Model for Predicting the Mean Drop Size in Effervescent Sprays

This paper is focused on the development of a model for predicting the mean drop size in effervescent sprays. A combinatorial approach is followed in this modeling scheme, which is based on energy and entropy principles. The model is implemented in cascade in order to take primary breakup (due to exploding gas bubbles) and secondary breakup (due to shearing action of surrounding medium) into account. The approach in this methodology is to obtain the most probable drop size distribution by maximizing the entropy while satisfying the constraints of mass and energy balance. The comparison of the model predictions with the past experimental data is presented for validation. A careful experimental study is conducted over a wide range of gas-to-liquid ratios, which shows a good agreement with the model predictions: It is observed that the model gives accurate results in bubbly and annular flow regimes. However, discrepancies are observed in the transitional slug flow regime of the atomizer.

Mass Distribution Studies in Effervescent Sprays

An experimental study on liquid mass distribution in effervescent sprays using water and air as working fluids is presented in this paper. Optical patternation and techniques of image processing are employed for analyzing the spray. The flow regime inside the effervescent atomizer largely dictates the mass distribution patterns. The patterns are seen to vary from concentrated, poorly atomized liquid lumps to uniformly distributed, fine droplets as the flow regime changes from bubbly flow to annular flow. A large variety of instantaneous spray patterns are observed in bubbly flow regime indicating a highly unsteady atomization process. However, relatively better consistency in spray patterns is observed at higher gas flow rates. Thus, the degree of unsteadiness gradually diminishes as gas flow rate is increased. The axial evolution of the spray in annular mode shows good mixing of liquid and gas across the interface.

Vaporization and collision modeling of liquid fuel sprays in a co-axial fuel and air pre-mixer

Droplet collision occurs frequently in regions where the droplet number density is high. Even for Lean Premixed and Pre-vaporized (LPP) liquid sprays, the collision effects can be very high on the droplet size distributions, which will in turn affect the droplet vaporization process. Hence, in conjunction with vaporization modeling, collision modeling for such spray systems is also essential. The standard O'Rourke's collision model, usually implemented in CFD codes, tends to generate unphysical numerical artifact when simulations are performed on Cartesian grid and the results are not grid independent. Thus, a new collision modeling approach based on no-time-counter method (NTC) proposed by Schmidt and Rutland is implemented to replace O'Rourke's collision algorithm to solve a spray injection problem in a cylindrical coflow premixer. The so called ``four-leaf clover'' numerical artifacts are eliminated by the new collision algorithm and results from a diesel spray show very good grid independence. Next, the dispersion and vaporization processes for liquid fuel sprays are simulated in a coflow premixer. Two liquid fuels under investigation are jet-A and Rapeseed Methyl Esters (RME). Results show very good grid independence in terms of SMD distribution, droplet number distribution and fuel vapor mass flow rate. A baseline test is first established with a spray cone angle of 90 degrees and injection velocity of 3 m/s and jet-A achieves much better vaporization performance than RME due to its higher vapor pressure. To improve the vaporization performance for both fuels, a series of simulations have been done at several different combinations of spray cone angle and injection velocity. At relatively low spray cone angle and injection velocity, the collision effect on the average droplet size and the vaporization performance are very high due to relatively high coalescence rate induced by droplet collisions. Thus, at higher spray cone angle and injection velocity, the results expectedly show improvement in fuel vaporization performance since smaller droplet has a higher vaporization rate. The vaporization performance and the level of homogeneity of fuel-air mixture can be significantly improved when the dispersion level is high, which can be achieved by increasing the spray cone angle and injection velocity. (C) 2012 Elsevier Ltd. All rights reserved.

Correlations of vaporization performance of conventional and biofuel sprays in a crossflow heated chamber

Pre-vaporization and pre-mixing are the two main features of LPP type of combustor that operate on liquid fuels. The pre-vaporization length scale is one of its most important design parameters. In this study, the goal is to put forward a simulation based correlation for fuel vaporization performance as a function of dimensionless parameters for crossflow type of injections. Two types of fuels are studied here: jet-A and one of its potential biofuel substitutes, RME. Different sets of spray simulations are considered for crossflow type of injections. Correlations are provided for both jet-A and RME's vaporization performance as a function of non-dimensional inlet air temperature, fuel/air momentum flux ratio and normalized spray traverse distance. (C) 2012 Elsevier Ltd. All rights reserved.

