Recently I was working with a company who grows plants using a method I’ve never heard of before, aeroponics. See I grew up on a farm, so I’m used to the old fashion way to grow crops! Dirt, water and sunlight, or as my grandpa would call them “The three pillars of life as we know it”.
So I had to do some research into aeroponics so I could understand if we could help him. It turns out aeroponics does not use a dirt medium, they relay on a very fine mist to provide the nutrients the plant needs to grow. But its very important that the mist have droplet sizes of less than 50 microns, or the roots will not be able to absorb it.
We ended up going with the AW8010SS Internal mix wide angle round pattern. And after playing with them the customer ran the nozzles at 5 PSIG air pressure and 10 PSI of liquid pressure. running the nozzle every 10-15 mins kept the room at the perfect humidity for the plants they are growing.
They are planning to install up to 20 of the AW8010SS Internal mix wide angle round pattern in each section of their facility once they build their building!
To discuss your application and how an EXAIR Intelligent Compressed Air Product can help your process and save you money, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.
In today’s market, the cost of consumable products are on the rise; especially with paints, oils, and yes, even the cost of water. You can help alleviate some of that cost by being more effective when spraying these liquids.
The EXAIR Atomizing Nozzles can accomplish this by using compressed air to shear the liquid into small micron-sized droplets. By reducing the diameter of a particle by half, this will multiply the number of droplets by eight. This will increase the surface area and coverage of the droplets; thus, requiring less material in your application. EXAIR manufactures three families of Atomizing Nozzles; Internal Mix, External Mix, and the Siphon Fed. In this blog, I will cover the Siphon Fed Atomizing Nozzles that EXAIR manufactures.
When no liquid pressure is available, the Siphon Fed Atomizing Nozzles will create a vacuum to draw the liquid into the nozzle. This action is done by the unique design of the air cap. As the velocity of the air passes through the air cap, a low pressure is created by a venturi. The Siphon Fed Atomizing Nozzles can draw liquid from a suction height of 36” (91 cm), or it can be gravity fed from 18” (46 cm) away. They are manufactured from stainless steel for durability and corrosion resistance. The Siphon Fed models can spray viscous fluids up to 200 centipoise, and are used in many applications like washing, coating, cooling, quenching, and dust control.
EXAIR carries three different body sizes in 1/8” NPT, ¼” NPT, and ½” NPT ports; so, you can create a light mist or a monsoon. The maximum liquid flow rate through each body size is controlled by the air cap and liquid cap. A unique feature of the EXAIR Atomizing Nozzle is that the caps are easily interchangeable for each body size to modify the spray patterns, control the amount of fluid, and reduce any downtime if cleaning is required. Here is a video that shows how this can be done:
The amount of liquid to be applied is easily adjusted by the siphon height, the inlet pressure, and the liquid adjusting stem. So, you can dial in the exact amount of fluid required for your process to eliminate any excess waste. They are very compact and easy to install. We carry mounting brackets for each size to allow for easy mounting and positioning. Versatility is very important in saving, applying, and spraying costly fluids; and, the Siphon Fed Atomizing Nozzle has it.
To help reduce waste even more, EXAIR has a No Drip option. This patented design is used to keep the expensive liquid from dripping out of the Atomizing Nozzles. When the compressed air is turned off, a valve inside the body will create a seal on the liquid side. For delicate applications, the No Drip options will eliminate unwanted drips that can ruin the finish of your product. This option also enhances the function of the Siphon Fed Atomizing Nozzle for intermittent processes. It will keep the liquid inside the body of the nozzle; so, when air pressure is applied, the Atomizing Nozzle will give an instant spray.
The minimum air pressure required to open the No Drip valve is 30 PSIG (2.1 bar) for the ¼” NPT and the ½” NPT port sizes, and 20 PSIG (1.4 bar) for the 1/8” port size. Unlike some manufacturers, there is no need to run a separate compressed air line to operate the no drip function. The Siphon Fed Atomizing Nozzle with the No Drip option is compact, efficient, and precise without any drips.
