Many industries rely on mist nozzles to provide cooling for specific processes. In industrial metal fabrication, atomization is used to cool metal strands in a controlled manner to help maintain the desired properties of cast metal. The water may contain sediment and scale when using water from a tank or central water supply line. These materials enter the nozzle through the water line and are deposited there. Over time, sediment and scale can build up and clog the opening of the mist nozzle.
Cleaning the mist nozzle ensures that water can enter the nozzle unimpeded and enter the application at the desired flow rate and droplet size. CYCO Spray As a professional nozzle manufacturer, we offer many types of aerosol nozzles for major industries. This article will introduce you to the cleaning method of mist nozzles.
How to clean and repair clogged mist nozzles
If an mist nozzle is clogged, you will need to remove the nozzle from the mist system. If the deposit is not caked and clinging to a metal surface, gently tap the nozzle against the hard surface and then rinse the accumulated debris with water. However, if hard water deposits cannot be removed with a simple rinse, you can use various cleaning solutions.
Cleaning solutions can consist of CLR or white vinegar. You want to dilute both of these mixtures in a container with water. Next, you want to remove the O-ring so that the cleaning solution does not damage it. Place the fogging nozzle in the cleaning solution and let it sit for about 45 minutes to an 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 mist nozzle and install the nozzle back into the mist system.
Before replacing the mist nozzle on the system, inspect the nozzle for any signs of damage or worn areas. There may be signs of wear on the o-rings that need to be replaced.
How do I remove the O-ring from the mist 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 from this joint. However, aging and continued use of the nozzle can cause the O-ring to wear or break. Therefore, when performing regular maintenance, remove the O-ring and replace it with a new one. In addition, you should permanently remove the O-ring before cleaning the mist nozzle to prevent the cleaning solution from damaging the elastomeric material.
You will need a small flathead screwdriver. Remove the mist 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 mist nozzle. Otherwise, replace the O-ring with a new one of the same size. The new o-ring will be slightly looser compared to the old one. This looseness is regular because the o-ring will compress when you retighten the mist nozzle onto the mist system.
Why is the mist nozzle not spraying?
There may be a blockage in the pipe or one of the pipes leading to the fogging system. You will need to flush the system without the fogging nozzle attached to determine if the problem is with the nozzle or the fogger itself. Another problem could be that a metal part on the nozzle is flaking off. So it may be clogging the hole in the mist nozzle. Using a needle vise or wire brush may help to remove the metal flake.
If your atomization system has a filter, the filter may be clogged with debris and hard calcium buildup. You will want to remove the filter according to the manufacturer’s instructions and remove the dirty filter from the housing. You can wash out the filter buildup or replace the old filter with a new one. Place the new filter back into the filter housing and return the filter housing to the fogging system.
Suppose you are still experiencing problems with the fogger not spraying water after performing this maintenance. In that case, the problem may involve low water pressure causing the water to not pass through the line at the correct rate. Check the fogging system settings and the main water line or pressurized water tank. You may need to readjust the pressure or perform maintenance on these systems to bring 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.
If only part of the nozzle is clogged, it may resend the water mist at a different angle, which only partially cools the application or fails to cool the entire application. Running a complete line quickly can 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 get through production deadlines.