A method for measurement of planar liquid volume fraction in dense sprays

A methodology for measurement of planar liquid volume fraction in dense sprays using a combination of Planar Laser-Induced Fluorescence (PLIF) and Particle/Droplet Imaging Analysis (PDIA) is presented in this work. The PLIF images are corrected for loss of signal intensity due to laser sheet scattering, absorption and auto-absorption. The key aspect of this work pertains to simultaneously solving the equations involving the corrected PLIF signal and liquid volume fraction. From this, a quantitative estimate of the planar liquid volume fraction is obtained. The corrected PLIF signal and the corrected planar Mie scattering can be also used together to obtain the Sauter Mean Diameter (SMD) distribution by using data from the PDIA technique at a particular location for calibration. This methodology is applied to non-evaporating sprays of diesel and a more viscous pure plant oil at an injection pressure of 1000 bar and a gas pressure of 30 bar in a high pressure chamber. These two fuels are selected since their viscosity values are very different with a consequently very different spray structure. The spatial distribution of liquid volume fraction and SMD is obtained for two fuels. The proposed method is validated by comparing liquid volume fraction obtained by the current method with data from PDIA technique. (C) 2012 Elsevier Inc. All rights reserved.

Review on atomization and sprays of biofuels for IC engine applications

Ever increasing energy requirements, environmental concerns and energy security needs are strongly influencing engine researchers to consider renewable biofuels as alternatives to fossil fuels. Spray process being important in IC engine combustion, existing literature on various biofuel sprays is reviewed and summarized. Both experimental and computational research findings are reviewed in a detailed manner for compression ignition (CI) engine sprays and briefly for spark ignition (SI) engine sprays. The physics of basic atomization process of sprays from various injectors is included to highlight the most recent research findings followed by discussion highlighting the effect of physico-chemical properties on spray atomization for both biofuels and fossil fuels. Biodiesel sprays are found to penetrate faster and haw narrow spray plume angle and larger droplet sizes compared to diesel. Results of analytical and computational models are shown to be useful in shedding light on the actual process of atomization. However, further studies on understanding primary atomization and the effect of fuel properties on primary atomization are required. As far as secondary atomization is concerned, changes in regimes are observed to occur at higher air-jet velocities for biodiesel compared to those of diesel. Evaporating sprays revealed that the liquid length is longer for biodiesel. Pure plant oil sprays with potential use in CI engines may require alternative injector technology due to slower breakup as compared to diesel. Application of ethanol to gasoline engines may be feasible without any modifications to port fuel injection (PFI) engines. More studies are required on the application of alternative fuels to high pressure sprays used in Gasoline Direct Injection (GDI) engines.

Studies on microscopic structure of diesel sprays under atmospheric and high gas pressures

In the present work, the spray structure of diesel from a 200-mu m, single-hole solenoid injector is studied using microscopic imaging at injection pressures of 700, 1000 and 1400 bar for various gas pressures. A long-distance microscope with a high resolution camera is used for spray visualization with a direct imaging technique. This study shows that even at very high injection pressures, the spray structure in an ambient environment of atmospheric pressure reveals presence of entangled ligaments and non-spherical droplets during the injection period. With increase in the injection pressure, the ligaments tend to get smaller and spread radially. The spray structure studies are also conducted at high gas pressures in a specially designed high pressure chamber with optical access. The near nozzle spray structure at the end of the injection shows that the liquid jet breakup is improved with increase in gas density. The droplet size measurement is possible only late in the injection duration when the breakup appears to be complete and mostly spherical droplets are observed. Hence, droplet size measurements are performed after 1.3 ms from start of the injection pulse. Spatial and temporal variation in Sauter Mean `Diameter (SMD) is observed and reported for the case corresponding to an injection pressure of 700 bar. Overall, this study has highlighted the importance of verifying the extentof atomization and droplet shape even in dense sprays before using conventional dropsizing methods such as PDPA.

