LIQUID ATOMIZING SPRAY NOZZLES – how they work and available options

EXAIR’s Liquid Atomizing Nozzles are some of the very few items that we make that do not use compressed air as the energy source. Instead, pressurized liquids provide the energy. Sometimes the nozzles will create an internal spinning liquid or the nozzle will cause the liquid to impact another surface. Each method , spinning or impacting, causes the liquid to lose its surface tension and atomize into small droplets. These nozzles can generate more liquid flow than our Air Atomizing Nozzles, which mix the liquid with air and produce the smallest droplet sizes. Depending on your liquid atomizing nozzle selection, you can spray anywhere from 0.48 gallons per minute, up to 17.64 gallons per minute.

This amount of liquid is typically used for cooling, rinsing, dust suppression and washing, but there are many other applications as well. These nozzles will work well with solution that have particulates in it, including slurries.

With a very small footprint, all stainless steel construction, and no moving parts, these are a great fit, for not only the easy to get to conveyors or containers, but also those hard to reach spots as well. Couple this with not needing air, and they are easy to plumb, and easy to use. They are made of 303 Stainless Steel and can accommodate temps up to 800°F.

Currently, we have 2 liquid nozzle types. One type is a FullStream Cone which comes in 1/4″, 3/8″ and 1/2″ NPT. The other type is a HollowStream Cone that comes in 1/4″ and 3/8″ NPT. With these nozzles, the fluid is supplied into the body creating a swirling action within the vortex chamber. This Vortex is what creates the cone pattern. Then the precision orifice of the nozzle breaks this surface tension, and it leaves the nozzle with a full circular pattern (FullSstream), or a hollow ring pattern (HollowStream).

With this information, we are now down to choosing the size we need. We offer performance tables, within our catalogue, or on the website, that will show you the following:

  1. Inlet Connection
  2. Nozzle Capacity
  3. Max Free Passage (Orifice size for particulate)
  4. Flow Rates in Gallons (or Litres) per minute bases on psi of liquid
  5. Spray width based upon the psi, and distance from the surface

Here is an example of the FullStream Cone Nozzles – 1/4″ NPT:

As you choose your Liquid Atomizing Nozzle, it all comes down to the type of spray you need and how much liquid you need to spray. Once you decide betwen FullStream or HollowStream Cone and you know the amount of liquid pressure you have (and can adjust too) and the amount of liquid you are wanting to spray, comes down to scouting the performance tables of the sizes we offer and selecting the perfect one for your application.

Thank you for stopping by,

Brian Wages

Application Engineer EXAIR Corporation
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Engineered, Intelligent Compressed Air® Products: Save Air AND Get a Rebate!

This rebate example results in FREE air nozzles – read on to learn more!

Here at EXAIR we are continuously trying to share the basic facts that engineered air nozzles save compressed air. We then connect that with the amount of money that it saves, this is generally backed with formulas, this isn’t a new concept, we blog, tweet and even have easily accessed calculators for it. The final part that we like to share is that, on top of saving throughout the life of the nozzle, there are also many energy providers and municipalities that extend a rebate program as well! That means this lowers the ROI on implementing engineered nozzles into your system.

For instance, if your facility is located in Holland, Michigan, the Holland Board of Public Works wants to offer a rather simple rebate that requires the engineered nozzle and application be installed and submitted by December 31, 2022. The program is offering up to $100 per engineered nozzle installed on an open pipe or tube. (The incentive cannot exceed 100% of customer cost.) Not sure if you have open pipes in your facility? I’m sure you will hear them if you walk near the production lines where air is used. Or, better yet, get in touch with your production maintenance team and have them go throughout the facility and perform an open tube/pipe tagging event. Then report back and contact an Application Engineer here at EXAIR. We will all be able to help you with selecting the appropriately sized engineered nozzle to convert that open pipe/tube blowoff to an efficient and safe blowoff.

The Holland program is focused on open pipe/tube blowoffs while there are countless other programs out there which focus on replacing any blowoff with an engineered nozzle that also fits certain flow criteria for select pipe sizes. These programs can be searched by using the site Dsireusa.org This is a site that is maintained by NC State University and NC Clean Energy Technology. You can easily navigate to your state and scan the list for a rebate program which will then even take you to the application and stipulations for the selected incentive.

No matter where you are located in the world, you don’t have to use a rebate to save money by installing engineered nozzles. The savings and ROI all starts as soon as they are installed. The rebates available in various parts of the US are just ways to expedite the ROI. If you want to discuss any engineered nozzle application, contact an Application Engineer today.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Rugged, Stainless Steel Liquid Nozzles Available to Ship From Stock: The FullStream Cone Nozzles

New to EXAIR’s line of Liquid Atomizing Nozzles are the FullStream Liquid Only Atomizing Nozzles. This family of nozzles does not require any source of compressed air to operate, just a supply of pressurized liquid.

