Rotary atomizer

Types of rotary atomizers

A rotary atomizer is a device that breaks up liquid feed into a thin film and jets it into fine droplets. Four common types of rotary atomizers are called disk, spray, nozzle, and drum atomizers.

• Disk rotary atomizer:

  The disk rotary atomizer uses the centrifugal force generated by the rapid rotation of the disk to rupture the liquid film, thus scattering fine droplets into the surrounding space. The design of the atomizer is simple, and it is easy to manufacture and maintain. The atomizer can adapt to different working environments and requirements by changing the size and rotating speed of the disk. This kind of atomizer is widely used in agricultural plant protection, chemical industry, and painting industry.

• Spray rotary atomizer:

  The spray rotary atomizer is a device that uses the centrifugal force generated by the rotation of the atomizer to spray fine liquids. The atomizer has a simple structure and is relatively easy to manufacture. Additionally, it can atomize various types of liquids, including water, oil, and chemical solutions. The atomizer works by feeding the liquid into the atomizing cup, where it is rotated at high speed. Under the action of centrifugal force, the liquid is atomized into fine droplets that are sprayed outward.

• Nozzle rotary atomizer:

  The nozzle rotary atomizer is an atomizer that uses the centrifugal force generated by the rotation of the nozzle to atomize the liquid. The rotational speed of the nozzle can adjust the size and dispersion of the atomized particles. Moreover, the atomizer can operate at high pressures. Thus, it is suitable for different working environments and application fields. The nozzle rotary atomizer has high production efficiency and can meet large-scale processing requirements. It is widely used in industrial production and agricultural fields.

• Drum rotary atomizer:

  The drum rotary atomizer is a device that uses the centrifugal force generated by rotating the drum to atomize the liquid. The design of the atomizer is simple, and the manufacturing process is convenient. The atomizer can atomize various liquids, including water, oil, and chemical solutions, and it can meet different production needs by adjusting the parameters. The atomizer has high efficiency and low energy consumption, which can save production costs for enterprises.

Specifications and maintenance of rotary atomizers

An atomizer's specifications differ based on the industry application and type. However, some standard specifications are based on the food-processing industry.

• Capacity: An atomizer's capacity is the volume of liquid it can spray in a given time. The model will determine whether the capacity is thirty to a thousand liters per hour.
• Fan diameter: The fan diameter is the average spread of the sprayed liquid. Depending on the model, it can vary from 1 to 3 meters. The atomizer will use a smaller fan diameter to spray a more concentrated liquid, such as pesticide or paint.
• Power: The atomizer's driving motor uses AC or DC power of a specific voltage. For example, a large atomizer may use 2.5 kWh of rotary motor power to spray liquids efficiently. The motor's power will determine the rotation speed and liquid atomization.
• Weight: An atomizer can weigh from 5 kg to over 50 kg, depending on the material used and the components.
• Operating temperature: An atomizer can operate in temperatures ranging from -20 degrees C to 60 degrees C. It may be exposed to the sun and need to atomize liquid at high temperatures, such as spraying water on crops.
• Materials: Atomizers are made of various materials, including stainless steel, nylon, copper, and alloy materials. AC motors, for example, are often made of nylon, which is lightweight, easy to install, and resistant to corrosion.

Maintaining a rotary atomizer is essential to ensure its efficient functioning, long life, and consistent performance. Regular checking, cleaning, lubrication, part replacement, and timely repair of the atomizer should be part of its maintenance process. Here are some essential maintenance tips:

• Operating manual: Before starting the atomizer, read the manufacturer's operating manual. The manual will include details about the specific model and precautions.
• Cleaning: Before atomizing, the equipment should be cleaned to remove any residue or impurities. Cleaning also helps prevent clogging, dirt build-up, and corrosion.
• Lubrication: The moving parts of the atomizer should be regularly lubricated to minimize friction and wear. Lubrication improves the machine's operating accuracy, reduces power consumption, and extends its lifespan.
• Checks: The atomizer and its accessory parts should be regularly checked for wear, traction, loosening, damage, and leakage.
• Consumable parts: Dust rings, filters, and spray nozzles are the atomizer's consumable parts. They show signs of wear after frequent use and should be replaced.
• Repairs: Any damage to the atomizer or abnormality in its functioning should be repaired promptly. Delaying repairs can result in further damage and expensive repair costs.

Uses of rotary atomizers

As a machine widely used in industrial and agricultural fields, the rotary atomizer covers a variety of application scenarios.

• Agriculture:

  In the agriculture industry, rotary atomizers are used for crop protection and farm management. Powered by tractors or through self-propelled mechanisms, they efficiently spraying pesticides, fungicides, herbicides, fertilizers and other liquids onto crops. By atomizing the liquids into fine droplets, rotary atomizers ensure even coverage on plant surfaces, including leaves, stems, and fruits, which promotes disease control, pest management, and nutrient optimization.

