EXAIR Internal Mix Atomizing Nozzles: Deflected Flat Fan & Hollow Circular Pattern

EXAIR Atomizing Nozzles

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 efficient when spraying.  The EXAIR Atomizing Nozzles are designed to accomplish this objective of saving fluid.  With the help of compressed air, the liquid can be sheared into smaller micron-sized droplets.  For reference, if the radius of a particle is reduced by one-half, this will increase the number of droplets by eight.  With smaller diameter particles, the surface area and coverage will increase; thus, reducing the liquid requirement in your application.  EXAIR manufactures three families of Atomizing Nozzles; Internal Mix, External Mix, and the Siphon Fed in three different body sizes to accommodate for the different liquid flow rates.  In this blog, I will be discussing the Internal Mix Atomizing Nozzles with two specific spray patterns; the Deflected Flat Fan and the 360o Hollow Circular Pattern.

To start, the Internal Mix Atomizing Nozzles are designed; like the name suggests, to atomize the liquid inside the nozzle.  The pressurized liquid and compressed air are separated until they get into the “mixing” chamber.  The mixing chamber is created by two types of caps; a liquid cap and an air cap.  The liquid cap is designed to create a high velocity air stream to “break” up a small liquid droplet.  The air cap is then used to create the spray pattern for applying the liquid material more effectively.  The Deflected Flat Fan and the 360o Hollow Circular Pattern are the air caps.

Deflected Flat Fan Air Cap

The model AD1010SS, deflected flat fan atomizing spray nozzle, sprays small micron-sized particles at a right angle.  This type of air cap works very well to direct the atomized fluid like paints and coasting onto surfaces.  These nozzles are also useful for spraying liquids in close quarters like inside ductwork or enclosures.  The viscosity of the pressurized liquid has to be under 300 CPS, and it can spray as much as 6.9 GPH (26 LPH) of fluid.  The model AD1010SS has ¼” NPT inlets and has a manual liquid valve to precisely control the amount of fluid being sprayed to eliminate any runs.  EXAIR also offers a No-Drip option with this Atomizing Nozzle; model AD2010SS.  This option will not allow the liquid to drip from the nozzle when not in use.  This is a great option for reducing liquid waste from drips and for intermittent spraying.   If a right-angle spray pattern is required, both models will work well to accomplish this.

 

360 Hollow Circular Pattern Air Cap

The 360o Hollow Circular Pattern Internal Mix Atomizing Nozzle sprays the atomized liquid outward in all directions.  This works well for applications where wide areas are needed to be covered.  It can also be used inside pipes and ductwork that needs to be covered around the circumference.  With liquid water applications, they are the primary atomizing nozzles for humidification and dust suppression.  The small particles of water can be sprayed in the ambient air to increase the relative humidity as well as “clinging” to dust particles to weigh them down.  This type of atomizing nozzle is manufactured in two types of body styles; the AT1010SS, ¼” NPT inlets, and the AT5010SS, ½” NPT inlets.   The AT1010SS has a maximum spray volume of 14.7 GPH (55.7 LPH) while the AT5010SS has a maximum spray volume of 150 GPH (568 LPH).  The unique design of the air cap creates a very wide spray diameter up to 53” (135 cm) for the AT1010SS and 156” (396 cm) for the AT5010SS.  As with the Deflected Flat Fan, these atomizing nozzles are available with the No-Drip option; AT2010SS and AT6010SS respectively.

If you need to maximize your liquid dispersion and minimize liquid consumption, the EXAIR Atomizing Nozzles are the products to use.  With the Deflected Flat Fan and 360o Hollow Circular Pattern, we can direct the spray patterns to better suite your application.  If you require any additional information on these nozzles or any of the other EXAIR Atomizing Nozzles, an Application Engineer will be happy to help you.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

 

EXAIR Atomizing Nozzles in a Forging Plant

A steel forging plant was using a releasing agent in their process. This particular operation was to make a blank gear.  It started with a heated ingot that was placed in a two-part dual stamp die.  The front section of the die creates the hub of the gear, and the back section would finish the outer diameter of the gear.  The operator would use tongs to grab the hot part and place it in the front and back portion of the die.  Each time the press would cycle, a release agent would be sprayed onto the die so that the parts would not stick.  As you can see in the picture below, they had six liquid spray nozzles modified to spray the entire surface.  Two of the spray nozzles were blowing the release agent to the top portion of the die, and four spray nozzles would spray the entire bottom portion of the die.  Every time the press would cycle, the release agent would be sprayed.

