Cleaning Mist Nozzles: How to Clean Mister Nozzles

 

Misting Nozzle

Many industries rely on misting nozzles to provide cooling to certain processes. In industrial metal manufacturing, misting is used to cool the metal's strand in a controllable way to assist in maintaining the desirable properties in the cast metal. When using water from tanks or main water lines, the water may contain sediment and limescale. These materials travel through the water pipes and into the nozzle, where they become deposited. In time, the sediment and limescale builds up and blocks the openings of the misting nozzle.

Cleaning the misting nozzle ensures that the water can move unimpeded into the nozzle and onto the application at the desired flow rate and droplet sizes. At Lechler, we offer several types of air mist nozzles for continuous casting processes when operations require secondary cooling methods. Learn about how to clean out your misting nozzles to ensure optimal performance.

How to Clean and Fix a Clogged Misting Nozzle

If your misting nozzle is clogged, you want to remove the nozzle from off the misting system. If the deposits are not caked and attached tightly to the metal surface, you can tap the nozzle on the hard surface gently and then rinse out the buildup debris using clean water. However, if the hard water deposits cannot be removed with a simple rinse, you can use several different cleaning solutions.

Cleaning solutions can consist of either CLR or white vinegar. You want to dilute both mixtures with water in a container. Next, you want to remove the O ring so it does not become damaged by the cleaning solutions. Drop the misting nozzle into the cleaning solution and let it sit for about 45 minutes to an hour until the hard calcium dissolves away or falls off. Next, run the misting system to flush out the lines. Then place the O ring back onto the misting nozzle and attach the nozzle back onto the misting system.

Before replacing the misting nozzle onto the system, check the nozzle for any signs of damage or worn areas. There may be signs of wear on the O ring, which would need to be replaced.

How Do You Remove O Ring from Misting Nozzle?

The O ring is a flexible piece of elastomer that goes over the nozzle's fitting when it is screwed into the misting system. This O ring is designed as a seal to prevent water from leaking at this joint. However, age, and constant use of the nozzle can cause the O ring to wear out or break. So you want to remove the O ring and replace it with a new one when performing regular maintenance. Also, you should always remove the O ring before cleaning the misting nozzles to prevent the cleaning solution from damaging the elastomer material.

You will need a small flat head screwdriver. Remove the misting nozzle from the system and set it on a flat surface. Place the flat end of the screwdriver gently between the area where the O ring and the metal meets. Lift upward and the O ring should slip off.

If the O ring is still in good shape, place it back on the misting nozzle. Otherwise, replace the O ring with a new one of the same size. The new O ring will be slightly loose compared to the older one. This looseness is normal as the O ring will become compressed when you tighten the misting nozzle back onto the misting system.

Why is My Mister Not Spraying?

It is possible that there is a clog within one of the pipes or tubing leading to the misting system. You will want to flush out the system without the misting nozzle attached to determine if the issue is with must the nozzle or with the mister itself. Another problem could be that a piece of metal on the nozzle partially flaked off. So it may block the holes to the misting nozzle. Using a pin vise or a wire brush may help to remove the metal flake.

If your misting system has a filter, the filter may be clogged with debris and hard calcium buildup. You want to remove the filter based on the manufacturer's instructions and take the dirty filter from the housing. You can wash off the filter of the buildup or replace the old filter with a new one. Put the new filter back into the filter housing and replace the filter housing back onto the misting system.

After performing this maintenance and still experiencing problems with the mister not spraying, the issue may involve having low water pressure that is causing the water to not move through the line at the right rate. Check the misting system settings and the main water line or pressurized tank. You may have to readjust the pressure or perform maintenance on these systems to get the water pressure to the appropriate level.

Benefits to Clean Mist Nozzle System

You should make a cleaning schedule for your mist nozzles to ensure they are operating at their fullest potential and to extend the life of your nozzles. When a misting nozzle becomes clogged, it impacts the flow rate of the mist coming out of the system. This factor can ruin applications and cause the nozzle to become damaged in time.

If only part of the nozzle is blocked, it could send redirect the water mist in a different angle, which could only partially cool the application or not cool the entire application. If running a full production line at rapid speeds, numerous applications and products could be created of lesser quality that will have to be scrapped. This problem causes a large amount of waste and unnecessary large expenses. It can also through off production deadlines.

Here at Lechler, we offer spray nozzle technologies, including air mist nozzles, for various industries. Learn more about our nozzles and additional services by contacting our company today.