Spray Nozzle Technology Guide
Spray Nozzle Technology Guide
NOZZLE TECHNOLOGY
INTRODUCTION
To help you to make the best use of Delavan products and services we have
produced a guide to spray nozzle technology. This is designed to take you
through the fundamentals of spray nozzle technology step by step. In addition,
in the Nozzle Technology and Application Guide sections you will find useful
advice on how to choose the best type of nozzle for your application.
BASIC PRINCIPLES
Although the requirements of each spray nozzle may vary considerably from
one application to another, the basic functions of a nozzle are:
1) Control of liquid flow
2) Atomisation of liquid into droplets
3) Dispersal of droplets in a specific pattern
4) Generation of hydraulic momentum or impact.
To break up any liquid into droplets energy is required and in fluid handling
this energy is usually provided by pressure from a pump. This pressure
must be converted into velocity energy by forcing the liquid through restrictive
passages in the nozzle. The resulting energy change is then utilised to
atomise the liquid into droplets and disperse them into a specific spray pattern.
TYPES OF NOZZLE
There are several different basic types of nozzle which can be categorised
by the type of spray that they produce. These are:
a) Flat sprays
b) Hollow cone sprays
c) Solid cone sprays
d) Air atomising sprays
In addition there are variations on these sprays for specific applications.
Refer to the Application Guide section.
2. Operating pressure
3. Spray pattern
4. Spray angle
5. Liquid to be sprayed
6. Quality of atomisation
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NOZZLE TECHNOLOGY
P2
Q2 and P2 are the known flow rate and pressure taken from the
charts given for each nozzle type.
Specific Gravity 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8
Conversion Factor 1.2 1.12 1.05 1.0 .95 .91 .88 .85 .82 .79 .77 .75
2. Operating pressure
This is the major factor that affects the flow rate through a nozzle. To determine
the operating pressure to achieve a specified flow that is not indicated in the
capacity charts, the previous formula can be re-written as follows:
any special requirements: where P1 is the calculated pressure for the desired flow rate Q1
Tel: +44 (0) 151 424 6821
Fax: +44 (0) 151 495 1043 P2 and Q2 are the known pressure and flow rate.
e-mail:[email protected]
Web:www.delavan.co.uk Again this relationship is acceptable for most industrial nozzle
applications but is not correct for all nozzle types.
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NOZZLE TECHNOLOGY
3. Spray pattern
In general a minimum pressure of 0.7–1.0 Bar is required to generate a well
developed spray but this pressure needs increasing where the restrictive
passages of the nozzle are very small. There are a number of basic types of
spray patterns and each can be achieved in a variety of ways, some of which
are as follows:
a) Flat spray – this is a narrow elliptical/oval or rectangular orfice shape which
can be produced by the following methods:
i) An elliptical orifice
formed by the
intersection of
a ‘V’ groove with
a hemispherical
cavity.
iii) A rectangular
orifice formed by
the intersection
of a slot in a
hemispherical
cavity or
cylindrical tube.
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NOZZLE TECHNOLOGY
c) Solid cone – this is a solid area of spray which can be circular or square
shaped. It can be produced by the following methods:
NOZZLE TECHNOLOGY
3. Spray pattern (continued)
d) Air atomising sprays – these are produced by using air as the atomising
agent and sprays are generally of the external (siphon or pressure) and
internal (pressure) mix design. Some of these types are as follows:
i) External mix –
Cone spray.
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NOZZLE TECHNOLOGY
4. Spray angle
The spray angle is typically measured at close proximity to the nozzle orifice
with a tolerance of 5° on tested spray angles. As the spray distance increases
the droplets are affected by gravity and gas friction which reduces the spray
angle. The diagram below shows this effect.
All the capacity charts are based on the theoretical spray width.
