Particle production comparison between the conventional and blade-designed two-fluid pressure nozzles via CFD simulation

This study investigates particle production characteristics in two different nozzle designs : a conventional pressure twin-fluid nozzle and a blade-designed nozzle, to enhance nozzle productivity. Simulations were conducted under two conditions using water as a Newtonian liquid (viscosity 1 mPa·s), fixed air velocity (178 m/s), and constant pressure (1 bar). Case 1 involved a liquid mass flow rate of 50 kg/h, while Case 2 varied the rate at 20, 35, and 50 kg/h, with Gas to Liquid Ratio(GLR) of 0.7, 0.4, and 0.28 respectively. Results indicate that nozzle design significantly influences velocity distribution and mixing behavior. In the blade-designed nozzle, the dispersed blade outlet directs internal gas flow prior to expulsion, reducing velocity stratification and enhancing gas-liquid interaction near the exit. This design achieves a broader atomization range and more uniform particle size distribution at certain regions. • Two pressure twin fluid nozzles are compared by simulation, while validation is accomplished by an experimental thesis. • Simulation of the particle behavior of bladed air outlet and ring shape liquid outlet nozzle is accomplished. • The nozzle design led to significant differences in particle size and distribution.