Good for SchematicModelling of Externally Mixed Air Blast Atomizer
Good for SchematicModelling of Externally Mixed Air Blast Atomizer
Abstract
Introduction
The process of atomization is one in which liquid is disintegrated into droplets by the
action of internal and/or external forces. In the absence of such forces, surface tension
tends to pull the liquid molecules together to form liquid jets or sheets. According to
Lefebvre[1], “Atomization can be considered as a disruption of the consolidating
influence of surface tension by the action of internal and external forces”.
The literature on the theory of droplet formation [2-5] is quite extensive, but it
deals with fairly low velocity and low Reynolds’s number flows, which are not very
important in practice. Currently, there is no known model of the disintegration of a
high velocity liquid discharge. This is due to the highly complex, turbulent and
26 Suresh Lal, A. Kushari, J.C Kapoor and S. Maji
The theoretical basis for the capillary instability was first investigated by
Rayleigh[7], who conducted a linear, inviscid analysis neglecting the effects of gas
pressure variations on jet distortion. He obtained the following relationship between
the initial jet diameter and the droplet diameter:
D = 1.89d (1)
Thus, for the Rayleigh breakup mechanism, the average drop size is nearly twice
the diameter of undisturbed jet.
Weber [8] developed a linear theory similar to Rayleigh’s that included the effects
of both the liquid viscosity and the pressure of the surrounding gas on the jet
behavior. He assumed that any disturbance causes rotationally symmetric oscillations
of the jet. If the wavelength of the initial disturbance is less than a particular
wavelength, the surface forces tend to damp out the disturbance. However, if λ is
greater than λmin, the surface tension forces tend to increase the disturbances, which
Modelling of Externally Mixed Air Blast Atomizer 27
eventually lead to disintegration of the jet. There is, however, one particular
wavelength, λopt, that is most favorable for drop formation. For viscous liquids
λmin = πd (2)
0.5
⎛ 3μl ⎞⎟
λopt = 2πd ⎜1 + (3)
⎜ ρ σ d ⎟
⎝ l ⎠
After breakup, a cylinder of length λopt and diameter d forms a spherical drop of
diameter D, so that
π π
d 2λopt = D3 (4)
4 6
No simple expressions, relating droplet size to other parameters, exist for the
wind-induced regimes and atomization regime. To predict the behavior of these
regimes, basic fluid dynamics conservation equations for both the liquid and air flows
are numerically solved, along with matching boundary conditions at their interfaces
[9-11]. Small perturbations or disturbances are imposed on the surface of the liquid
jets or sheets and the optimum wavelengths of disturbances that cause maximum
instabilities are estimated numerically, which are then correlated to the droplet sizes.
Although these theories can predict the conditions suitable for the initiation of jet or
sheet disintegration, they cannot accurately predict the size spectrum of the generated
droplets. These theories have successfully predicted the formation of droplets in well-
controlled laboratory conditions, as in the case of capillary droplet formation, but they
have not yet succeeded in accurately modeling the actual droplet formation in a
practical system. These fundamental studies have identified, however, an important
criterion that governs the formation and breakup of droplets. Specifically, the above
discussed research points to the existence of a critical value of the Weber number,
which is the ratio of inertial and surface forces acting on the surface of a liquid jet or
sheet, above which the liquid flow is very unstable and disintegrates into droplets.
The Weber number is defined as
ρ V 2D
We = a r (5)
σ
Therefore,
We * σ
D= (6)
ρ aV r2
correlated to the droplet diameter. However, their model relies upon empirical
relationships to estimate the ligament diameters and the slip velocity between the gas
and liquid streams. Therefore, their model cannot be used to model the atomization
process in an airblast atomizer. Therefore, a new model has been developed to study
the behavior of the investigated atomizer.
The atomization modeling effort in the present study was primarily focused on the
modeling of a design newly developed air blast atomizer. This atomizer is a multi-
hole, siphon fed, air-blast atomizer.
Geometry of Atomizer
A sectional drawing of the atomizer assembly is shown in Fig.1. Liquid enters the
water chamber (2) through water inlet port (1). The liquid is sucked through three
hypodermic needles (3) because of the pressure difference created at the needle tip by
air pressure. The air is supplied through air inlet port (4) and injected through three
holes (5) at the upstream of water entry point. Two streams, air and water, interact at
the exit of the atomizer and droplets are discharged through outer chamber (6).
