4.2 Performance Analysis .................................................. 316

6.1.5 Problems and Future Challenges ............................................... 322 6.2 Industrial Gas Turbines ........................................................................ 324

6.2.1 Introduction ............................................................................... 324 6.2.1.1 Basic Applications ....................................................... 324 6.2.1.2 Manufacturing Gas Turbine Atomizers ....................... 324

6.2.2 Process Description ................................................................... 326 6.2.3 Atomizer Types ......................................................................... 326 6.2.4 Measurement Techniques and Performance Analysis ............... 338

6.2.4.1 Verification and Validation of Fuel Injectors .............. 338 6.2.5 Problems and Future Challenges ............................................... 349

6.3 Industrial Diesel Engines ...................................................................... 350 6.3.1 Introduction ............................................................................... 350 6.3.2 Engines ...................................................................................... 350

6.3.2.1 General Description ..................................................... 350 6.3.2.2 Combustion Process and Engine Valve and Fuel

Injection Timing .......................................................... 351 6.3.3 Injection Systems ....................................................................... 356 6.3.4 Measurement Techniques and Performance Analysis ............... 367 6.3.5 Problems and Future Challenges ............................................... 376

References ..................................................................................................... 377

7. Spraying Hot Surfaces for Making Steel and Other Metals .................... 379 7.1 Continuous Casting .............................................................................. 379

7.1.1 Introduction ............................................................................... 379 7.1.2 Process Description ................................................................... 380 7.1.3 Spray Properties ......................................................................... 385

7.1.3.1 Atomizer Types and Designs ....................................... 385 7.1.3.2 Measurement Techniques and Data Analysis .............. 390

7.1.4 Problems and Future Challenges ............................................... 397 7.2 Hot and Cold Rolling Mills .................................................................. 398

7.2.1 Introduction ............................................................................... 398 7.2.2 Process Description ................................................................... 398 7.2.3 Nozzle Types and Operating Parameters ................................... 403 7.2.4 Measurement Techniques and Performance Analysis ............... 410 7.2.5 Problems and Future Challenges ............................................... 414

7.3 Descaling .............................................................................................. 419 7.3.1 Introduction ............................................................................... 419 7.3.2 Process Description ................................................................... 419 7.3.3 Spray Properties ......................................................................... 427

7.3.3.1 Atomizer Types and Designs ....................................... 428 7.3.3.2 Measurement Techniques and Performance Analysis. 430

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Contents XIll

7.3.4 Problems and Future Challenges ............................................... 437 References ..................................................................................................... 438

8. Spraying Molten Metals .............................................................................. 441 8.1 Spray forming ....................................................................................... 441

8.1.1 Introduction ............................................................................... 441 8.1.2 Process Description ................................................................... 441

8.1.2.1 Historical Background ofSpray Forming Process ....... 441 8.1.2.2 The Fundamental Process ofSpray Forming ............... 444 8.1.2.3 Various Spray Forming Plants ..................................... 446

8.1.3 Atomizers and Spray Properties ................................................ 452 8.1.3.1 Definition of Atomizer, Nozzle and Orifice in Spray

Forming ....................................................................... 452 8.1.3.2 Nozzle Types, Design and Operating Parameters ........ 452 8.1.3.3 Measurement Techniques and Performance Analysis. 467

8.1.4 Problems and Future Challenges ............................................... 481 8.2 Metal Powder Manufacture .................................................................. 482

8.2.1 Introduction ............................................................................... 482 8.2.2 Atomizer Types ......................................................................... 484

8.2.2.1 Introduction ................................................................. 484 8.2.2.2 Gas (Two-Fluid) Atomization ..................................... 485 8.2.2.3 Water Atomization ...................................................... 486 8.2.2.4 Other Techniques ......................................................... 486

8.2.3 Measurement Techniques and Performance .............................. 489 8.2.3.1 Measurement Techniques ............................................ 489 8.2.3.2 Atomizer Performance ................................................. 491

8.2.4 Problems and Future Challenges ............................................... 494 References ..................................................................................................... 496

Index ................................................................................................................... 499

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Nomenclature

A C CD D d F Fnv

f G g K L m N N P M> Q q

ReL S T T t U flU V v

We WeGand WeL

x

z

Projected or cross-sectional area, e.g. of spray (m2)

