One of the most difficult aspects of handling and working with dusty materials is suppression of airborne contaminants. Small particles can easily become a dust cloud, minimizing visibility and decreasing the quality of working conditions. This then leads to lower productivity, low morale, and a missed opportunity to maximize the potential of personnel and equipment.
Our distributor in New Zealand recently assisted one of their customers facing this set of problems when working with cement and microsilica as it was poured into a mixer. An exhaust fan was in place, but failed to extract the dust sufficiently, so a new approach was needed to minimize the dust.
The solution was to use an EXAIR AN2010SSNo Drip Internal Mix Atomizing Nozzle, shown above in the red box, to produce an atomized water mist. The dust produced during pouring is captured by the small droplets of atomized water produced with this nozzle, reducing the dust and allowing proper use of the mixer.
In order to position the nozzle exactly where it needs to be, an 18” Stay Set Hose, shown above with the red arrow, was used to position the nozzle. This hose is built specifically to have “memory” of the desired position, allowing for quick, easy, and repeatable position of the nozzle attached to the hose.
This simple setup is controlled through a timer to ensure water and compressed air use realize maximum efficiency. It’s an easy solution to a painful problem for this customer.
If you’d like to explore how an EXAIR solution can solve problems in your facility or application, please contact an EXAIR Application Engineer.
In this summer of 2016, we are nearing the beginning of one of the largest sporting events on the planet, The 2016 Summer Olympics. At the heart of this celebration will be sporting events of all kinds. And in the tradition of the Olympics there is always a gold, silver and bronze winner to award the top three athletes in each event.
EXAIR is participating in a competition as well. It isn’t one of a sporting nature, but rather, one of ingenuity and innovation. Flow Control Magazine holds an annual competition for innovations in new products available in industry and we have entered the No Drip Atomizing Nozzle into the competition.
In general, Atomizing Nozzles are used for the application of high value fluids within industrial processes. In some cases where the Atomizing Nozzles are mounted above the target, residual fluid that is left inside the nozzle body can drip out when de-energized and cause un-wanted blemishes on the target surface.
EXAIR No Drip Atomizing Nozzles allow for external adjustment of compressed air and liquid inputs to adjust the liquid spray flow rate as well as droplet size for a wide range of applications. That’s pretty common amongst atomizing nozzles in general. So what is so innovative about the No-Drip Atomizing Nozzles?
We have found a way to control the on/off function of the atomizing spray which supports the no-drip feature as well as the atomizing flow with only one compressed air supply. Most other manufacturers require a nozzle that has a separate control for the small valve within the nozzle and another for the airflow that atomizes the fluid coming through. It is this innovation that dramatically improves the simplicity with which these nozzles can be installed into an application and controlled through typical air automation techniques. It was innovative enough that the US Patent Office granted EXAIR a patent on the design (Patent # 9156045). So, we’ve made the No-Drip Atomizing Nozzle available with 3 different spray patterns and 14 different liquid volume options to suit a wide variety of application need. Operating pressures can fall anywhere between 30 – 250 PSIG to atomize fluids up to 300 centipoise.
If you agree with the US Patent Office on the innovation and think that EXAIR’s No Drip Atomizing Nozzles should be a winner in this competition, we would appreciate your official vote.
The patented (no longer patent pending) EXAIR No-Drip Atomizing Spray Nozzles have been nominated and are a finalist in the Flow Control 2016 Innovation Awards. The No Drip Atomizing Nozzles are just a portion of the entire Liquid Atomizing Nozzle products that EXAIR Offers. The No-Drip’s patented liquid shut off valve design eliminates the need for a separate pilot air line to positively shut off liquid flow ensuring there are no drips or excess flow from the nozzle. These are ideal when dealing with fine surface finishes, costly liquids, or intermittent spraying needs. The nozzles are offered in both pressure fed liquid and siphon fed liquid versions.
For the pressure fed version, the nozzle will require both compressed air and a pressurized liquid source. Both pressures can be adjusted independently giving a large spectrum of adjustment to fine tune the spray pattern and droplet sizes. The siphon fed nozzles can draw liquid up to 36″ vertically or be gravity fed up to 18″ overhead. This makes installation quick and easy when a pressurized liquid source, or liquid pump is not at hand.
The No-Drip Atomizing Spray Nozzles have also proven themselves in many applications, you can even read about a few of them here on our blog, links below.
Some of the reasons the EXAIR No-Drip Atomizing Nozzles were selected for these applications are the patented no-drip valve, their ability to atomize liquids to a range of 22-71 micron droplet size, the ability to fit into a tight space as well as the many spray pattern options. These features have ranked the nozzles as a finalist in Flow Control’s 2016 Innovation Awards.
We are very grateful if you choose to vote for our nozzle at the link below. Please vote.
EXAIR Atomizing Nozzles are a reliable way to clean, cool or coat a wide variety of products. Constructed of 303ss, the units are extremely durable, provide superior corrosion resistance and are able to withstand temperature up to 400°F.
The Atomizing Nozzles are separated into 3 categories – Internal Mix, External Mix and Siphon Fed:
Internal Mix Atomizing Nozzles require a pressurized liquid source and compressed air source and mix the two flows inside the air cap to produce a fine mist of atomized liquid. These nozzles are better suited for applications that don’t require independent control of the air or liquid and are suitable for fluids up to 300 cP.
