Dust suppression by means of pneumatic atomising nozzles.

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Suspension of particles in suspension by means of hydro-pneumatic nozzles (dry fog).

Pneumatic atomising nozzles are an excellent way to control dust in industrial applications. They work by injecting pressurised air into a stream of liquid to create tiny droplets that capture dust particles and carry them to the floor. This prevents dust from dispersing into the air and creating safety or product quality hazards.

The effectiveness of the airborne dust control system depends largely on the size of the water droplets generated by the atomiser nozzles. When the droplet size is comparable to the size of the dust particle, the probability of the droplet capturing the particle and causing it to fall to the ground is greater. Therefore, greater suppression of airborne dust is achieved. This is important to consider when designing and implementing a dust control system in a mineral factory or other industrial environment.

 

Elements of a dust or particulate matter control system:

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– Atomising nozzles: There are several types, including flat blast nozzles, hollow cone nozzles, deflector nozzles and flat fan nozzles. Each produces droplets of different sizes and angles for different applications. Selecting the right nozzle is key to system performance.

– Air source: Dry, filtered compressed air is required for injection into the nozzles. Air pressure largely determines droplet size; typically between 20 and 125 psi.

– Liquid supply: Water or oil is required as the carrier liquid that is atomised by the nozzles. Liquid tubing must be installed to deliver the liquid to each nozzle.

– Control: A pneumatic nozzle system requires a control valve to activate liquid atomisation only when necessary. This helps to conserve fluid and air consumption. Timers and sensors can be used to automatically activate the system.

– Filters: Filters to remove impurities from the air and liquids should be installed before feeding the dust suppression system. This will prevent nozzles from clogging or damage.

– Arrangement: Nozzles should be oriented and spaced correctly to optimise system performance. Mist coverage must be positioned to capture dust, which is dependent on the layout. Physical barriers can be placed to help direct the flow if necessary.

A well-designed pneumatic atomising nozzle system is a very effective way to control airborne dust and maintain a clean and safe working environment. Contact Spraying Systems for recommendations on the design of your dust suppression system.

Applications where proper dust suppression is required:

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  • Hopper discharge: At hopper discharge, hydro-pneumatic water atomiser nozzles can be installed at the top of the hopper to spray a fine spray of water that mixes with the dust and causes it to fall to the ground. Water curtains can also be installed at the hopper outlet to capture the dust.
  • Water curtains can also be installed at the hopper outlet to capture the dust.
  • Shredders: In shredders, water spray systems can be installed at material discharge points to reduce the amount of dust generated. In addition, covers can be installed on the shredders to prevent dust from escaping.
  • Conveyor belt discharge: At the conveyor belt discharge, water curtains or water spray nozzles can be installed to reduce the amount of dust generated.
  • Conveyor belt discharge: At the conveyor belt discharge, water curtains or water spray nozzles can be installed to reduce the amount of dust generated.
  • Dump discharge: At the dump discharge, water spray systems can be installed at the discharge points to reduce the amount of dust generated. Water curtains can also be installed to capture the dust.
  • Gathering: In stockpiles, water spray systems can be installed on top of the stockpile to reduce the amount of dust generated. In addition, covers can be used to prevent the wind from blowing the dust away.
  • Loading: At loading, vacuum systems can be installed to capture dust generated during loading. Water spraying systems can also be installed at loading points to reduce the amount of dust generated.
  • Dusting: At loading, vacuum systems can be installed to capture the dust generated during loading.
  • Silo unloading: In silo unloading, water spray systems can be installed at the unloading points to reduce the amount of dust generated. Water curtains can also be installed to capture the dust.
  • Screens: On screens, vacuum systems can be installed to capture dust generated during screening. Water spray systems can also be installed at the screening points to reduce the amount of dust generated.
  • Screens: Water spray systems can be installed at screening points to reduce the amount of dust generated.
  • Shearing: On shears, vacuum systems can be installed to capture the dust generated during shearing. Water spray systems can also be installed at the cutting points to reduce the amount of dust generated.
  • Wagons.
  • Wagons: On wagons, vacuum systems can be installed to capture dust generated during loading and unloading. Water spraying systems can also be installed at loading and unloading points to reduce the amount of dust generated.
  • Wagons: On wagons, vacuum systems can be installed to capture dust generated during loading and unloading.
  • Dumpers: On dumpers, vacuum systems can be installed to capture dust generated during loading and unloading. Water spray systems can also be installed at the loading and unloading points to reduce the amount of dust generated.
  • Dumpers: On dumpers, vacuum systems can be installed to capture the dust generated during loading and unloading.
  • Continuous miners: On continuous miners, vacuum systems can be installed to capture dust generated during excavation. Water spray systems can also be installed at excavation points to reduce the amount of dust generated.

Which type of hydro-pneumatic dust suppression nozzles are most suitable?

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The choice of the most suitable type of hydro-pneumatic nozzle for dust suppression depends on several factors:

– Dust particle size: finer nozzles, such as fog nozzles, are best for suppressing fine dusts with small particles. Coarse droplet nozzles are more effective against more granular dusts.

– Air velocity: Nozzles that produce larger droplets, such as fog nozzles, generally have a longer range for suppressing dusts carried by fast air currents. Fine mist nozzles improve coverage in poorly ventilated areas.

– Available water flow: The type of nozzle must be chosen to provide the desired coverage with the available water flow. Finer nozzles require higher flow rates.

– Visibility: Some applications require maintaining good visibility. In those cases, nozzles that produce finer, more dispersed droplets are usually better.

– Clogging: Large nozzles tend to clog less than finer nozzles.

In conclusion, there is no single “best fit” nozzle type for all situations. The best choice depends on the particular characteristics of each application. The selection is made by evaluating factors such as particle size, flow rate, required range and visibility to choose between fine mist, medium mist or coarse droplet nozzles.

What type of maintenance is required for a pneumatic atomising nozzle system?

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A pneumatic atomising nozzle system will require regular maintenance to function properly and maximise its service life. Some of the key maintenance points include:

– Inspect and clean nozzles: Nozzles can become clogged or damaged over time due to dust or sediment build-up. They should be inspected periodically and cleaned or replaced as necessary. Partial or damaged clogging will reduce system performance.

– Filter and replace filters: Air and liquid filters should be changed according to the maintenance schedule to remove trapped particles and ensure proper flow. Dirty filters reduce pressure and flow, which affects droplet size.

– Inspect hoses and connections: Air and fluid hoses must be flexible with no cracks, cuts or wear for proper operation. All connections must be secure to prevent leaks. Leaks reduce system pressure and performance.

– Adjust air pressure: The system pressure gauge should be checked to ensure that the air pressure remains in the correct operating range. Incorrect air pressure will affect droplet size and dust suppression performance. The pressure should be adjusted manually using an isolation valve if necessary.

– Add carrier fluid: The fluid level in the reservoir should be checked and replenished as necessary to prevent depletion during operation. The fluid should be the type recommended by the manufacturer.

– System Testing: Periodically test the system by activating the fog sprinkler to identify any problems with performance before they affect critical operation. Note the quality and coverage of the fog, as well as any obvious leaks or problems.

– Preventive maintenance: All system components, such as valves, tanks, pumps, compressors, etc., require preventive maintenance according to the manufacturer’s recommendations. Preventive maintenance will help ensure the long-term reliability of the system.

A sound maintenance program is essential to maximize the life and performance of a pneumatic atomizing nozzle dust suppression system. Always follow your equipment manufacturer’s specific recommendations.

YOU CAN SEE ALL OUR NOZZLES THAT GENERATE FINE MIST (DRY FOG) HERE