IF spray performance isn’t precise, product and process quality can be compromised dramatically. In critical spray operations such as dust control, Spraying Systems’ Spray Analysis and Research Services group provides specialised advanced testing in its spray labs, process modelling and/or fluid dynamics modelling, as well as dust mitigation services.
Using advanced tools to simulate a customer’s operating environment enables the group to accurately predict spray performance before finalising a design solution or product recommendations.
The team conducts comprehensive tests that probe into spray characterisation, drop size distribution, drop velocity, spray impact, spray coverage, evaporation, while Computational Fluid Dynamics (CFD) modelling investigate gas flow, flow patterns, velocity, temperature, droplet trajectories and gas/liquid distribution to ensure optimal nozzle/lance performance.
“Using state-of-the-art instrumentation and software at our spray laboratories, we are able to diagnose and solve nearly any spray related questions,” Spraying Systems dust management specialist Matthew Hayward said.
“Our Computation Fluid Dynamics (CFD), Finite Element Analysis (FEA), and Fluid Structure Interaction (FSI) modelling for our customers helps achieve an optimised spray-related solution.
“Using simulation, it is possible to gain a better understanding of the keys factors that impact the success of an application.
“Computer modelling allows you to investigate multiple parameters that may be difficult or impossible to replicate in a laboratory environment.”
Spraying System’s custom CFD models integrate data collected in its spray labs and proprietary design elements of the injectors, which offer many benefits to the end user, including liquid and gas flow in scrubbers, towers, ducts and dryers; spray droplet trajectories and distributions in towers and ducts; internal flow characteristics of spray nozzles; gas and liquid mixing in two-fluid nozzles; wall impact and shadowing; pollution reduction effectiveness; and blending in large vessels.
In addition, the company also specialises in dust control for the mining, manufacturing, and processing industries.
“Uncontained dust or lack of suppression causes major health and safety hazards for workers and the surrounding environment, as well as damage and blockage of equipment,” Mr Hayward said.
Dust suppression and control concerns may include suppression and reduction of airborne particles; preventing surface dust from becoming airborne; ineffective suppression and control of the current system; and safety hazards due to drifting particles.
“In order to capture small dust particles, it is typically optimal to match the droplet size with the particulate size,” he said.
“By measuring a sample of solid dust particles, a spray system may be designed and a nozzle/spray may be optimally tuned to generate the targeted drop size while achieving adequate coverage.”