If you need to maximize the liquid dispersion and minimize liquid consumption, the EXAIR Atomizing Nozzles are the products to use. Instead of researching the requirements for liquid pumps or pressure pots, the Siphon Fed Atomizing Nozzle can draw the liquid through the feed line and start spraying. It can help reduce the cost of your project as well as save you money on your consumable products. If you have an application involving liquid spraying, an Application Engineer at EXAIR can help determine the correct model for you.
EXAIR’sAtomizing Spray Nozzles are used in a variety of applications where atomization of a fluid is necessary. They combine a liquid source and compressed air to atomize the liquid into a very fine mist. With a wide variety of spray patterns and ability to customize the maximum flowrate, there’s an Atomizing Nozzle available for just about any application.
I’d like to take a moment to highlight two particular spray patterns that EXAIR has available: Internal Mix Deflected Flat Fan and Internal Mix 360° Hollow Circular. With both of these particular spray patterns an “internal mix”, the mixing of the compressed air and the liquid will occur inside of the nozzle.
The Model AD1010SS Internal Mix Deflected Flat Fan Pattern is a ¼ NPT Type 303 stainless steel nozzle designed for applications where mounting space is at a premium. The spray pattern deflects at a right angle to the nozzle’s orientation, allowing the spray to be placed precisely where it’s needed in close quarters. An ideal application for this particular spray pattern is coating the inside of an in enclosure or duct work.
The Internal Mix 360° Hollow Circular Pattern is available in two sizes: ¼ NPT and ½ NPT. These nozzles provide a large 360° circular pattern that works well in applications where a smooth, even coating is needed on the ID of pipe or duct work. Due to the large coverage area (up to 13’ in diameter for Model AT5010SS) they’re also ideal for applications including dust suppression, humidification, and cooling.
Both of these styles of spray patterns are available with or without the No-Drip feature. EXAIR’s patented No Drip Atomizing Nozzles work just the same way as the standard ones, but have the added benefit of positively stopping the liquid flow when compressed air supply is shut off. If your application cannot accept post spray liquid flow dripping onto the product or process, these nozzles are able to accommodate up to 180 cycles per minute with a required 30 PSIG minimum air pressure.
EXAIR offers an ever-expanding selection of Atomizing Spray Nozzles. One style with many iterations within the line is the Internal Mix. Internal mix refers to the physical action of the compressed air atomizing the liquid before they leave the air cap. Because this action takes place inside the nozzle, internal mix atomizing spray nozzles are recommended for lower viscosity fluids. Water, water soluble/diluted lubricants, lightweight way oil, or rust inhibitors are a few examples that can easily be sprayed through these nozzles. The nozzles are also able to spray in five different spray patterns.
The Internal Mix Atomizing Spray nozzles are available in Narrow Angle Round Pattern, Wide Angle Round Pattern, Flat Fan Pattern, Deflected Flat Fan Pattern and 360° Hollow Cone Pattern. These nozzles can cover anywhere from 1.5″ diameter up to 13′ diameter and almost any dimension in between. To cover this vast array of spray dimensions they are offered in three inlet port sizes, 1/8″, 1/4″ and 1/2″ NPT.
Each NPT size offers a variable spray pattern as well as liquid flow rates for each type of spray pattern. The 1/8″ nozzles are available up to 28 GPH of flow rate. The 1/4″ nozzles are able to flow up to 42 GPH. The 1/2″ models are able to flow up to 264 GPH. These flowrates can all be varied to minimal flows by adjusting the liquid needle valve. See the video below for a demonstration of that variability.
These nozzles are all easily installed and can be mounted with the available mounting brackets. One for each size.
If you would like to discuss your atomizing spray nozzle application or need help determining if an Internal Mix Atomizing Spray Nozzle is the correct fit for your needs, please contact us.
EXAIR Corporation’s Research & Development team often finds themselves at odds with our Marketing department, who thinks R&D, through their constant introduction of new ideas & products, is trying to turn our catalog into something resembling a phone book.