Effect of viscosity and surface tension on breakup and coalescence of bicomponent sprays

This work deals with an experimental study of the breakup characteristics of liquids with different surface tension and viscosity from a hollow cone hydraulic injector nozzle induced by pressure-swirl. The experiments were conducted at Reynolds numbers Re-p=9500-23,000. The surface tension and viscosity of the surrogate fuels were altered from 72 to 30 mN/m and 1.1 to 1.6 mN s/m(2), respectively. High speed photography and Phase Doppler Particle Anemometry were utilized to study the atomization process. Velocity and drop size measurements of the spray using PDPA in both axial and radial directions indicate a dependency on surface tension. However, these effects are dominant only at low Reynolds numbers and are negligible at high Reynolds number. Downstream of the nozzle, coalescence of droplets due to collision was also found to be significant and the diameters were compared for different liquids. For viscous fluids up to 1.6 cP, the independent effects of viscosity and injection pressure are studied. In general, the spray cone angle increases with increase in pressure. At high pressures, an increase in viscosity leads to higher drop sizes following primary and secondary breakup compared to water. This study will extend our understanding of surrogate fuel film breakup and highlight the importance of long and short wavelength instabilities. (C) 2013 Elsevier Ltd. All rights reserved

Experimental Studies on High-Pressure Spray Structure of Biofuels

The high-pressure spray characteristics of biofuels, specifically, Pongamia oil and its blends with diesel are studied for various gas pressures. Two single-hole solenoid injectors with nozzle diameters of 200 and 260 mu m are used along with a high-pressure common-rail direct-injection system to inject fuel into a high-pressure spray visualization chamber. The spray structure is characterized using a high-speed laser-based shadowgraphy technique. The spray structure of Pongamia oil revealed the presence of an intact liquid core at low gas pressure. At high gas pressures, the spray atomization of the Pongamia oil showed marked improvement. The spray tip penetration of Pongamia oil and its blends with diesel is higher compared to that of diesel for all test conditions. The spray cone angle of Pongamia oil and 50% Pongamia oil blend with diesel is lower as compared to that of diesel. Both these observations are attributed to the presence of large droplets carrying higher momentum in oil and blend. The droplet size is measured at an injection pressure of 1000 bar and gas pressure of 30 bar at 25 mm below the nozzle tip using the particle/droplet image.analysis (PDIA) method. The droplet size measurements have shown that the Sauter mean diameter (SMD) in the spray core of Pongamia oil is more than twice that of diesel. The spray tip penetration of the 20% blend of Pongamia with diesel (P20) is similar to that of diesel but the SMD is 50% higher. Based on experimental data, appropriate spray tip penetration correlation is proposed for the vegetable oil fuels such as Pongamia.

Spray characterization of straight vegetable oils at high injection pressures

We present results of high pressure spray characterization of Straight Vegetable Oils (SVOs) which are potential diesel fuel substitutes. SVO sprays are visualized at high injection pressures (up to 1600 bar) to study their atomization characteristics. Spray structure studies are reported for the first time for Jatropha and Pongamia vegetable oils, under atmospheric conditions. Jatropha and Pongamia SVO sprays are found to be poorly atomized and intact liquid cores are observed even at an injection pressure of 1600 bar. Non-Newtonian behavior of Jatropha and Pongamia oil is shown to be the reason for observed spray structure. (C) 2012 Elsevier Ltd. All rights reserved.

