One of a kind:
Upon multiple requests by its clients, CS COMBUSTION SOLUTIONS has invented a unique ultrasonic nozzle that combines all the advantages of typical jet-type nozzles with a drastically reduced air demand of approximately 50%. JULIP opens up large potentials for minimizing operating costs as well as substantially enhancing the performance of thermal oxidizers and sulphuric acid production plants.
Market trends indicate that in the future, demands on the capacity of thermal oxidizers and the throughput of low calorific waste feeds will continue to grow particularly for sulphuric acid production plants.
Subsequently, the number of ultrasonic nozzles employed for these applications will rise and result in increased requirements of atomizing air. In many cases, however, a limited compressed air supply and the need to avoid an escalation of operating costs are very likely to act as constraining factors.
As an expert drawing on 25 years of experience in equipping combustors and thermal oxidizers with ultrasonic jet-type nozzles, CS has been asked by its clients to help solve this dilemma and investigate possibilities to boost plant capacity without increasing atomizing air consumption. Since ultrasonic atomizing still sets the benchmark for such applications, CS took on the challenge of refining this technology.
Major advantages of typical jet-type appliances include long-term operation without plugging, suitability for highly viscous and polluted liquids, a turn down of up to 1:10, an extended life span due to very low speed and pressure of the liquid feed, and a fine and homogeneous droplet distribution. Our objective was to develop a nozzle that retains all these benefits while simultaneously allowing a reduction of atomizer consumption and an indirectly lower OPEX respectively.
After different approaches and tests, CS has created a completely new generation of ultrasonic atomizing nozzles.
Due to a novel geometry, all of JULIP’s parameters for atomizing quality (droplet size and droplet distribution) are better than those of customary appliances. The air demand is even reduced to approximately 50 % of the traditional jet-type nozzle: conventional ultrasonic atomizers require approximately 20–30 % of compressed air (Nm³/hr) related to liquid throughput (l/hr), whereas JULIP runs with only 15–20 % and exhibits a better spray pattern as well. Overall, this allows yearly cost savings of up to 50 % (see table below for details). Particularly thermal oxidizers with several lances for injection of low calorific liquids and sulphur burning plants are going to profit drastically from this reduced energy consumption.
After completing the internal testing and evaluation phase, the patented JULIP nozzles are already in operation at some of CS’s longterm clients’ plants.