2 5
3
4
6
Figure 1: Schematic of the Atomizer [(1) Liquid inlet port, (2) Water chamber, (3)
Hypodermic needle for water injection, (4) Air inlet port, (5) Air discharge port, (6)
Outer chamber for discharge of droplets].
The major parameters required for the modeling effort are the number and size of
air injection holes, the number and size of water supply holes and the air pressure
used in the study [14]. Although the information regarding the water head would have
been beneficial in estimating the mist generation rate, in the absence of that
information a physical model for the pressure drop across the water head was
developed to predict the water flow rate. The model used fundamental physical
relationships to predict the atomizer performance and a novel model, based on energy,
force and mass balance was developed to predict the droplet SMD. Some physical
relaxation variables were introduced in the model to compensate for the real flow
effects.
The basic geometric parameters of the investigated atomizer used in this study are:
No. of air injection holes = 3
Modelling of Externally Mixed Air Blast Atomizer 29
4
1
6
5
7 8
Figure 2: Schematic of the mist generation setup [ (1) Externally mixing air atomizer,
(2) Pressure gauge, , (3) Air rotameter, (4) Control Valve, (5) Compressed air line (6)
Water Bottle, (7) Solid cone water spray, (8) Stand for holding atomizer, water bottle
and air rotameter,].
vibration during the measurements. The droplet size distribution measurements were
taken at a fixed location i.e. at a distance of 1 meter from the atomizer.
Air Line
Atomizer
Air Rotameter
Laser Sheet Water Bottle Pressure Gauge
Pressure
Laser Source Regulator
Atomizer
Traversing From
System Compressor
CCD Camera
PC
spray off), was taken and the pixel wise intensity distribution was estimated. Once the
spray was turned on, the zone containing the spray got brighter than the background
resulting in an increase in the corresponding pixel intensities in the image matrix.
Thus, a pixel, in an image containing the spray, with an intensity value higher than the
corresponding values in the image containing solely the background was considered
to be the one representing the spray.
Figure 4 shows images of the spray produced by the presented atomizer at
different air flow rates. It is observed that with an increase in air flow rate, the kinetic
energy of the flow keeps on increasing causing a increase in spray cone angle. It was
observed that spray forms the solid cone at all the operating conditions.
Figure 4: Spray Images at different ALR [(a) ALR = 1.147., (b) ALR = 1.117., (c)
ALR =1.057., (d) ALR = 1.004].
In the present study, the liquid supply pressure was kept constant and the air flow
rate through the atomizer was varied over a range of air supply pressure to obtain the
variation in ALR. The spray solidity was studied by taking pictures of the spray at
different liquid air supply pressures. The liquid flow rate corresponding to a particular
air flow rate (i.e .ALR) was measured using a calibrated rotameter. The liquid supply
pressure was then varied and the entire procedure was repeated for different values of
air supply pressure and a performance map was obtained.
Computational Modeling
For the computational modeling of the atomizer, three sub-models were developed.
These sub-models are:
1. Model for predicting the air flow rate
32 Suresh Lal, A. Kushari, J.C Kapoor and S. Maji
T0 γ −1 2
= 1+ M
T 2
a = γRT
v = Ma
Then, the exit air density is estimated using
1
ρ 0 ⎛ γ − 1 2 ⎞ γ −1
= ⎜1 + M ⎟ (10)
ρ ⎝ 2 ⎠
Next, the flow rate of air was calculated using the equation
m& a = C f ρAv (11)
Where, Cf is a constant to take care of the real gas and other un-modeled effects.
The value of Cf was chosen to be 2.35 for this study.
Where Nf is the factor estimated in the neurons by training the system with the
data available. After estimating the pressure ratio across the water supply, the pressure
drop was estimated using the relation
ΔP = Pa − Pi (13)
Then, the water flow rate is calculated using the continuity equation, i.e.,
m& w = C d Aw 2 * ΔP * ρ w (14)
The value of Cd used in this study was equal to 1.0.
and surface tension) etc. Therefore, it is not possible to propose a unified theory for
droplet formation. Most of the droplet size correlations available in the literature are
empirical relations that work over a limited range of operating conditions and for
specific atomizer designs. Keeping this in mind, a new phenomenological model to
predict the droplet SMD for the atomizer being investigated was developed. The
model uses basic mass and energy balance as well as the Weber number to predict the
droplet SMD. The details of the developed model are given in this section.
