Helpful Engineering Information Related to Spray Nozzles

Nozzle Type
Typically full cone nozzles have the largest size droplet followed by flat spray nozzles and hollow cone nozzles. This trend applies equally to hydraulic and air assisted nozzles, however, air assisted nozzles provide very fine droplets that are smaller in size than traditional hydraulic nozzles. For a better description of the characteristics of various types of spray nozzles, click here to go to the nozzle index page.

Flow Rate
Flow rate has a direct effect on droplet size. An increase in flow rate will increase the droplet size; similarly, a decrease in flow rate will decrease droplet size. Example: A 150 gpm hollow cone nozzle at 10 psi has a larger droplet than a 100 gpm hollow cone at 10 psi. Similarly, a 50 gpm full cone nozzle at 7 psi has a smaller droplet size than a 120 gpm full cone nozzle at the same pressure.

Pressure (use our automated Spray Nozzle Flow Converter)

Pressure has an inverse effect on droplet size. An increase in pressure will reduce the droplet size, whereas a reduction in pressure will increase the droplet size. Example: A 1 gpm flat spray nozzle has a larger droplet at 30 psi than at 60 psi. Similarly, a 10 gpm full cone nozzle has a smaller droplet size at 40 psi than at 10 psi. Of the factors affecting flow rate, the most influential is pressure. Theoretically, the flow rate varies in correlation with the square root of the pressure, neglecting all other factors. Therefore, to compute flow rates other than those tabulated in the catalog, the following formula may be used (or use our automated flow calculator online by clicking here):

Q1 and P1 are the known flow rate and pressure. Q2 is the resulting flow rate for the desired pressure P2. If you need to calculate the pressure to achieve a specific flow rate, you can use a variation of the same formula:

P1 and Q1 are the known pressure and flow rate. P2 is the resulting pressure for the desired flow rate Q2.

Temperature
Temperature influences a liquid's viscosity, surface tension, and specific gravity, which in turn can affect spray nozzle performance.

Liquid Properties
Viscosity and surface tension increase the amount of energy required to atomize the spray. An increase in any of these properties will typically increase the droplet size. Virtually all droplet size data supplied from Lechler is based on spraying water under laboratory conditions. The effect of liquid properties should be understood and accounted for when selecting a nozzle for a process that is droplet size sensitive. Viscosity Viscosity is probably the most significant of all liquid properties because it can vary over an extreme range. Liquid viscosity resists surface formation. If the viscosity is great enough, a nozzle may produce a mass of filaments instead of a spray. Liquid viscosity is remarkably sensitive to temperature. Thus, liquid viscosity has a significant effect on all of the spray characteristics, Specific Gravity The main effect of the specific gravity of a fluid being sprayed is on the flow rate of the nozzle. The lower the specific gravity of a liquid, the higher the velocity through the nozzle, and vice versa. Thus, for lower specific gravity, the flow rate is larger than for liquid with a higher specific gravity at the same pressure.

Example: For a fluid with a specific gravity of 1.2 the flow rate would only be about 90% as compared to the flow of water which has a Specific Gravity of 1:

Surface Tension Surface tension is an important physical property affecting surface formation, and makes the liquid resist breaking into droplets. The main effect of surface tension is on the spray angle and droplet size of the sprayed fluid as well as the spray distribution.

Spray Angle
Spray angles have an inverse effect on drop size. An increase in the spray angle will reduce the droplet size, whereas a reduction in spray angle will increase the droplet size. Click Here to use our automated spray nozzle coverage and header layout calculator. Example: A 3 gpm flat spray nozzle with a 50 spray angle has a larger drop size than a 3 gpm flat spray nozzle with a 110 spray angle at the same operating pressure.

Impact
The impact or impingement of a spray is measurable, and should be taken into consideration in many applications. For more specific impact information consult with Lechler. As a general rule, the narrower the spray angle, the greater the impact over a given area.

Nozzle Wear
Nozzle wear is denoted by an increase in the nozzle flow rate and the subsequent deterioration of spray performance. A reduction in system operating pressure is often an indication of increased nozzle wear, especially when positive displacement pumps are used. Flat fan axial nozzles exhibit a narrowing of the spray pattern with wear. Other types of spray nozzles reveal a loss in spray uniformity within the spray pattern - though without a noticeable change in pattern size.