I do not believe that is their aim or intention, though (and to be fair, Marketing doesn’t either.) Honestly, we just want to help folks in a wide range of industries solve problems. And a diverse range of engineered compressed air products is our tried-and-true, successful method for doing so.
Today I’m going to focus on the Internal Mix nozzles with the patented No Drip Functionality.
The No Drip option eliminates the occurrence of post spray liquid flow that results in unwanted drips that can mar a finish on painted or coated surfaces. Also, excess liquid loss is minimized saving on expensive materials like chemicals or coatings. When the compressed air is shut-off, the No Drip nozzle positively seals off the flow, eliminating the chance for a drip or lost liquid. Only one compressed air line is needed, as the line to combine and atomize the liquid also provides the no drip operation and control. At the 41 second mark in the video below you can see the No Drip in Action!
The Internal Mix type operates under the principle that the air and liquid come together and mix ‘internal’ to the nozzle. This type provides the finest atomization and smallest droplet size. The Internal Mix type of nozzle can be used with liquids up to 300 centipoise in viscosity. Both the air and liquid sides are pressure fed. The No drip Internal Mix Atomizing Nozzles are best for pressure fed applications not requiring independent air and liquid control.
The No Drip Atomizing Nozzles are available in (3) sizes – 1/8, 1/4, and 1/2 NPT – to provide a wide range of flow rates and pattern sizes. The No Drip feature does not impact the flow rates compared to the standard models. Minimum air pressure operation is 30 PSIG for the 1/4 and 1/2 NPT, and just 20 PSIG for the 1/8 NPT models.
Like the standard Internal Mix Atomizing Nozzles, spray patterns include narrow and wide angle round, flat fan, deflected flat fan and a 360° hollow circular pattern offering a wide selection to best meet the application needs.
Operation at up to 180 spray cycles per minute is possible. Air and Liquid Caps can be switched out to change the pattern and flow rates.
No post spray drip
Easily used with EFC
Minimizes air and liquid consumption
All stainless steel construction
Interchangeable liquid and air caps
If you need an Atomizing Spray Nozzle or any of the EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.
EXAIR’s Atomizing Spray Nozzles are used to atomize fluids in a wide range of different spray patterns. They utilize a small amount of compressed air which mixes with the liquid supply to create a fine mist of atomized liquid. EXAIR manufactures Atomizing Spray Nozzles in (3) different varieties: Internal Mix, External Mix, and Siphon Fed. For this blog, I’m going to focus on just the External Mix variety.
On all External Mix Atomizing Nozzles the volume of liquid is easily adjusted by adjusting the valve stem on the standard Atomizing Nozzle, or by regulating the liquid pressure (the only option with the No-Drip style). Increasing the liquid pressure will result in an increased liquid flow rate.
The External Mix nozzles have the highest flow rates and can be used with liquids with a viscosity greater than 300 centipoise (cP). Since the air and liquid are mixing just outside of the nozzle, thicker liquids have a lesser chance of clogging in the nozzle. Both the liquid stream and the air stream will come into contact with each other just outside both the air and liquid caps. The compressed air breaks the liquid up into very small particles, allowing you to use much less liquid than a liquid only nozzle.
This makes them very effective in applications that utilize expensive paints, oils, or other liquids. Rather than wasting the expensive materials, the nozzle can be set to precisely dispense only what is necessary to achieve a successful application. The External Mix Atomizing Nozzle is available in the standard configuration as well as the No-Drip style.
The No-Drip Atomizing Nozzle is used in a variety of applications where any liquid dripping from the nozzle after the air supply has shut off would cause a problem. This is common in painting applications where any paint dripping would affect the quality.
The External Mix Atomizing Nozzle is available in (3) different sizes: 1/8” NPT, ¼” NPT, and ½” NPT. If your application could benefit from utilizing the fine atomized spray of liquid look no further than EXAIR’s Atomizing Nozzles. With all sizes and configurations available from stock, we can get one out to you quickly!