Let
Surface Energy of the droplets = E s = σS
Total number of drops = N
Surface area of a single drop (assuming spherical drops) = Si = πDi2
Where the subscript ‘I’ represents individual drops
NN
Therefore, Total Surface Area = ∑ ∑
S = S i = πDi = π Di2
2
∑ (15)
i i =1 i =1
N
Total mass of the atomized liquid = M = ∑ M i (16)
i =1
Where, mass of individual droplets = M i = ρVi (17)
4 π
Here, volume of a drop = Vi = πri3 = Di3 (18)
3 6
π
∴ M i = ρ lVi = ρ l Di3
6
N N (19)
π
⇒ M = ∑Mi = ρl ∑ Di3
i =1
6 i =1
N N
σ ∑ Si σπ ∑ Di2
E s σS
Surface energy per unit mass = = = i =1 = i =1
(20)
N N
M M π
∑ M i 6 ρ l ∑ Di3
i =1 i =1
N
∑ Di3
By definition, SMD = D32 = i =1 (21)
N
∑ Di2
i =1
Es 6σ
Therefore, = (22)
M ρ l D32
Now, Total energy of the liquid per unit mass = surface energy of liquid per unit
mass + kinetic energy of liquid per unit mass
E E E
⇒ T = s + k (23)
M M M
Modelling of Externally Mixed Air Blast Atomizer 35
12 (1 + We )σ
D 32 =
η ( ALR )v a2 ρ l (29)
In order to use this model to estimate the droplet size, one has to specify the We as
well as the efficiency (η). In order to estimate the We, the air velocity and density
estimated in the first section of the model as used along with the measured droplet
size. The relationship used was
ρ a va2 D
We = (30)
σ
(3) The average We for the entire data set was calculated and that was found to be
equal to 43. Therefore, that value was used in the model. Similarly, the average
value of η was estimated to be equal to 0.013 and that was used in the model.
Using these numbers and the value of ALR estimated in the previous section, the
droplet SMD was calculated and the predicted droplet diameter were compared
with the measured values. The model predictions, along with the measured values
are shown in Fig. 10.
The data presented in Fig. 10 shows very good agreement between the model
predictions and the measured SMD. It should be noted that the model inputs were
only the atomizer exit geometry and the air supply pressure and the model
estimated the air flow rate, the water flow rate, the ALR as well as the droplet
SMD. The deviation of the model prediction from the measured data at higher
values of ALR was again due to the change in water head, which brings about an
error in the prediction of ALR. It should be pointed out that the model prediction
will be better if the atomized liquid is also pressurized and the liquid head
information is made available.
0.0035
Measured
Predicted (Bernoulli)
0.003
Corrected (Bernoulli)
0.0025
Air Flow Rate (Kg/s)
0.002
0.0015
0.001
0.0005
0
0 0.5 1 1.5 2 2.5 3 3.5
Air Supply Pressure (bar)
80
1.8
1.6 70
1.4 60
E x it A ir M a c h N u m b e r
0 0
0 0.5 1 1.5 2 2.5 3 3.5 0 0.5 1 1.5 2 2.5 3 3.5 4
Air Supply Pressure (Bar) Air Supply Pressure (Bar)
90 3.5
Predicted
80
Measured
70 3
Water Flow Rate (ml/min)
60
2.5
50
ALR
40
2
30
Predicted
20 Measured
1.5
10
0 1
0 0.5 1 1.5 2 2.5 3 3.5 4 0 0.5 1 1.5 2 2.5 3 3.5 4
Air Supply Pressure (Bar) Air Supply Pressure (bar)
Figure 8: Measured and predicted water Figure 9: ALR vs. Air Supply Pressure.
flow rate.
70
60 Predicted
Measured
50
Droplet SMD (μm)
40
30
20
10
0
0 0.5 1 1.5 2 2.5 3 3.5 4
Air Supply Pressure (Bar)
Conclusions
A phenomenological model is developed and used to predict the performance of a
siphon fed airblast atomizer. The model uses compressible flow relationships to
predict the air flow rate, a neural network based model to predict the water flow rate
and a novel droplet formation model to predict the droplet SMD. The model
predictions are found to be in good agreement with the measured data.
References
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40 Suresh Lal, A. Kushari, J.C Kapoor and S. Maji
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