Nozzle Materials
Lechler nozzles are available in many problem-solving materials. To spray corrosive fluids or for operation in corrosive environments, choose from a variety of chemically and thermally resistant materials, which include stainless steels, titanium, and Hastelloy; or corrosion resistant plastics, such as PVC, PP, PVDF, POM, and PTFE. To meet high wear and corrosion resistance requirements, Lechler manufactures nozzles from stainless steel, ceramic, tungsten carbide, Stellite, and silicon carbide.

Flat spray nozzles for washing and cleaning applications

FLAT SPRAYS Flat spray nozzles are one of the most common nozzles in use today. Available in virtually any material and numerous spray angles, the pattern generated by this type of nozzle concentrates the fluid in a thin line. Not all flat sprays are created equal! Spray nozzle design and precision machining have a significant effect on the stability of the spray pattern and impact achieved. The impact received is directly related to the density of the spray pattern, so the tighter you maintain the spray pattern, the more impact per in2 will be received. Reducing the spray height to the minimum amount possible and using more nozzles also significantly increases the impact received.

There are several different types of flat spray nozzles including axial and deflector configurations. The narrower the spray angle, the greater the impact you'll receive at a given distance. Therefore narrower angle nozzles are used for difficult cleaning applications and wider angle nozzles are used for less intensive washing, foam control, dust suppression, coating and similar applications.

Axial Flat Spray

Deflector Flat Spray

Effective Coverage Overlap

There are two types of flat spray patterns, some have tapered patterns and others provide an even distribution. The most common type has a tapered spray distribution and the diagram above shows overlapping the nozzles by about 30%. Since the edges of the spray flow less than the center portion, the overlapping of the spray patterns help equalize the flow distribution across the target. In some applications 100% or more overlap is required if there is a potential for nozzle pluggage problems. You must also remember to offset your spray nozzles so that their patterns do not intersect prior to impacting the target. Our latest Spray Nozzle Engineering Manual has several pages dedicated to flat spray nozzles as well as an introductory page on flat spray nozzles in general. Related Links:

Atomizing Spray Nozzles

Twin Fluid (Air Atomized) Hydraulic (Pressure Atomized) Overview of the basic choices for Atomizing Nozzles

mized spray nozzles are the most common type of ng nozzles and are offered in many specialized designs. le in virtually any material and several spray angles, fluid (usually air) is mixed with the process liquid. The g spray is a high velocity flat or full cone pattern of very plets. With this type of nozzle your air and liquid e ratios play a very important role in the droplet size d. Some of our air atomizing nozzles can generate s as fine as 10 microns SMD.

Typical low capacity Twin Fluid Atomizing Nozzle

Air atomizing nozzles are often used for lubricating, scenting, coating, moistur humidifying, cooling and gas conditioning because they can generate a range droplets from fine to very fine in size. Air Atomizing Droplets can generate the fine droplet sizes of all atomizing nozzle types, as low as 10 microns SMD.

Why Atomize?

Imagine two droplets of the same size, one droplet you break up [atomize] into 10 smaller droplets and the other you leave alone. If you measure the surface area o "small droplet" and add them up, the result will be more than the total surface area single large droplet. Simply put, the smaller the droplet size, the more surface are have at a given flow rate. More surface area translates into more efficient heat tra surface contact or reaction within a gas stream.

"Which is better, a Twin Fluid Atomizing Nozzle or Hydraulic Atomizing Nozzle?"

As with most questions in life, that depends! Air atomizing nozzles usually have lo flow rates and as a result are measured in gallons per hour (GPH) vs. gallons per (GPM). In order to generate very fine droplets with hollow cone nozzles it often re operating at higher discharge pressures (up to 2,000 PSI) and air atomizing nozzl require a compressor or blower air of some type. So the droplet size and flow rat required as well as the resources available all play a part in the decision making p

There are several variations of air atomizing nozzles pictured to the left such as de that have co-axial inlets (both atomizing fluid and process fluid enter from same si Overview of the basic choices for Atomizing Nozzles

This is Where We Can Assist!

Most customers do not know what droplet size they require. They may not even know the flow rate required. Although each application has its specific requirements, you can tap into our experience for recommendations. In some cases a certain residency time is desirable, such in SOx reduction applications. In many applications the droplets require a certain mass and velocity in order to provide the distribution desired within a pressurized reactor or high velocity gas stream. These are all factors that help determine the droplet size required. We can work with you to help minimize the guesswork and maximize your spraying efficiency.