Forging press with liquid spraying nozzles
Forging press with liquid spraying nozzles

At a rate of making a part every six seconds, much release agent was being sprayed. This lubrication for forging was not inexpensive, and it was adding cost to their operation.  They called EXAIR to see if we could help in this matter.

 

The EXAIR Atomizing Nozzles use compressed air to help “shear” the liquid into a very fine mist. The smaller the liquid particle size, the more surface area is created.  This is very beneficial in saving liquid material without reducing the required performance.  This customer purchased two Internal Mix Narrow Angle Round Pattern Atomizing Nozzles, model AN1040SS to replace the six liquid nozzles that he was using.  With a stainless steel construction as standard, it makes the Atomizing Nozzle very corrosion resistant and able to handle 400 deg. F (204 deg. C) temperatures.  With the narrow angle round spray pattern, they could position the Atomizing Nozzles to cover the entire top and bottom of the die (reference the photo below).  With the liquid adjustment valve, they could dial in just the right amount of release agent to keep the process running smoothly.  After the first week in modifying their operation with EXAIR Atomizing Nozzles, they noticed that they were using only half the amount of releasing agent.  This helped to cut cost in their operation, increasing their profit margin.

Forging press with EXAIR Atomizing Nozzles
Forging press with EXAIR Atomizing Nozzles

We can spray liquids very economically and efficiently. We have different types of spray patterns for three different styles.  We have the Internal Mix style for low viscosity fluids as purchased by the above customer; the External Mix for high viscosity fluids, and the Siphon Fed for unpressurized liquid systems requiring gravity or siphoning.  We can atomize liquids up to a rate of 5 gallons per minute (19 liters per minute).  If you believe that you are going through too much liquid in your process, you can contact an Application Engineer to see if we have the correct Atomizing Nozzle for you.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

EXAIR No-Drip Atomizing Spray Nozzles Recognized By Plant Engineering

AW2030ss559
EXAIR’s patented Model AW2030SS No-Drip Atomizing Spray Nozzle

If you follow our blog, Twitter, or Facebook pages, you may have seen us mentioning recent nominations for Plant Engineering Product of the Year Awards.  2015 will mark the 28th anniversary for this award, in which Plant Engineering readers select the most outstanding new products that help them do their jobs smarter, safer, more efficiently, and more productively.

Considering the pre-qualifiers for such an award, it makes sense that EXAIR products would show up, and show up repeatedly.  This year our No-Drip Atomizing Spray Nozzles have been nominated as a finalist in the Fluid Handling category.

Products in this field are recognized to present improvement potential, allowing users to create a more innovative process.  EXAIR No-Drip Atomizing Spray Nozzles do so by providing effortless integration of controlled liquid spraying.

Compressed air and pressurized (or non-pressurized) liquid are plumbed to the nozzle.  When compressed air is flowing, liquid will flow as well.  When compressed air flow stops, liquid flow stops.  Immediately.

For an end user of this product, this means that a precise volume of a specific liquid can be sprayed in a given time (duty cycle), with complete control before, during, and after nozzle activation.

The key to adding this innovation rests in the proprietary, patented (#9,156,045) design  of EXAIR’s No-Drip Atomizing Spray Nozzles.  Our engineers have worked tirelessly to create a stand-alone nozzle capable of controlling liquid flow without requiring a liquid control solenoid.

The viability of these nozzles has been recognized by Plant Engineering as an innovative new product in 2015.  If you agree and would like to cast a vote for EXAIR, please click here.

We thank you for your readership and, hopefully, for your support in this competition.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE