Many industries rely on atomizing nozzles to provide cooling for specific processes. In industrial metal fabrication, atomization is used to cool the metal casting stream controlled to help maintain the desired properties of the casting metal. When water from a tank or main water line is used, the water may contain sediment and scale. This material enters the nozzle through the water pipe and is deposited there. Over time, sediment and scale can build up and clog the opening of the spray nozzle.
Cleaning the spray nozzle ensures that water enters the nozzle and flows onto the application unimpeded at the desired flow rate and droplet size. The following atomizing nozzle manufacturer will share with you how to clean atomizing nozzles.
How to clean and repair clogged atomizing nozzles
If your atomizing nozzle is clogged, you will need to remove the nozzle from the atomizing system. If the deposit is not caked and clinging to a metal surface, you can tap the nozzle gently on a hard surface and then rinse off the accumulated debris with water. However, if a simple rinse cannot remove hard water deposits, you can use several different cleaning solutions.
The cleaning solution can consist of CLR or white vinegar. You want to dilute the two mixtures in a container with water. Next, you want to remove the O-ring so that the cleaning solution does not damage it. Drop the atomizing nozzle into the cleaning solution and let it sit for about 45 minutes to 1 hour until the hard calcium dissolves or comes off. Next, run the fogging system to flush the lines. Then place the o-ring back on the fogging nozzle and reconnect the nozzle to the fogging system.
Before replacing the spray nozzle on the system, inspect the nozzle for any signs of damage or worn areas. The O-rings may show signs of wear and need to be replaced.
How do I remove the O-ring from the atomizing nozzle?
The O-ring is a flexible elastomer that crosses over the nozzle fitting when it is screwed into the atomization system. This O-ring is designed as a seal to prevent water from escaping at this joint. However, aging and continued use of the nozzle can cause the O-ring to wear or break. Therefore, when performing regular maintenance, you will need to remove the O-ring and replace it with a new one. In addition, you should permanently remove the O-ring before cleaning the atomizing nozzle to prevent the cleaning solution from damaging the elastomeric material.
You will need a small flathead screwdriver. Remove the atomization nozzle from the system and place it on a flat surface. Gently place the flat end of the screwdriver between the O-ring and the area of metal contact. Lift upward, and the o-ring should slip off.
If the o-ring is still in good condition, place it back on the spray nozzle. Otherwise, replace the o-ring with a new o-ring of the same size. The new o-ring will be slightly looser compared to the old o-ring. This looseness is expected because the o-ring will compress when you retighten the atomizing nozzle onto the atomizing system.
Why is my fogging nozzle not spraying?
There may be a blockage in the pipe or tubing leading to the fogging system. You will need to flush the system without the spray nozzle to determine if the problem is the nozzle or the sprayer itself. Another problem may be a piece of the metal part of the nozzle that is flaking off. It may therefore be clogging the hole in the spray nozzle. Using a needle vise or wire brush may help to remove the flaking metal.
If your atomization system has a filter, the filter may be clogged with debris and hard calcium build-up. According to the manufacturer’s instructions, you will want to remove the filter and remove the dirty filter from the housing. You can wash out the filter build-up or replace the old filter with a new one. Put the new filter back into the filter housing and then put the filter housing back into the atomization system.
After performing this maintenance and still experiencing problems with the fogger not spraying, the problem may involve low water pressure causing the water to not pass through the pipes correctly. Check the fogging system settings and the main water line or pressurized tank. You may need to readjust or perform maintenance on these systems to get the water pressure to the proper level.
Benefits of cleaning the fogging nozzle system
You should have a cleaning schedule for your fogging nozzles to ensure they perform to their maximum potential and extend their life of the nozzles. When fogging nozzles become clogged, it affects the flow rate of the fog coming out of the system. This factor can disrupt the application and cause timely damage to the nozzles.
Suppose only part of the nozzle is clogged. In that case, it may send redirected water mist at a different angle, which may only partially cool the application or not cool the entire application. Running a complete line quickly may result in many poor-quality applications and products that must be scrapped. This problem creates a lot of waste and unnecessarily large expenses. It can also pass production deadlines.