10 0,9 1,8 2,6 3,5 4,4 5,3 7,0 8,8 10,5 12,3 14,0 17,5 21,9 26,2
15 1,3 2,6 4,0 5,3 6,6 7,9 10,5 13,2 15,8 18,4 21,1 26,3 32,9 39,5
20 1,8 3,5 5,3 7,1 8,8 10,6 14,1 17,6 21,2 24,7 28,2 35,3 44,1 52,9
25 2,2 4,4 6,7 8,9 11,1 13,3 17,7 22,2 26,6 31,0 35,5 44,3 55,4 66,5
30 2,7 5,4 8,0 10,7 13,4 16,1 21,4 26,8 32,2 37,5 42,9 53,6 67.0 80,4
35 3,2 6,3 9,5 12,6 15,8 18,9 25,2 31,5 37,8 44,1 50,5 63,1 78.8 94,6
40 3,6 7,3 10,9 14,6 18,2 21,8 29,1 36,4 43,7 51,0 58,2 72,8 91,0 109
45 4,1 8,3 12,4 16,6 20,7 24,9 33,1 41,4 49,7 58,0 66,3 82,8 104 124
50 4,7 9,3 14,0 18,7 23,3 28,0 37,3 46,6 56,0 65,3 74,6 93,3 117 140
55 5,2 10,4 15,6 20,8 26,0 31,2 41,7 52,1 62,5 72,9 83,3 104 130 156
60 5,8 11,6 17,3 23,1 28,9 34,6 46,2 57,7 69,3 80,8 92,4 115 144 173
65 6,4 12,7 19,1 25,5 31,9 38,2 51,0 63,7 76,5 89,2 102 127 159 191
70 7,0 14,0 21,0 28,0 35,0 42,0 56,0 70,0 84,0 98,0 112 140 175 210
75 7,7 15,4 23,0 30,7 38,4 46,0 61,4 76,7 92,1 107 123 153 192 230
80 8,4 16,8 25,2 33,6 42,0 50,4 67,1 83,9 101 118 134 168 210 252
85 9,2 18,3 27,5 36,7 45,8 55,0 73,3 91,6 110 128 147 183 229 275
Contact our Helpline for 90 10,0 20,0 30,0 40,0 50,0 60,0 80,0 100 120 140 160 200 250 300
any special requirements:
Tel: +44 (0) 151 424 6821 95 10,9 21,8 32,7 43,7 54,6 65,5 87,3 109 131 153 175 218 273
Fax: +44 (0) 151 495 1043
e-mail:[email protected]
100 11,9 23,8 35,8 47,7 59,6 71,5 95,3 119 143 167 191 238 298
Web:www.delavan.co.uk 110 14,3 28,6 42,9 57,1 71,4 85,7 114 143 171 200 229 286
120 17,3 34,6 52,0 69,3 86,6 104 139 173 208 243
130 21,5 42,9 64,3 85,8 107 129 172 215 257
140 27,5 55,0 82,4 110 137 165 220 275
150 37,3 74,6 112 149 187 224 299
NOTE:
Liquids more viscous than water will form smaller spray angles. In some cases
the nozzle will generate a solid stream depending on the size of the restrictive
passages of the nozzle, the degree of viscosity and the operating pressure.
Liquid surface tension also has an effect on the spray angle; lower values than
water (73 dynes/cm) will increase the spray angle.
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NOZZLE TECHNOLOGY
4. Spray angle (continued)
IMPACT
As well as the operating pressure and flow rate the spray angle also affects the
amount of impact that is created on the surface being sprayed. For a straight
stream nozzle the impact (kg/cm2) can be determined by the formula 1.9 x
operating pressure (kg/cm2). For other nozzles it is necessary to first determine
the theoretical total impact by the formula (based on water):
The following table will assist in calculating the actual impact in kg/cm2 based
on a distance of 30cm from the nozzle.
IMPACT CHART
Nozzle Nozzle Total Impact Per cent impact
type spray angle Efficiency 30cm of the theoretical
from nozzle total impact 30cm
from nozzle
STRAIGHT STREAM
Has high impact efficiency with only slight losses due 96% See the above formula
to friction. No value is given for the per cent impact 0˚ to for impact percentage
per cm2 since the impact per cm2 remains constant 99% of any straight nozzle.
for all capacities, the pressure being constant.
