Spray Analysis and Research

We work with clients to solve their problems. Our unique combination of industrial practice of applying spray technology coupled with problem solving tools provides your problems.

Do you have any of these needs

  • Optimize your nozzle selection?

  • Increase the reliability of your spray system?

  •  Analyze a spray system design?

We use a number to tools to analyze spray systems that include experimental spray quantification and computational fluid mechanics. Our approach is to apply the least complex and least costly method to resolve an issue. We provide the experience to select the right tools for the work and the access to up-to-date spray diagnostics including Phase Doppler Particle Analysis, PDPA. Computationally we use modeling simulation tools from MATLAB based to CFD simulations with 5 million grid cells. Our experience allows the most complex tools to be used cost effectively.

Need more information contact us at  chuck@lakeinnovation.com

Spray technology is used in diverse applications in industries. Our expertise in applying sprays in chemical and petrochemical processes is based on fluid dynamics fundamentals. We provide unbiased and independent perspective on selection and design considerations for the selection of spray technology and troubleshooting. Sprays are used for enhancing the rate of heat and mass transfer in many processes. Today the term of "Process Intensification" is used to describe the cost effective process improvements.

Our expertise include the design and development of custom nozzle applications some of which have been patented by clients.

The selection of a nozzle is a tactical move that influences the outcome, and is certainly more than just "choosing a spray nozzle." Misconceptions often limit how well we practice the art and science of engineering. Without state-of-the-art knowledge of fundamentals and "rules-of-thumb," the technology can be misapplied.

Spiral type spray nozzle- Bete TF nozzle


Spray Usage: sprays are used for two purposes:  1. Distribute liquid over an area, 2. Surface area for evaporation (heat or mass transfer) 

The range of drop size in many commercial spray nozzles is ~30 which results in  27,000 of the smallest drops for the same mass as a single large drop.

Units of drop diameter are typically microns (μm  or micrometers) which is equal to 0.001 mm or 1/25400 inch . 

The image below provide some perspective of the range of size of drops observed.

Drop size

Spray nozzle types:

Nozzles are often classified by the source of energy used to create the dispersion of the liquid into drops, atomization.

Single fluid nozzles use the kinetic energy of the liquid itself to cause the formation of drops.  This liquid stream is often highly turbulent which causes disruption of the liquid surface.  A vast majority of spray nozzles used industrially are hydraulic nozzles.  There are hundreds of designs that are commercially available and many sizes of each design.  This type of nozzle is the nearly always the most energy efficient at generating drop surface area.  Many different spray patterns are available, flat fan, hollow cone, and solid cone.

Flat Fan spray

Solid cone spray

Two fluid spray nozzles use the kinetic energy of expanding gas as the energy source to atomize the liquid. This also provides a second degree of freedom to control spray parameters (drop size ) independent of liquid flow rate.  This type of atomizer is the second most common type of spray nozzle. Many designs customized to specific applications ranging from gas turbine (jet engine) fuel spray to spraying paint.

Rotary nozzles use a high speed rotating plate or cup that “slings” liquid from the outer edge to generate a spray.  This nozzle type is used in spray drying and some spray painting.

Ultrasonic atomizers use a high frequency driver (~50 KHz) as the energy source coupled to a liquid discharge surface to cause a fine low velocity spray.  This type of nozzle is frequently used where the liquid flow rate is low.

Spray Physics: one example

The plot below is a cross-section showing the relative velocity of the internal circulation pattern developed in a liquid drop moving in a gas. The gas motion is in the horizontal direction results in a doughnut shaped, toroid, flow known as a Hill’s vortex. The cause of the internal circulation is the shear force at the drop surface created by the gas moving along the surface.