Specialty Atomizing Nozzles

We also manufacturer specialized nozzles for high flow rate gas cooling applications and chemical injection applications such as Lime Slurry Atomizing and Aqueous Ammonia Injection. A cost effective way for gas cooling that provides for a flow rate turndown ratio of 10:1 are Spillback Injection Lances. Spillback Lances maintain a constant pressure at the orifice

while allowing for adjustments in flow rate depending upon the gas volume and temperature that you are cooling. These are often used in cooling towers prior to electrostatic precipitators and bag houses at Cement Plants, Waste-to-Energy Plants and other manufacturing processes that have a varied gas flow/temperature for gas cooling. For atomizing Lime Slurry, Carbon Slurry and other difficult to atomize fluids Supersonic Spray Nozzle is often ideal. Supersonic Nozzles have the largest free passage of any equivalent capacity air atomizing nozzle and eliminate pluggage as a concern for applications involving slurries or particle laden gas streams.

Atomizing Nozzle Options:

Which is Best for Your Application?
There are many types of atomizing nozzles to choose from and we offer practically every type that there is; you can browse this page for a quick overview of your options and then send us an inquiry so that we can recommend a nozzle, spray header or complete atomizing system for your specific application. Basic Atomizing of non-viscous liquids, both internally and externally atomized with manual an pneumatic control valve options. View Datasheet Here

:50 to 100 microns :0.10 to 40 GPH

The 136 series air atomizing nozzles enhance a spraying process by increasing flexibility and ensuring reliability while maintaining superior control over the spray application. These are available in the standard manual form, or as the 166H Series with a pneumaticactuated solenoid valve attachment that allows for precise spray control. The 136 Series Nozzle Body can be easily combined with dozens of interchangeable spray tips for almost endless choices for spray patterns and capabilities. This enables these air mist nozzles to be used for: Coating Cooling Humidification Odor Control Chemical Processing

Droplet Size Range:10 to 50 microns Liquid Flow Range: 1 to 60 GPH

Atomizing nozzles for viscous fluids and for applicatio droplet size independent of shape air or atomizing air Datasheet here

The ViscoMistTM nozzle incorporates an on/off and clean-out needle assembly, so it characteristic of viscous atomizing applications.

The ViscoMistTM offers independent regulation of both atomizing and pattern shape a size. The ViscoMistTM nozzle is available in nickel plated brass or stainless steel, and for the most demanding spraying processes.

Interchangeable air tips and numerous flow capacities are available to suit most spr other specialized requirements. Droplet Size Range:100 to 200 microns Liquid Flow Range: 1 to 4 GPM

148 series high capacity atomizing nozzles were de flow rate of atomized fluid is required. These are in droplets.

Continuous casters in steel mills use tremendous volumes of water for cooling the s molten hot product through the mill. There are numerous challenges for brutal appli nozzles are designed to use air and water efficiently and to be very reliable as well a to the individual applications requirements. Such customizations include modificatio

Droplet Size Range:30 - 100 microns Liquid Flow Range: 2 GPH to 40 GPM

Supersonic air atomizing nozzles are unique for the used for spray drying applications, especially those excellent choice for in-duct lime slurry injection for plants and other applications that require 100% eva

Slurry atomization is hard on nozzles and for this reason we offer Supersonic nozz liquid flow ratio is critical to maintaining the desired performance across your flow modeling the gas flow through your conditioning tower or ductwork as well as com online inquiry for for gas cooling and conditioning applications will enable us

Droplet Size Range:75 to 125 microns Liquid Flow Range: 1 to 7 GPM

Spillback nozzle lances are single fluid (pressure a Spillback nozzles different from an ordinary hydrau operating range of 10:1. This is accomplished by m required.

Spillback nozzle spray lances are an energy efficient alternative to two fluid atomi we can provide the complete pump and control system for a turnkey installation. U us to custom design the most efficient spray nozzle network for your gas cooling a

Droplet Size Range:50 to 150 microns Liquid Flow Range: As Required

Our gas conditioning systems consist of the pump spray nozzles. Systems are designed fist by the p appropriate mechanical system is designed and m

Our pump skids and control systems are typically applied to gas cooling applicatio single fluid (pressure atomization) and two-fluid (air atomized) nozzle systems, w This turnkey system approach ensures an efficient spraying system that will provi flow turndown ratios of at least 10:1. Click here to fill-out our online gas coolin