They produce droplets by spinning the liquid and breaking its surface tension through a precise orifice or by impacting the liquid onto the surface of the nozzle. Compared to EXAIR’s Air Atomizing Spray Nozzles, these nozzles generate more liquid volume and produce a coarser spray pattern. This higher liquid volume is beneficial for industrial applications including cleaning, cooling, rinsing, dust suppression, and washing. Constructed of Type 303 stainless steel, these durable and rugged nozzles are ideal for industrial applications. They’re available in three sizes: ¼ NPT, 3/8 NPT, and ½ NPT these nozzles can achieve flowrates ranging from 0.5 GPM to 17.64 GPM.

This style of nozzle is a good fit for general-purpose applications in industry and will commonly be used to spray inexpensive liquids such as water, rinse aids, or detergents. They’re also effective for spraying a variety of chemicals, pesticides, and herbicides.

Adjustments to the nozzle’s liquid flow rate can be achieved by regulating the liquid pressure supplied to the nozzles. As we increase the liquid pressure, the flow through the nozzle will increase. As the pressure increases, not only do we increase the overall liquid flow rate but also the size of the spray pattern. If a tight tolerance in liquid flowrate is needed, the Air Atomizing Nozzles will provide more precise control over the application of fluids.

The FullStream Cone Nozzles produce a full cone spray pattern and are among the most common style of spray nozzle available on the market today. They produce a uniform distribution of liquid in a cone shaped round pattern. Their tangential flow is vaneless, creating open internal features that are resistant to clogging for liquids with suspended particles.

The nozzles are manufactured out of Type 303 stainless steel for durable and rugged applications up to a maximum temperature of 800°F. With absolutely no moving parts, these nozzles are Built to Last. All sizes are available in stock to ship today with an order in by 2:00 EDT.

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

Atomizing Spray Nozzles: Breaking Down The Spray Patterns

Once upon a time, there was a process engineer that needed to solve a production issue on a rinsing line. They had used a spray nozzle that had too large of a spray pattern, with too much volume. And used a hollow cone pattern with not enough heat removal…Okay, so maybe I took this a little too far into the fairytales. I have legitimately had a very similar discussion with customers that are trying to find a spray pattern that is “Just Right” for their needs – the Goldilocks discussion of spray patterns. The best part of Atomizing Spray Nozzles from EXAIR is that we do help you find the nozzle that fits your needs. The shape of the spray pattern is one of the key variables that is decided first.

When determining what spray pattern is needed we need to take into account the purpose of the spray, whether it be to coat, rinse, cool, or add humidity. To go along with the purpose we need to understand the geometry of the part/target and whether the part is stationary, is the part moving, or is the nozzle moving. Once those variable are determined then we can select one of the three main spray patterns to drill down the final selection.

The main three patterns are:
Round Pattern
Flat Fan
Hollow Cone

FullStream – Round Pattern Liquid Atomizing Nozzle rinsing parts after coating.

Round Pattern – These are found in air atomizing and liquid atomizing. The air atomizing are available in both siphon fed liquid or pressure fed liquid. These are also broken into narrow angle or wide angle round. The diameter of the full cone spray of liquid will expand on both styles however the narrow angle tends stay more concentrated and can often be seen in rinsing, washing or heavy coating applications. Distance from the target that the nozzle can be will also help with whether a wide angle or narrow angle will be needed.

Flat Fan Spray Pattern rinsing parts after a chemical wash.

Flat Fan Pattern – These are currently offered in the air atomizing spray nozzles and both siphon fed or pressure fed options. They are also offered in narrow angle flat fan, wide angle flat fan, and deflected flat fan. These options will all be dictated by the target area needing covered and the distance to the target area. Flat fan pattern nozzles are often used with fine surface finish coatings that are being applied to either moving parts, or with nozzles that move around stationary parts.

Model AT5010SS 1/2 NPT 360° Hollow Circular Pattern Atomizing Spray Nozzles are ideal for smooth, even coatings in large pipe or duct ID’s, or for a mist or fog over a large area.

Hollow Cone – This pattern is available in both liquid atomizing and air atomizing. The liquid atomized hollow stream nozzle is great for rinsing, or washing parts. The center of the cone being hollow can help to conserve liquid where it is not needed. The air atomizing hollow cone 360° nozzle can spray so wide it has been used for inside pipe wall cleaning / coating as well as for dust suppression in large areas.

No matter the application, there is a combination of spray nozzles that should fit “just right”. The Application Engineer team here at EXAIR are all equipped with knowledge and experience to help determine what is needed or at the very least some methods to get to a final solution. If you would like to discuss the needs within your facility, contact us.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF