喷雾对促进细颗粒物声波团聚的影响

以燃煤烟气为对象,实验研究了各参数对喷雾促进声波团聚的影响。结果表明,添加喷雾后,声波团聚效率提高了25%~40%。无论有无喷雾,声波团聚均存在相同的最佳频率,为1400 Hz左右。较低液气比时,团聚效率随液气比的增加而明显增大,但超过0.10后,团聚效率趋于稳定。添加喷雾时,团聚效率随停留时间的增加而提高,但达到4.2 s时基本达到最大值。分析了喷雾提高团聚效率的机理,在喷雾作用下,颗粒之间形成比范德华力更强的液桥力,增大了有效碰撞系数;同时,雾化液滴的加入为气溶胶团聚提供了种子颗粒,周围的细颗粒易与之发生碰撞团聚,使团聚效率提高。研究表明,喷雾方法可以大幅降低声波团聚工艺的操作能耗。     

声波与喷雾对于飞灰颗粒团聚的影响

为了研究声波团聚的影响因素,以燃煤飞灰细颗粒作为声波团聚的实验对象,使用光学颗粒物粒径谱仪测量颗粒的粒径分布与浓度,主要研究了声波频率与喷雾对声波团聚的影响。结果表明：在声波的作用下,细颗粒浓度显著减少,且声波团聚效果对频率较为敏感;无论在高声压还是低声压级下,1400Hz的频率下能获得最佳的团聚效果;在加入喷雾后,颗粒物浓度显著减小,且随着喷雾量增大,颗粒物浓度越小;分析了喷雾增强团聚效果的机理：在加入喷雾后,细颗粒间的相对运动增强;同时喷雾颗粒增大了颗粒浓度,增大了细颗粒碰撞概率;此外,喷雾改变燃煤飞灰细颗粒的表面特性,使颗粒的表面黏性增大,有助于团聚体形成。     

Comparing the crystallization of sucrose and lactose in spray dryers

The relative extent of crystallization for lactose and sucrose within spray dryers allows the WLF equation to be tested for this type of in-process crystallization, since this equation suggests that the crystallization rate is related to the difference between the material temperature and the glass-transition temperature of that particular material. In this study, the amount of sucrose crystallization during drying was studied using a bench-top spray dryer (Buchi B290) over a practical range of inlet gas temperatures (95–220 °C). It has been found that very large changes in the degree of crystallinity for the final spray-dried product can be achieved for sucrose by using different inlet gas temperatures, compared with much smaller changes in the crystallinity of lactose for a similar range of inlet temperatures. This result supports the suggestion that the crystallization rate is related to the difference between the material temperature and the glass-transition temperature, since sucrose has a much lower glass-transition temperature than lactose. The results have the potential to be implemented to achieve specified degrees of crystallinity in many powder materials produced from spray-drying processes.     

Spray drying with a two-fluid nozzle to produce fine particles: Atomization,scale-up,and modeling

This article presents experimental and modeling work to complete previously reported work on spray drying. Back-calculated droplet sizes have been verified by measurements with a laser imaging rig. Flow patterns in a cylindrical spray chamber have been simulated by computational fluid dynamics and demonstrated that droplet residence times are much shorter than expected. A droplet tracking population balance model has been implemented in gSOLIDS and shows how drying times vary with droplet diameter. Particle collection by cyclone and bag filter have also been compared experimentally.     

Highly swirling transient flows in spray dryers and consequent effect on modeling of particle deposition

Cotton turf and hotwire measurements were used to experimentally assess the highly swirling flow characteristics in a spray dryer fitted with a rotary disc atomizer. The numerical simulation captured key features of the flow field. Analysis revealed that rapid rotation of an atomizing disc tends to centrifugally split the central inlet jet. The flow field exhibited significant long time-scale transient behaviour. However, this centrifugally split jet resulted in a balanced upward recirculation region in the chamber as expected by the jet-feedback mechanism. Detailed analysis using a ‘transient air-steady particle’ approach revealed that this approach is applicable for such highly swirling transient flows as well. However, caution should be exercised when interpreting the deposition results, particularly in regions of low particle velocities. This is anticipated be an important consideration in future attempts to simulate the predominantly transient flows in spray dryers.     