Spray Nozzle Glossary

Following are descriptions of terms found throughout our website. You can click-on the alphabetized list to jump right to a particular definition. In some cases you can click-on glossary terms to get sent to web pages that describe those topics in more detail. If there are specific terms or questions that you have and they are not listed here, please let us know and we'll do our best to explain them to you. Click on a link below to jump down the page to that section Air Atomizing Spray Nozzles Hollow Cone Spray Nozzles Spray width Droplet size PVDF Material Flat Fan Spray Nozzles Solid Stream Nozzles Full Cone Spray Nozzles Spray angle

Air Atomizing Spray Nozzles: Use collision of metered air and liquid to provide the finest atomization of a liquid. Internally Mixed: Air and liquid are mixed inside a nozzle body for low viscosity and clean fluids. Externally Mixed: Liquid and air mixing occurs outside of the nozzle for viscous and fluids with particulate. Droplet Size: The precision orifice(s) of spray nozzles are designed to break-up liquid into a multitude of droplets, usually for the purpose of increasing surface area, or concentrating liquid to create high impact force. Droplet size is frequently denoted by a mean of median diameter. The following seven nomenclatures are commonly used to describe droplet size. Each have different numerical values which vary widely. Mass Volume Median Diameter is the largest of all and number median diameter is the smallest. The differences between the various mean and median diameters provide a convenient way of specifying the "spread" of droplet sizes produced. If all the spray droplets had been uniform in size, the mean and median diameters would have been identical with the uniform size. Lechler measures droplet size with a PDPA system. Arithmetic Mean: The simple weighted average based on the diameters of all the individual droplets in the spray sample. Surface Mean: The diameter of a droplet whose surface area, if multiplied by the total number of droplets, will equal the total surface area of all the droplets in the spray sample. Sauter Mean: Also referred to as "volume surface mean", is the diameter of a droplet whose ration of volume to surface area is equal to that of the entire spray sample. Volume Surface Mean: Also referred to as, "sauter mean" is the diameter of a droplet whose ratio of volume to surface area is equal to that of the entire spray sample. Mass (Volume) Median Diameter: The diameter which divides the mass (volume) of spray into two equal halves. Surface Median Diameter: The diameter which divides the surface area of the droplets into two equal halves. Number Median Diameter: The diameter which divides the number of droplets into two equal halves. Flat Fan Spray Nozzles: Produce a sharply defined linear spray pattern and high impact force.

Axial Flat Fan Nozzles: Straight through flow design having elliptical orifice. Deflector Flat Fan Nozzles: Use a precision machined deflector to sculpt a round orifice and solid stream pattern into a evenly distributed flat fan pattern. Full Cone Spray Nozzles: Uniform distribution of liquid across a circular or square area. Axial Full Cone Spray Nozzles: Straight through design having a "X" styled vane which provides uniform distribution of liquid. Tangential Full Cone Spray Nozzles: A right angle liquid flow design to provide uniform distribution without the need for internal vanes or swirl chambers. Hollow Cone Spray Nozzles: Used to provide a finely atomized flow having a pattern shaped like a ring. Axial Hollow Cone Nozzles: Straight through design having spiral grooves or inclined channels to produce a swirl and atomization. Tangential Hollow Cone Nozzles: Utilize a right angle supply of liquid. Swirl and atomization achieved via a swirl chamber. PVDF : Polyvinylidene Fluoride, a plastic material that lends itself to injection molding. As compared to stainless steel, PVDF resists erosion and corrosion better and is generally more compatible with a broad range of chemicals. Solid Stream Spray Nozzles: Provide concentrated impact with prolonged pattern stability and integrity prior to liquid break-up. Spray Angle: Also referred to as spray width, it is typically measured near the nozzle orifice. As the spray distances increase, the measure of the spray pattern length/diameter become significantly less accurate and dependant upon gravity and ambient conditions such as air friction losses and other external influences affecting the spray pattern trajectory. Spray Width: Related to the spray angle, it is typically measured near the nozzle orifice. As the spray distances increase, the measure of the spray pattern length/diameter become significantly less accurate and dependant upon gravity and ambient conditions such as air friction losses and other external influences affecting the spray pattern trajectory. Surface Tension: This physical property is related to the resistance of the sprayed liquid to break-up into droplets. The primary effects of surface tension are spray angle, droplet size and spray distribution. Leidenfrost phenomenon: A cushion of vapor repels liquids from surfaces the temperature of which is above their boiling point. See illustration below: