Experimental and Computational Study of a Water Wash Spray Injection

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1 Experimental and Computational Study of a Water Wash Spray Injection Rudolf J. Schick*, Kathleen J. Brown, Keith L. Cronce Spray Analysis and Research Services Spraying Systems Co.

2 PRESENTATION TOPICS Company Overview Problem Description Methodology Results Conclusion and next steps

3 Global leader in spray technology Global manufacturing Global sales and support Spray nozzles, headers, injectors, spray controls, research & testing 75 years old

4 Spray Analysis & Research Services Identify Techniques and Methodology for Spray Applications Proof-of-concept, modeling, prototypes, implementation Educational and Consulting Services Customer s knowledge of spray technology and applications Optimization of Spray Performance Increase efficiencies, validate performance, reduce risk

Problem Description Wash Water Injection Processing of crude oil creates various salts which can lead to

Water wash is used to scrub the salts from the process stream and to mitigate corrosion risks.

The interaction of a spray plume within a confined cross-flow environment controls the level of liquid gas

5 Problem Description Wash Water Injection Processing of crude oil creates various salts which can lead to corrosion or plugging at various stages in the equipment. Water wash is used to scrub the salts from the process stream and to mitigate corrosion risks. Even distribution of water wash increases the effectiveness of a water-wash system. The interaction of a spray plume within a confined cross-flow environment controls the level of liquid gas mixing and absorption effectiveness. CFD is used in environments that are difficult to access, validation is necessary to be sure injector recommendations are accurate and optimized. Process Stream Flow

Airflow 2-50m/s capability Operated at 10m/s and 20m/s

6 Empirical Setup Wind Tunnel Large capacity Ambient air Modified Test Section Ø40cm x 300cm Optical access Nominally Uniform Airflow 2-50m/s capability Operated at 10m/s and 20m/s Injectors Hollow cone 1/2BX-40 Full cone 1/2GA-SS25 Dual Full cone 3/8HH-15

7 Experimental Setup Spray Uniformity Acquisition Laser Sheet Imaging (LSI) LaVision GmbH LSI Orientation Mounted at exit of wind tunnel Vertical and Horizontal 2D measurement of spray pattern Time dependant fluctuations Light Intensity Spray uniformity Mie Scattering

8 LSI Results 10m/s wind speed Hollow cone (1/2BX-40) Full cone (1/2GA-SS25) Dual Full cone (3/8HH-15)

9 LSI Results 20m/s wind speed Hollow cone (1/2BX-40) Full cone (1/2GA-SS25) Dual Full cone (3/8HH-15)

10 LSI Results Live Images Hollow cone (1/2BX-40) Dual Full cone (3/8HH-15) Largest drop size and least uniform distribution Smallest drop size and most uniform distribution

Experimental Setup Drop Size Acquisition Phase

wind tunnel Vertical and Horizontal Traverse y

11 Experimental Setup Drop Size Acquisition Phase Doppler Interferometer (PDI) Artium Technologies Inc. PDI-200MD PDI Orientation Mounted at exit of wind tunnel Vertical and Horizontal Traverse y 2 cm measurement resolution z 6 cm measurement resolution Drop Size Distribution Axial Velocity

Drop Size Theory Injector Flow = 45 lit/min Increase effectiveness More small droplets increases surface area Increase interaction with gas stream with even distribution across pipe

12 Drop Size Theory Injector Flow = 45 lit/min Increase effectiveness More small droplets increases surface area Increase interaction with gas stream with even distribution across pipe / duct Heat/Mass transfer and chemical reactions are proportional to the droplet surface area! 100 µm 150 µm 200 µm 250 µm 300 µm 400 µm 500 µm Surface Area = 4πr 2 Volume = 4/3 πr 3

13 PDI Results Drop Size at 10m/s Hollow cone Full cone Dual Full cone (1/2BX-40) SMD (μm) 165 (1/2GA-SS25) SMD (μm) 155 (3/8HH-15) SMD (μm)

14 PDI Results Drop Size at 20m/s Hollow cone Full cone Dual Full cone (1/2BX-40) SMD (μm) 165 (1/2GA-SS25) SMD (μm) 145 (3/8HH-15) SMD (μm)

15 PDI Results Volume Flux at 10m/s Hollow cone Full cone Dual Full cone (1/2BX-40) VF (cc/cm 2 /s) 0.22 (1/2GA-SS25) VF (cc/cm 2 /s) 0.40 (3/8HH-15) VF (cc/cm 2 /s)

16 PDI Results Volume Flux at 20m/s Hollow cone (1/2BX-40) VF (cc/cm 2 /s) 0.25 Full cone (1/2GA-SS25) VF (cc/cm 2 /s) 0.55 Dual Full cone (3/8HH-15) VF (cc/cm 2 /s)

outlet of the tunnel ANSYS Workbench 14.

17 Computational Setup Mesh Details 3D Model of Wind Tunnel Upstream and downstream of injector End of contraction to the outlet of the tunnel ANSYS Workbench 14.0 Dense mesh near injection / orifice Course mesh throughout the remainder Approx. <750,000 cells

18 CFD Setup ANSYS Fluent 14.0 Boundary Conditions Inlet: Constant Velocity Outlet: Constant Pressure Wall: Rigid, no slip, adiabatic Model Selection k-ε Realizable Turbulence Model DPM for LaGrangian tracking of water droplets Species Transport

19 Spray Visualization DPM Concentration Hollow cone (1/2BX-40) Full cone (1/2GA-SS25) Dual Full cone (3/8HH-15)

20 CFD Results Drop Size Distribution at 20m/s Hollow cone (1/2BX-40) Full cone (1/2GA-SS25) Dual Full cone (3/8HH-15)

21 CFD Results Spray Distribution at 20m/s Hollow cone (1/2BX-40) Full cone (1/2GA-SS25) Dual Full cone (3/8HH-15)

22 Conclusions Hollow Cone Less uniformity / Dispersion Quick attachment to wall Dependent on secondary shear Large Free Passage (No clogging) Single Full Cone Better uniformity / Dispersion Greater distance to wall attachment Longer adherence to wall Moderate Free Passage Dual Full Cone Best Uniformity /Dispersion Greater distance to wall attachment Longer adherence to wall Smallest Free Passage Mass transfer is proportional to the droplet surface area! 100 µm 150 µm 200 µm 250 µm 300 µm 400 µm 500 µm Surface Area = 4πr 2 Volume = 4/3 πr 3

23 Next Steps Secondary breakup estimation with & without transient CFD Additional measurement locations (from injector) VOF of internal near orifice for better estimation of exit velocity Wall interference studies User feedback From customers case studies Corrosion and de-salting effectiveness

24 Questions & Comments? Hollow cone - (1/2BX-40) Very short contact area Dual Full cone - (3/8HH15 Longer contact area More videos on Spraying Systems Channel

25 Thank You END

R J. Schick*, K J. Brown, W. Kalata Spraying Systems Co.

R J. Schick*, K J. Brown, W. Kalata Spraying Systems Co. Background The reduction of environmental contaminants is a worldwide goal that has seen an increased focus in recent years, especially from power