FLAT SPRAY (AC)
Impact Efficiency is high. Narrow spray angles have 15˚ 30%
higher Total Impact Efficiency. 25˚ 95% 18%
40˚ to 12%
50˚ 90% 10%
65˚ 7%
80˚ 5%
DEFLECTED FLAT SPRAY (TJ)
The Total Impact Efficiency is not as high as the 15˚ 80% 30%
FLAT SPRAY because of friction losses due to the 35˚ to 13%
deflector surface. However, the spray is more 40˚ 75% 12%
concentrated and the per cent impact per cm2 is 50˚ 10%
as high as the FLAT SPRAY.
SOLID CONE (BI)
Impact Efficiency varies with the spray angle 15˚ 85% 11%
for this type of nozzle. 30˚ 81% 2.5%
50˚ 77% 1.0%
65˚ 70% 0.4%
80˚ 61% 0.2%
100˚ 50% 0.1%
HOLLOW CONE (AE)
Has the lowest Total Impact Efficiency but because
Contact our Helpline for
of its concentration, the impact per cm2 will be 60˚ 2% any special requirements:
slightly higher than the SOLID CONE. The 60˚ to to 50% to Tel: +44 (0) 151 424 6821
80˚ spray angle range is given which covers most 80˚ 1% Fax: +44 (0) 151 495 1043
standard HOLLOW CONE nozzles. e-mail:[email protected]
Web:www.delavan.co.uk
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NOZZLE TECHNOLOGY
5. Liquid to be sprayed
With a liquid different from water there are a number of factors that can affect
the nozzle type to be used, the required operating pressure and the optimum
material of manufacture. These are as follows:
a) Specific gravity (density)
b) Viscosity
c) Surface tension
d) Temperature
The following chart shows the various effects that changes to the above have
on the performance of a spray nozzle.
PERFORMANCE CHART
Increase Increase Increase Increase Increase
in pressure in specific in viscosity in liquid in surface
gravity temperature tension
Spray pattern quality Improves Negligible effect Deteriorates Improves Negligible effect
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NOZZLE TECHNOLOGY
6. Quality of atomisation
All of the variables previously mentioned influence the degree of atomisation;
that is, the size of the droplets produced by a nozzle. In general, spray nozzles
do not generate droplets of equal size. Liquid break-up is caused by the
collapse of unstable fluid sheets, jets or ligaments, or by the shearing action of
air. These mechanisms produce a broad spectrum of droplet sizes; often
submicron up to several hundred microns in the same spray.
Fog 1-30
Mist 30-100
Drizzle 100-300
Droplet size may vary within the pattern of a given spray. For example, because
of their greater momentum, the larger drops in a cone spray are typically found
near the outside of the pattern. Induced air pushes the small droplets toward
the centre. Variations may also occur as droplets move away from the nozzle;
but the net change is difficult to predict, due to the offsetting effects of
coalescence and evaporation.
Although droplet size is affected by nozzle type, most pressure atomisers give
similar results if the flow rate, pressure and spray angle are the same. Droplets
may be somewhat larger for flat spray nozzles, particularly at the edges of
the pattern.
Two-fluid nozzles are often recommended for extremely fine atomisation (e.g.
below 50 microns). With this type of atomiser, droplet size is a function of air
pressure (or relative air velocity) as well as the air-liquid ratio.
Contact our Helpline for
The two most important liquid properties that affect atomisation are viscosity any special requirements:
and surface tension. As viscosity increases, larger viscous forces must be Tel: +44 (0) 151 424 6821
overcome by the energy supplied to the nozzle. This reduces the energy Fax: +44 (0) 151 495 1043
e-mail:[email protected]
available for droplet break up, resulting in coarser atomisation. With very Web:www.delavan.co.uk
viscous liquids, satisfactory atomisation may become difficult and two-fluid
nozzles should be considered. In addition to viscous forces, surface tension
must also be overcome in creating droplets. Liquids having high surface
tension are more difficult to atomise.