• Painting and Coating:

  In the painting and coating industry, rotary atomizers play a crucial role in applying a wide range of coatings. Whether it's automotive coatings, industrial equipment coatings, furniture varnishes, or architectural paints, these atomizers ensure uniform and efficient coating application. Rotary atomizers atomize the coating materials into fine particles that provide complete coverage and a smooth finish. This not only improves the appearance and durability of coated objects but also enhances resource utilization.

• Powder Coating Recovery Systems:

  Powder coating recovery systems utilize rotary atomizers for effective application and recovery of powder coatings. Rotary atomizers apply electrostatically charged powder coating onto grounded workpieces, creating a coating with excellent adhesion and durability. After coating, the overspray powder is reclaimed by suction systems equipped with rotary atomizer to separate atomized powder from overspray. This enables the re-coating of overspray powder, improving material utilization and reducing waste.

• Pharmaceuticals and Biotechnology:

  The rotary atomizer plays a crucial role in the field of pharmaceuticals and biotechnology by assisting in the process of spray drying. This technology is extensively utilized in the production of pharmaceutical powders, biotechnology products, and food additives. By atomizing the liquid into tiny droplets and accelerating the evaporation of solvent through heated air, the rotary atomizer achieves the formation of solid particles. It offers benefits such as precise control over particle size and exceptional product purity.

• Air Quality Management:

  In the area of air quality management, rotary atomizers are utilized in dust suppression and wet scrubber systems. Dust suppression refers to the control of airborne particulate matter in order to reduce the impact of blowing dust, improve air quality and protect human health. By atomizing liquids such as water or chemical additives into fine droplets, rotary atomizers reduce atmospheric dust and enhance environmental conditions. In wet scrubber systems, they are used to abate gas emissions and control air pollution. The atomizers atomize reactive liquids or absorbents to treat industrial waste gases, facilitating the removal of pollutants through chemical reactions or adsorption processes, thereby improving air quality.

How to choose rotary atomizers

Here are some factors to consider when choosing a rotary atomizer:

• Nature of the Product to Be Sprayed

  Choose an atomizer compatible with the product to be atomized, considering factors like viscosity, density, acidity, temperature, concentration, and liquid-to-gas ratio. For example, a perfume rotary atomizer will be different from a paint rotary atomizer.

• Atomizer Specifications

  Consider essential atomizer specifications such as droplet size, flow rate, pressure range, capacity, and spray pattern. Ensure the selected atomizer meets specific requirements for optimal performance.

• Source of Power

  Rotary atomizers can be electrically, pneumatically, mechanically, or hydraulically driven. Choose the atomizer's driving power according to the applicable environment and product requirements.

• Ease of Use

  Consider factors such as installation and adjustment, cleaning and maintenance, operational safety, and the need for additional equipment. Choose an atomizer that is easy to use and maintain.

• Cost

  When choosing a rotary atomizer, it is essential to balance cost and performance to select an atomizer that offers good value for money.

Q&A

Q1 What is the difference between atomizer and rotator atomizer?

Atomizer refers to a device used to create or generate atoms, which are tiny particles or droplets. An atomizer can be喷雾器，喷雾器，喷雾装置，进程设备，药物装置，疫苗输送装置，食油输送装置；Rotary atomizer, also known as a rotating atomizer, is a specific type of atomizer that uses rotation to atomize liquids. It is commonly used in industrial processes, agriculture, and healthcare. Rotary atomizers spray liquid by spinning them, which then breaks the liquid into small droplets. They are used in places like crop spraying, coating production, and oil refining. Rotary atomizers are great for evenly distributing liquids over large areas.

Q2 How does a rotary atomizer work?

When working, the rotary atomizer first feeds the liquid into the atomizer from the feed system, which can be a feed pump or a feed tank. Then, through the high-speed rotation of the rotor, the liquid is spread to form a thin film on the surface of the atomizer. Finally, due to the centrifugal force, the thin film is broken into fine droplets and sprayed into the air.

Q3 What are the advantages of rotary atomizers?

Rotary atomizers possess numerous advantages that make them ideal for a variety of industrial applications. One of these benefits is their ability to provide consistent spraying patterns. Rotary atomizers are able to create even droplet distributions, which leads to greater coating uniformity and improved product quality. In addition, they offer flexible handling of liquid products. Rotary atomizers can be used on a large scale with high throughput capabilities. They are also able to process liquids with varying viscosities, including those that leave behind residues and are abrasive.

Q4 What are the disadvantages of using a rotary atomizer?

One of the major drawbacks of rotary atomizers is their maintenance requirements. Compared to static atomizers, which are relatively low-maintenance, rotary atomizers require regular upkeep to ensure optimal performance and extend the lifespan of the equipment. This can be a burden for some users who prefer hassle-free devices. Another downside is the cost of replacement parts and servicing. The need for periodic replacement of components and the cost of servicing can add up over time, making it more expensive in the long run compared to static alternatives.