双流体管道喷雾系统的计算和评述

分析了新型干法预分解窑广泛采用的增湿塔雾化系统所存在的水压大、喷嘴磨损大、水滴蒸发时间长等缺陷;介绍了双流体管道喷雾系统具有结构简单、水滴直径小,需蒸发时间短,占地空间小等优势;并进行了双流体管道喷雾系统的管道直径和水滴蒸发时间的设计计算;最后列举了双管道喷雾系统用于窑头烟气降温调质处理的实际应用效果。     

The role of wall deposition and re‐entrainment in swirl spray dryers

A new experimental method is outlined to study fouling in spray dryers and similar devices. In essence, it makes the deposits traceable so that one can quantify the material that comes off the walls, how long it remains there and how the deposits agglomerate with particles in the air. This paper investigates a countercurrent swirl spray dryer of detergent and provides sound evidence that fouling is a dynamic process: clusters form and break at the walls renewing an active layer of deposits. Remarkably, the wall generates >20% of the product and most of the large granules, and increases drastically the residence time of the powder. The assumptions of current numerical models are clearly invalid (i.e. particles rebound at the wall or deposit indefinitely). Several re‐entrainment mechanisms and their times scales are identified in this work, and accordingly, a new general framework to describe fouling in spray dryers is proposed. © 2015 American Institute of Chemical Engineers AIChE J, 61: 1804–1821, 2015     

烧结烟气半干法脱硫微细颗粒物特征分析

通过激光粒度分析仪（LPSA）对烧结烟气微细颗粒物进行粒度分析，获得烧结过程烟气排放的主要微细颗粒物粒径范围及分布特性。运用扫描电镜-能谱分析仪（SEM-EDS）、X射线衍射仪（XRD）对半干法脱硫前后烧结烟气中的微细颗粒物形貌、元素组成和物相成分进行分析对比。结果发现：脱硫前后的烧结粉尘颗粒特性存在较大差异。在粒径分布上，脱硫前后粒径范围分别为0.816～60.988μm和0.259～407.850μm，脱硫后中位粒径向小粒径偏移；在颗粒形貌上，大烟道中以不光滑球形和不规则颗粒为主，脱硫后以板块状和片状颗粒为主。在元素和物相组成上，大烟道中颗粒中主要元素为Fe、K、Cl，Fe元素以Fe₂O₃为主，K元素主要以KCl存在，并能观察到明显的立方体KCl颗粒；脱硫后，受脱硫剂影响，颗粒物中主要元素为Ca、O、S，主要以Ca(OH)₂、CaSO₃和CaSO₄为主，同时还含有一定量的石英、氧化镁及一些不定形玻璃相。     

确定喷雾干燥中雾滴粒度分布的轨迹分析法

由于喷雾干燥中雾滴的运动较复杂，所以目前多是通过实验测量来确定雾滴粒度分布，有限多不便因素。通过模拟粒子受力情况以及与空气的传质传热，采用时间增量法和拖动坐标系逐步跟踪粒子的运动轨迹，建立数学模型，再结合实验中样板取样所得到的数据，即可确定喷雾干燥中雾滴粒度分布。     

压力雾化喷嘴在受限空间气流中喷雾特性的实验研究

对出口直径为0.21、0.28、0.38、0.46mm的4种压力雾化喷嘴及其组合在150mm×150mm×1 000mm的矩形通道中的喷雾流场进行了实验研究,矩形通道中的空气流速为10m/s。研究了喷嘴布置和组合方式对雾化流场的影响。实验结果表明:喷雾不碰壁距离随入射角的增大而增大;顺流喷雾比无气流时液滴的平均D32减小10%,粒径范围略有扩大;逆流喷雾比无气流时液滴的平均D32增大约70μm,粒径范围扩大了3⁴倍;出口直径小的喷嘴可通过逆流布置和顺流布置的组合,获得液滴粒径分布范围更宽的气液两相流场。双喷嘴在有限空间内的雾化效果与流场中气液流量比有关。所得研究结论对天然气加湿技术的开发有一定参考价值。     