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NOZZLE TECHNOLOGY
RESEARCH
Delavan has been producing spray nozzles since 1946 and has developed
specialist nozzles for applications such as oil heating and specialised injectors
for gas turbine engines. These have now been built into successful, specialist
businesses in their own right within the Coltec Group and help provide
Delavan with a wealth of knowledge and expertise to draw upon.
Delavan is a major supplier of spray nozzles and accessories for agricultural
and industrial applications worldwide. Thousands of nozzle designs have been
developed and research and development is constantly undertaken to optimise
flow, spray pattern and droplet size of nozzles for new applications.
Operating conditions cover wide ranges – flow rates from 0.1 GPH to 60000
GPH, and pressures as high as 7000 psi. Delavan nozzles must also be
designed for many types of liquids: light and heavy oils, abrasive and corrosive
chemicals, and formulations containing suspended solids.
Contact our Helpline for Of particular interest are Delavan’s unique systems for determining spray
any special requirements: droplet size. For many years laboratory data has been accumulated using a
Tel: +44 (0) 151 424 6821
Fax: +44 (0) 151 495 1043
technique involving droplet collection, photomicrography and high-speed
e-mail:[email protected] image analysis. In 1982 Delavan augmented its research facilities by procuring
Web:www.delavan.co.uk laser spectrometer probes and custom software from Particle Measuring
Systems Inc. Also, the PMS light-scattering and imaging probes, used with a
dedicated computer, permit rapid spray analysis for a broad spectrum of
particle diameters.
The laboratory is now equipped with still another diagnostic tool, the Aerometrics
Phase Doppler Particle Analyser which is capable of measuring not only the
size distribution of droplets, but also their velocity, flux and concentration
within the spray sampling volume. This non-intrusive instrument may be
operated with a computer-controlled nozzle traversing mechanism to provide
global data or statistical information at designated locations within a three-
dimensional region.
Interest in spray analysis has grown steadily in recent years, and many
organisations are utilising droplet size information to improve their processes
and products. If you would like to have additional information about droplet
size, please contact our Customer Service Team.
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NozzleTechSection 10/5/01 6:37 am Page 11
NOZZLE TECHNOLOGY
6. Quality of atomisation (continued)
These research tools are a great asset in nozzle development and in supplying
useful data to Delavan’s customers.
• DISTRIBUTION PARAMETERS •
LENGTH MEAN DIAMETER (D10): 21.11 UM NUMBER MEDIAN DIAM. (DN.5): 14.65 UM
AREA MEAN DIAMETER (D20): 30.25 UM VOLUME MEDIAN DIAM. (DV.5): 119.37 UM
VOLUME MEAN DIAMETER (D30): 42.43 UM 10% – VOLUME DIAMETER (DV.1): 42.70 UM
SAUTER MEAN DIAMETER (D32): 83.48 UM 90% – VOLUME DIAMETER (DV.9): 200.07 UM
STANDARD DEVIATION (VOL): 59.20 UM MAXIMUM DIAMETER : 305.00 UM
COEFF. OF VARIATION (VOL): 0.483 UNIFORMITY INDEX (VOLUME) : 0.401_
The following charts show the estimated Sauter mean diameter of droplets
for various flow rates of typical 80˚ hollow and solid cone spray patterns based
on water.
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NOZZLE TECHNOLOGY
7. Material of manufacture
Delavan manufactures spray nozzles and accessories in a wide range of
materials to meet the various demands of all types of spraying applications.
Each nozzle type is manufactured in a range of standard materials for their
specific applications but can also be manufactured from a range of other
materials on request.
During the last 50 years of manufacturing spray nozzles Delavan has had
experience of many diverse applications which have involved corrosive and
abrasive liquids in both hot and corrosive environments. Our sales engineers
and technical staff would be pleased to discuss your specific application. The
following is a list of some of the materials from which we have manufactured
spray nozzles and accessories.
2.12