Analysis of some problems about nozzles

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2021-11-04

Analysis of some problems about nozzles

How much is the trouble-free operation of the nozzle worth?

　　In many occasions, the waste of cost caused by improper nozzle performance has been ignored. Here are a few examples that can show the value of waste due to improper nozzle performance. It should be noted that this is only a direct loss. In many occasions such as steel plants, more serious losses may be indirect economic and corporate image losses.

If you only spray water:

The total water spray volume of the system (tons/hour)	Amount of water wasted each year/tons (Assuming 15% waste)	Annual wasted water bill
1.2	1,120.0	896.0
2.4	2,250.0	1,800.0
12	11,230.0	8,984.0
24	22,460.0	17,968.0
120	112,300.0	89,840.0

Note: 6240 hours per year is based on 24 hours a day, 5 days a week; the water fee is based on 0.80 yuan/ton. In addition to the loss of water costs, water waste will also exacerbate the problem of insufficient water treatment and storage capacity.

Impact on power consumption:

The total water spray volume of the system (tons/hour)	The amount of water wasted each year, 15% of the ton is assumed to be wasted	Electricity wasted per year (KW) 3 bar	3 bar of electricity lost every year	Electricity wasted per year (KW) 100 bar	Electricity lost every year (yuan) 100 bar
1.2	1，120	129	10	4，280	3424
2.4	2，250	258	21	8，560	6848
12	11，230	1，290	103	42，800	34240
24	22，460	2，580	206	85，600	68480
120	112，300	12，980	1032	428，000	34，2400

Note: 6240 hours per year is based on 24 hours a day, 5 days a week; the electricity bill is based on 0.8 yuan/kWh

How to prevent and solve spray problems?

In any application, the first and most important step is to choose the nozzle. Secondly, it is also a very important step to establish a nozzle maintenance plan to test the performance of the nozzle, so that the required application parameters can be well maintained. Each application has its own specific requirements, and the performance parameters of the nozzles also have their order of requirements. For example, in certain spray applications, the nozzle has only one purpose. This purpose only requires spraying a certain amount of liquid into the tank; and in some applications, it is necessary to ensure that the flow rate of the nozzle is accurately maintained at a certain level.

　Application factors to be considered

　Flow-each nozzle

　Spray pressure-on a spray pipe

　Spray shape-each nozzle

　Product quality-provided by the quality management department

　Using effect-in dust control; spray drying; flue gas cooling; water cooling; spray humidification, etc.

　The maintenance plan for each nozzle should only consider the important factors in a particular application. In the entire maintenance plan, we must also consider nozzle cleaning system and method regulations; nozzle replacement time regulations; and other factors related to spraying. Finally, the person responsible for the nozzle repair plan must be designated to make the repair plan stick to the implementation.