旋风分离器内细颗粒浓度分布及运动分析

旋风分离器对5 μm以下颗粒的分离效率有待提高。通过雷诺应力模型和随机轨道模型研究1 μm颗粒在超高旋风分离器内的浓度分布。结果表明细颗粒在上行流和准自由涡的重叠区聚集,形成浓度高峰。分析不同轴向位置和不同时刻的颗粒径向分布,发现其形成机制有二：一是高度与自然旋风长不匹配导致旋涡尾端扫壁,引起大量颗粒返混,然后在内旋流的分离作用下向外移动;二是下行流向心汇聚对细颗粒的裹挟作用。机制一对颗粒浓峰的贡献更大。大部分浓环颗粒在上行过程中会继续外移,汇入下行流后再次经受外旋流的分离作用,少部分颗粒在上行流或短路流的裹挟下逃逸。抑制颗粒返混是改善颗粒浓环的关键,可通过优化高度或增加内购件的方式实现。     

Formulation of metformin hydrochloride nanoparticles by using spray drying technique and in vitro evaluation of sustained release with 32-level factorial design approach

The aim of this study was to investigate the combined influence of two independent variables in the preparation of sustained release metformin hydrochloride (MH) nanoparticles by 32-factorial design using a spray drying method. Polymer concentration and amount of organic solvent are selected as independent variables while drug loading and drug release were considered as dependent variables. The nanoparticles were characterized using particle size analyzer, which is obtained in the range of 400–700?nm, Fourier transform infrared spectroscopy, and X-ray diffraction. The kinetics of the dissolution process was studied by analyzing the dissolution data. The results suggested that MH nanoparticles are suitable for sustained release of drug.     

电除尘器飞灰粒径表征及细颗粒降温团聚

基于50000m³/h实烧烟气中试系统,采用Mastersizer 2000E激光粒度分析仪和电子低压冲击仪（ELPI）,首次对电除尘器飞灰几何粒径和空气动力学粒径进行全面表征。结果表明,电除尘器入口及各电场的飞灰几何粒度分布均呈双峰分布特征,各电场峰值依次右移,但末级旋转电极电场≤ 1μm的颗粒占比略有升高,电除尘器入口及第1～5电场飞灰几何中位径分别为6.607μm、17.378μm、2.884μm、2.577μm、2.460μm、2.480μm;温度降低,电除尘器入口飞灰几何粒度分布的双峰均右移,颗粒团聚现象明显,80℃、90℃、110℃、130℃、150℃时电除尘器入口飞灰几何中位径分别为13.183μm、10.500μm、10.171μm、6.607μm、7.586μm,从130℃降至90℃,电除尘器入口几何粒径≤ 1μm、≤ 2.5μm、≤ 10μm的飞灰占比分别减少了19.8%、19.2%、12.6%;不同温度时,电除尘器对空气动力学粒径0.03～10μm段颗粒的个数浓度、质量浓度均有较高脱除效率,均在75%以上,最高可达99.9%;温度降低,电除尘器进出口空气动力学粒径不同粒径段颗粒个数浓度和质量浓度均有不同程度降低,从130℃降至90℃、80℃,对应电除尘器入口PM_2.5团聚效率分别为46.76%、60.08%,对应电除尘器出口PM₁₀减排分别为59.80%、91.08%,PM_2.5减排分别为45.94%、76.22%,PM1减排分别为40.40%、62.12%。     

Aerosol analysis of residual and nanoparticle fractions from spray pyrolysis of poorly volatile precursors

The quality of aerosol‐produced nanopowders can be impaired by micron‐sized particles formed due to non‐uniform process conditions. Methods to evaluate the quality reliably and fast, preferably on‐line, are important at industrial scales. Here, aerosol analysis methods are used to determine the fractions of nanoparticles and micron‐sized residuals from poorly volatile precursors. This is accomplished using aerosol instruments to measure the number and mass size distributions of Liquid Flame Spray‐generated alumina and silver particles produced from metal nitrates dissolved in ethanol and 2‐ethylhexanoic acid (EHA). The addition of EHA had no effect on silver, whereas, 5% EHA concentration was enough to shift the alumina mass from the residuals to nanoparticles. The size‐resolved aerosol analysis proved to be an effective method for determining the product quality. Moreover, the used on‐line techniques alone can be used to evaluate the process output when producing nanopowders, reducing the need for tedious off‐line analyses. © 2016 American Institute of Chemical Engineers AIChE J, 63: 881–892, 2017     

Plerosphere and its role in reduction of emitted fine fly ash particles from pulverized coal-fired power plants

Fine particles (PM_2.5) emitted from the stacks of the coal-fired power plants are of environmental concern since they can easily enter the human respiratory track. The detailed study of the fly ash particles using scanning electron microscope/electron dispersive spectrometry (SEM/EDX) show that fine solid spherical particles (microspheres) are contained by the large cenosphere particles (>50 μm) during the combustion process. The resulting macro particles are known as “plerosphere”, which are typically impregnated by the fine microspheres. The coal-fired power plants’ particle control devices such as the electrostatic precipitators (ESP) and baghouse filters tend to capture the large plerospheres, more efficiently. Therefore, the result of this study suggests that the containment of the microspheres by plerospheres during the coal combustion process can effectively reduce the amount of fine particles and associated elements released into atmosphere.     