Spray characterization of gasoline-ethanol blends from a multi-hole port fuel injector

This work reports the measured spray structure and droplet size distributions of ethanol-gasoline blends for a low-pressure, multi-hole, port fuel injector (PFI). This study presents previously unavailable data for this class of injectors which are widely used in automotive applications. Specifically, gasoline, ethanol, and gasoline-ethanol blends containing 10%, 20% and 50% ethanol were studied using laser backlight imaging, and particle/droplet image analysis (PDIA) techniques. The fuel mass injected, spray structure and tip penetrations, droplet size distributions, and Sauter mean diameter were determined for the blends, at two different injection pressures. Results indicate that the gasoline and ethanol sprays have similar characteristics in terms of spray progression and droplet sizes in spite of the large difference in viscosity. It appears that the complex mode of atomization utilized in these injectors involving interaction of multiple fuel jets is fairly insensitive to the fuel viscosity over a range of values. This result has interesting ramifications for existing gasoline fuel systems which need to handle blends and even pure ethanol, which is one of the renewable fuels of the future. (C) 2012 Elsevier Ltd. All rights reserved.

AN EXPERIMENTAL STUDY ON EFFERVESCENT ATOMIZATION OF BIO-OIL FUELS

This paper presents the work on detailed characterization of effervescent spray of Jatropha and Pongamia pure plant oils. The spray characteristics of these biofuels are compared with those of diesel. Both macroscopic and microscopic spray characteristics at different injection pressures and gas-to-liquid ratio (GLR) have been studied. The particle/droplet imaging analysis (PDIA) technique along with direct imaging methods are used for the purpose of spray characterization. Due to their higher viscosity, pure plant oils showed poor atomization compared to diesel and a blend of diesel and pure plant oil at a given GLR. Pure plant oil sprays showed a lower spray cone angle when compared to diesel and blends at lower GLRs. However, the difference is not significant at higher GLRs. Droplet size measurements at 100 mm downstream of the exit orifice showed reduction in Sauter mean diameter (SMD) diameter with increase in GLR. A radial variation in the SMD is observed for the blend and pure plant oils. Pure oils showed a larger variation when compared to the blend. Spray unsteadiness has been characterized based on the image-to-image variation in the mean droplet diameter and fluctuations in the spray cone angle. Results showed that pure plant oil sprays are more unsteady at lower GLRs when compared to diesel and blend. A critical GLR is identified at which the spray becomes steady. The three regimes of spray operation, namely ``steady spray,'' ``pulsating spray,'' and ``spray and unbroken liquid jet'' are identified in the injection pressure-GLR parameter space for these pure plant oils. Two-phase flow imaging inside the exit orifice shows that for the pure plant oils, the flow is highly transient at low GLRs and the bubbly, slug, and annular two-phase flow regimes are all observed. However, at higher GLRs where the spray is steady, only the annular flow regime is observed.

Experimental studies on air-assisted impinging jet atomization

In the present study, a novel air-assisted impinging jet atomization is demonstrated. A configuration in which a gas jet is directed on to the impinging point of two liquid jets is used to improve the atomization. The effect of liquid properties such as viscosity and surface tension, angle between liquid jets and gas injection orifice diameter on spray characteristics has been experimentally studied. Backlit imaging and particle/droplet imaging and analysis techniques are utilized to characterize the sprays. The experimental results indicate that the effect of liquid viscosity is significant on the liquid sheet break up formed by the impinging jets. However, surface tension does not affect the spray structure significantly in this mode of atomization. At low liquid jet velocity, the prompt mode of atomization is observed where as atomization occurs in classical mode at higher liquid jet velocity. Results showed that variation in the angle between liquid jets do not affect the breakup phenomenon significantly. The spray angle is computed by finding the angle between the lines joining the impinging point and spray edge at an axial distance of 15 mm downstream of the impinging point from the ensemble-averaged data over 100 spray images. It was observed that effect of liquid jets impinging angle on the spray angle is higher at higher liquid velocity. Higher viscosity liquids exhibit lower spray angles. Droplet size measurements indicate a radial variation in the spray. An overall Sauter Mean Diameter (SMD) value is obtained by combining the droplet statistics at all radial locations at a fixed axial location. A very interesting trend is that the SMD is constant beyond a critical Gas to Liquid Ratio (GLR) and momentum ratio for a large variation in liquid viscosity and surface tension. This observation has important ramifications for fuel flexible systems. (C) 2013 Elsevier Ltd. All rights reserved.