Discharge coefficient ofnozzle, eqn 2.23 (dimensionless) Drag coefficient F/[nJ)2/8 Pg (Up _Ug)2] (dimensionless) Diameter of particle or drop let (um or m) Diameter of orifice, jet or chamber (mm or m) Force, e.g. drag force on particle (N) Nozzle flow number, eqn 2.24 (mz) Frequency (Hz) Liquid mass flux (kg m'z) Acceleration due to gravity (ms-z) Atomizer constant, eqn 2.29 (dimensionless) A characteristic length (m) Mass flow rate (kg S-I)

Number ofparticles (dimensionless) Normalized number distribution ofparticle diameters (j1m-1 or rn-I) Static pressure (absolute) (Pa) Pressure difference (Pa) Volume flow rate (at NTP) (m3s- l )

Heat transfer rate per unit area (Wm-z) Liquid phase Reynolds number = PLflUddJ1L (dimensionless) Span of size distribution, eqn 2.11 (dimensionless) Total measurement time (s) Temperature (K) Time (s) Velocity (ms- I )

Relative velocity between liquid and gaseous phases (ms- I )

Volume of droplets in sampie (m3)

Normalized volume distribution of droplet sizes (J1m-1 or rn-I according to dimensions used for D) Weber number We=pflU2D/a, or =PflU2d/(J (dimensionless)

Gas and liquid phase Weber numbers for drops, columns or sheets (dimensionless). NB: For gas phase use gas density and for liquid phase use liquid density Cartesian coordinate: distance downstream from the atomizer measured along axis (m) Ohnesorge (viscosity) number (dimensionless)

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XVI Nomenclature

z Distance (m)

Greek Alphabet a Parameter related to width of empirical size distribution (Section 3.2.5)

(dimensions depend upon type of distribution) 8 Heat transfer coefficient (Wm-zK I )

e Total included angle of spray boundaries (degrees) A Wavelength (m) J.l Dynamic viscosity (Nsm·z) v Kinematic viscosity (mzs· l )

p Density (kg m·3)

(J Surface tension (Nm· l )

(J Standard deviation of size distribution (dimensions vary) Q) Angular speed (radian S·l)

Subscripts c Cumulative undersize distribution d Disk or cup g Gas i Inlet L Liquid LN Refers to log-normal size distribution m Mass m,x m,0.5 max p andq R s v v, x v,0.5 1,2 10,20, 32 etc o

Value, smaller than which there is 100x% of particles by mass Refers to mass median value Maximum value Subscript in generalized mean diameter relationship Refers to Rosin Rammler size distribution swirl chamber Volume Value, smaller than which there is 100x% of particles by volume Volume, median value of diameter D Two positions

Different definitions of mean diameter, numerical, volume, Sauter Initial value

Note on Units Unless stated in the text all equations are presented in SI units, that is: kg, m, s, K, and derived units; J, N, Pa, and W. In figures, tables and text more convenient or commonly used units may be used and these units are always clear, for example: J.lill, mm and kJ.

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Some Relationships Length 1m = 106J.LDl (microns) = 3.281 ft = 39.37 inch Volurne 1m3 = 106ml = 106cc = 103 1 = 220UK gallons Mass lkg = 2.2051b (UK); 1 tonne (metric) = 103 kg

Nomenc1ature xvii

Pressure 1 bar = 105Pa=14.5Olb finch-2 = 750mm Hg = 10.2m H20; IPa = 1 Nm-2; Standard Atmospheric Pressure = 1 atm = 1.0132 bar

Force IN = lkgms-2 = 105 = dynes = 0.22481b f Energy IkJ = 103 Nm Power lkW = lkJs-1 = 1.341 HP (UK) Viscosity Dynarnic ().l); Ikgm-Is-I = 1 Pas = 10 Poise = 103 cP (centipoise) Viscosity Kinernatic (v=J.1Ip); Im2s-1 = 104 Stokes (St) = 106 cSt

Some Acronyms AD Anti-drift CFD Computational fluid dynamies CHP Combined heat and power FEor FEM FGD HIP HVAC HVLP LCV LDA LPDA LVHP MCR MPI NDT PaC PDA PIV ppm ppmvd PM SAR SMD USGA VCO VOC

Finite element model Flue gas de-sulphurization Hot isostatic pressing Heating, ventilation and air conditioning High volume, low pressure Low calorific value Laser Doppler anemometry SeePDA Low volume, high pressure Maximum continuous rating Multi-passage injector Non-destructive testing Painting and coating Phase Doppler anemometry Particle image velocimetry Parts per million by volume Parts per million by volume, dry gas Powder metallurgy Steam atomized residual (oil) Sauter mean (drop) diameter Ultrasonie gas atomisation Valve covered orifice (injector) Volatile organie compound