A Three-Dimensional Numerical Study of the Gas/Particle Interactions in an Industrial-Scale Spray Dryer for Milk Powder Production

Gas/particle interaction plays an important role in modern spray dryers and may have influences on wall deposition, agglomeration, powder degradation, etc. In the present study, the three-dimensional (3-D) transient multiphase flow in an industrial-scale spray dryer has been investigated using the CFD package FLUENT. The Eulerian–Lagrangian approach and two-way coupling method were used in the simulations. The reaction engineering approach (REA model) for milk particles has been implemented. Some new characteristics of the gas flow pattern and the particle behavior (e.g., temperature–time profiles) were identified from the numerical results; for example, the milk particles flow in such a way that makes the central jet oscillation more nonlinear. The discrete phase enhances the turbulence near the air/droplet inlet but damps it downstream. The transient turbulent flow causes significant uncertainties in the particle tracking, which presented some challenges in simulations. The study has highlighted the importance in performing 3-D transient simulations in order to understand the industrial-scale dryers.     

丁苯胶乳合成中的粒径及其分布

用动态激光光散射法测定了丁二烯－苯乙烯乳液聚合的乳胶料粒子的粒径及其分布,结果表明,在反应初期平均粒径较大,粒径分布最宽,当单体转化率为６０％左右时,乳胶粒子分散度最低,说明粒径较大的液滴逐渐消失,继续聚合,乳胶粒子发生合并聚结,其平均粒径略有增长,粒径分布下降,加入电解质ＫＣｌ是增大乳胶平均粒径的有效方法。     

Numerical Study of the Drying Process of Different Sized Particles in an Industrial-Scale Spray Dryer

Development of high-performance spray dryers that are more energy efficient and are able to produce high-quality milk powders is very important for the future of the dairy powder industry. Understanding and optimization of the exiting dryers are also of great value. Computational fluid dynamics is a powerful tool to simulate and help understanding the characteristics of spray drying and to introduce potentially improved designs. The present study has concentrated on the multiphase flow in an industrial-scale spray dryer using the CFD package FLUENT. A Eulerian-Lagrangian approach is used in the simulations. A new drying model, REA model, for milk particles has been implemented for the first time in a CFD application. The numerical results match well with the plant data. It is argued that the “reflecting wall” boundary condition produced more physically correct results for normal dryer operation than the “escaping wall” boundary condition. The second one is an oversimplification. The influences of the particle size and particle size distribution, residence time, kinetic energy, and maximum temperature have been analyzed. The initial droplet size range was set to be from 100 to 500 µm with Rosin-Rammler distribution function. One significant result of this study is that rather dense particle clouds of medium-size particles (224–285 µm) are found near the side walls. They are transported upwards along the side wall (conical wall surface) and then are dispersed. It is found the particles with initial diameters of between 225 and 270 µm have the largest residence times.     

立式缩放管内液固颗粒群浓度分布与汇聚特性

为分析颗粒群在立式缩放管内的运动规律,基于计算流体力学-离散单元（CFD-DEM）耦合方法模拟研究缩放比γ、肋高e和颗粒进口浓度α对管内颗粒群浓度分布与汇聚特性的影响。结果表明：在研究参数范围内,颗粒群的轴向浓度分布较为均匀,管下部颗粒滞留相对较多;颗粒群径向相对浓度遵循管中心区域浓度低,近壁面颗粒相对浓度较高的规律;肋高e=1.0mm的缩放管在颗粒进口浓度α≤2%时,管壁附近颗粒浓度最高。在管段中上部颗粒运动相对稳定阶段,在肋高e=2.0mm与缩放比γ≤1.0、颗粒进口浓度α≥3%工况下,颗粒群易出现汇聚现象。