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

EXAIR Catalog34: What’s new inside?

EXAIR Corporation has been manufacturing intelligent compressed air® products since 1983.  If your company uses pneumatic systems, you probably heard of us.  EXAIR has solutions to save you money in compressed air usage, improve your safety environment, and increase productivity.  You can review these products and our new products in Catalog34, which has just been released. 

We have great news for those customers that have been patiently waiting for our new catalog.  Catalog 34 is now in house.  You can now request a hard copy from our website at this link: Catalog Request Form.  If you wish to create an account on our website or are already signed in, you can find sections of the catalog in our PDF Library.  Since Catalog33, we have released quite a few new products that are now included in Catalog34.  Here they are:

TurboBlast® Safety Air Guns (page 115 – 116 in catalog) – To upgrade our large safety air guns, EXAIR decided to manufacture the TurboBlast Safety Air Guns.  We have upgraded the features to modernize our highest-forced air guns with comfort and ease-of-use.  Here are the improvements that we made:

1.            A pilot valve for single-finger button operation.

2.            A nozzle guard to protect the fins from damage.

3.            An optional gate valve to help control the outlet flow.

4.            Ergonomic soft grip and a foam sleeve to hold and balance.

As an overview, the TurboBlast Safety Air Gun comes with a 1” NPT or BSP inlet.  We offer seven different nozzle options in three different builds with adapters, extensions, and nozzle guards.  The nozzle guard helps protect the nozzle for a long operational life.  The standard unit comes with a 12” (305mm) length extension with a foam ergonomic grip, and we have optional 3-foot (0.9m) and 6-foot (1.8m) extensions.  They range in force levels from 4.5 lbs. (2Kg) to 23 lbs. (10.4Kg) at 80 PSIG (5.5 bar).  They are a great tool for cleaning large areas quickly and efficiently.  They are also OSHA safe.    

3/8” HollowStream™ Cone Liquid Atomizing Nozzles (page 103 in catalog) – EXAIR expanded our HollowStream Spray Nozzles to include a larger flow size in a 3/8” NPT or BSP liquid port.  They require no compressed air and only spray liquids efficiently and effectively. They produce droplets by spinning the liquid and breaking its surface tension through a precision orifice.  These nozzles spray a higher liquid flow rate and produce a coarser spray pattern than the EXAIR Air Atomizing Spray Nozzles.  With the higher liquid flowrates, they are ideal for quenching, cooling, washing, rinsing, sanitizing, and many other types of applications.

Intellistat® Ion Air Nozzle™ (page 143 – 144 in catalog) – The Intellistat Ion Air Nozzle is a lightweight solution for static elimination operations.  This intelligent product produces balanced-ionized compressed air to neutralize any type of static.  They come standard with a low-voltage 24Vdc power supply, a mounting fixture, 6mm tubing, and red and green LED lights for feedback.  The mounting fixture is designed to hold the nozzle with an adjustment to aim the nozzle at different angles for precise blowing.  One of the unique features is that the ionizing point is replaceable; and can decay static at a rapid rate.  The Intellistat Ion Air Nozzle is a great tool for removing particulates during clean processes, test procedures, and sensitive assemblies in laboratories, electronics, lenses, medical, and pharmaceutical areas.

Please don’t hesitate to get your new catalog.  EXAIR offers numerous ways to receive one.  You can go to our website, contact us by phone toll free at 800-903-9247 in the U.S. and Canada; or by Chat.  We have Application Engineers to help assist you with questions about any of our existing products or the new products that are now in Catalog34. We look forward to hearing from you.

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

Cleaning Foam From Beer Bottles

I was contacted by a company that was bottling beer; and they had an issue that they wished to solve.  They were producing 35,000 bottles per hour in two different sizes; the 24 oz. (710 mL) bottles and the “stick it in a brown paper bag” 32 oz. (946 mL) bottles.  The problem area was located at the wash system after capping the beer bottles.  They sprayed a solution of water and a low-concentration of chlorine dioxide as an antimicrobial agent.  Sanitation is at a premium to eliminate any bacteria growth. 

Currently, they were using two sets of three liquid nozzles that were spraying a flat pattern at the top and both sides of the bottle, just under the cap (reference photo below).  The issue that they were experiencing was too much solution was being used as well as creating a slip hazard on the floor outside the wash system.  They tried to reduce the liquid pressure to lessen the amount of solution, but the stream was not strong enough to clean properly.  So, they asked if the EXAIR Air Atomizing Nozzles could be a better solution.

Washing system

With liquid solutions, the smaller the particle size, the greater the surface area.  With higher surface areas, less liquid can be used to cover the same target area.  For this application; I recommended the model EF1040SS External Mix Atomizing Nozzle with a narrow-angle flat fan spray pattern.  The liquid spray pattern matched their current nozzles, and the liquid flowrate produced by this Atomizing Nozzle was within their recommendation.  By adding compressed air, we can shear liquid into much smaller particle sizes.  And as mentioned above, we can use less liquid to cover the same area.  Another feature of the EXAIR External Mix Atomizing Nozzles, the liquid and air pressures are independent.  Unlike the liquid nozzles that they were using, the liquid pressure can be changed while the air pressure can be increased.  Now, they can get a hard-hitting force to remove the beer foam while using less liquid.  This was exactly what this customer needed.   

EF1040SS

I suggested six pieces of the EF1040SS to replace each liquid nozzle to keep the same coverage around the caps.  The stainless-steel construction makes the Atomizing Nozzle corrosive resistant for Food and Beverage applications.  The flat fan pattern is able to reach multiple bottles and hit the target area evenly.  The amount of solution can be controlled by the liquid pressure and by the manual liquid needle valve.  So, the setup can be “dialed” in for the exact amount of cleaning solution needed to clean the bottles without flooding the floor.  This was important for safety as well as saving the company money by using less solution.  For this application, they were able to use about 20% less liquid.

If you have high-value liquids that you would like to spray evenly, efficiently, and effectively; EXAIR Air Atomizing Nozzles can do that for you.  We offer three different port sizes with a variety of liquid flowrates and spray patterns.  If you would like to discuss more about an application or need help in selecting the correct model, an Application Engineer will be happy to assist you.  For the customer above, the bottles were cleaned and ready to “pop the top”.  

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

Photo: Empty brown beet bottles by manfredrifchterPixabay License