External Mix Atomizing Nozzles require pressurized liquid and air as well, but allow for independent control to reach higher flow rates with more precise control. With the liquid and air being mixed external to the nozzle, they are able to handle higher viscosity fluids (300+ cP).
Siphon Fed Atomizing Nozzles are the ideal choice for applications without a pressurized liquid source. The liquid can be gravity fed or pulled from a siphon height up to 36″. Due to the liquid not being pressurized, these nozzles are limited to fluids of 200 cP or less.
With so many choices, it may seem somewhat cumbersome in making the correct selection. To simplify the selection the process, there are 5 common considerations:
How much liquid flow do I need?
Is the liquid pressurized?
What is the viscosity of the liquid?
How wide of an area needs to be treated?
What type of spray pattern fits the application?
The answers to these questions will allow you to make the best selection to fit your needs. Of course if you still are unsure, you can rest easy as one of our engineers is readily available should you require additional assistance.
For 28 years, Plant Engineering magazine’s knowledgable readers have chosen outstanding new products that help them do their jobs smarter, safer, more efficiently and more productively. These products, which are newly released in manufacturing industries, are recognized with Plant Engineering’s Product of the Year Award. Many products categories are represented including, Compressed Air, Automation and Controls, Electric Motors and Drives, Environmental Health, and Fluid Handling among others. Four of the products we released in 2015 are finalists in four different categories. Voting is open now and goes on through January 8, 2016.
Here are the products up for the 2015 award:
High Lift Reversible Drum Vac:Nominated in the Environmental Health category, our new High Lift Reversible Drum Vac is ideal for the recovery of fluids like: coolant, hydraulic oils, sludge and chips, waste water, tramp oil and liquid spills. The High Lift Reversible Drum Vac has been engineered to recover liquids found within below grade sumps, wells, underground tanks, pits and drains with up to 15′ of lift. VOTE HERE
No Drip Liquid Air Nozzles: These patented atomizing spray nozzles, in the fluid handling category, have the added benefit of positively stopping liquid flow when compressed air is shut off. The nozzles are ideal where no post-spray drip is permissible. When the compressed air supply is shut off, the no-drip nozzle positively seals off the flow of liquid, eliminating the possibility of drips. Effective when using liquids up to 300 cP. VOTE HERE
Electronic Temperature Control for Dual Cabinet Cooler Systems: The Electronic Temperature Control (ETC) for dual-cabinet cooler systems installed on large or high heat-load enclosures keeps electrical units cool while minimizing compressed air use. Available in cooling capacities up to 5,600 BTU/hr., It permits just enough cooling for the electronics without going so cold as to waste compressed air. VOTE HERE
Back Blow Air Nozzle:These nozzles are designed to effectively blow debris and liquids from pipe or hose inside diameters, channels, bores, holes, internal threads, and other internal part features. An array of holes provides forceful 360-degree airflow to clear out coolant, chips, and light oils from machining processes. This nozzle prevents blowing chips further into a part, tube, or pipe and eliminates any safety hazard created by blowing debris out the far end of a pipe or tube. VOTE HERE
We appreciate all who are willing to vote for our products and are proud to continue bringing you the best products we can offer. Thank you for the support.
A customer was faced with a problem. She worked at a local garbage dump. People would bring their garbage every week to dispose. Her responsibility was to keep track of the local patrons. On the warm days, the smell was at its peak. They supplied her with a limited amount of fragrance sanitizer to help with the smell, but depending on the amount of warm days and the amount of refuse, she was sometimes in the “stink”. She saw our advertisement about how EXAIR can save fluids and money with our atomizing nozzles. She purchased our SR1010SS nozzle. It is our siphon fed round pattern style nozzle. With a small air compressor, she was able to spray a small mist of fragrance. She could even adjust the amount with the liquid adjustment stem for those warm days. Thus, she was able to save the company money by conserving the fragrance and have enough good smell around her to keep her nose happy.
EXAIR offers a large line of atomizing nozzles. We use them in washing, rinsing, coating, cooling, quenching, humidification, and dust control. If you are able to pressurize the liquid, you can use the internal and external mix nozzles. In applying a mist instead of a spray, you will be able to save material. To even help more in the savings, we also offer the No Drip Atomizing Nozzle. This product is great if you are starting and stopping a process. As soon as the pressure is released, a seal is applied to keep the material in the atomizing nozzle.
If you want to apply liquid using compressed air, EXAIR could have the product for you. With a little ingenuity and help from your application engineer, we could turn waste into wonder.
The second atomizing air nozzle that EXAIR introduced in Catalog 27 is the Internal Mix 360 Degree Hollow Circular Pattern Spray Nozzle, part number AT1010SS. This nozzle produces circular air pattern perpendicular to the flow of most atomizing air nozzles. The AT1010SS can create a mist across 53 inch diameter circle. The nozzle is constructed of 303 Stainless Steel for use in corrosive environments. It operates on a continuous stream of compressed air and pressurized liquid. The AT1010SS features a compact design that is 3.20 inches long, 1.69 inches wide, and 0.88 inches thick to fit into small ducts or hard to reach corners.
This spray pattern is perfect for coating the inside of a pipe with rust preventative, paint, or protective coating. The flow pattern would also be able to coat a variety of duct shapes. Mounted over a process, the nozzle pattern is also great for dust suppression, humidification and cooling over a wide area.