Specially-Constructed FloMax® Boquillas Atomizadoras de Aire Withstand Corrosive Sulfuric Acid Manufacturing Process
 Costly Maintenance Downtime Eliminated
Air atomizing nozzles are frequently used in the re-manufacturing of sulfuric acid. The process involves burning off impurities of weak sulfuric acid in a large vessel thereby producing concentrated sulfuric acid. The manufacturing environment, the high temperatures of up to 1850°F (1010°C) and the acid result in a particularly hostile environment which is very corrosive to the spray nozzles.
PROBLEM: The existing air atomizing spray nozzles from a competitive supplier were coated in a corrosive-resistant alloy. However, even a slight coating blemish would cause the sulfuric acid to erode the spray nozzle from the underside. As a result, expensive spray nozzles had to be replaced every other day.
To reduce the frequent and costly nozzle replacement, the company purchased special welding rods. These rods were used to re-build the nozzle caps. However, this process required cooling the vessel, a process which took 6 to 7 hours. Then, once the nozzles were repaired or replaced, it took several hours to re-heat the vessel to its operating temperature.
SOLUTION: The company searched for an answer to this costly problem. They contacted Spraying Systems Co. who recommended the use of FloMax air atomizing nozzles. The FloMax air atomizing nozzles offered a unique advantage. The special ordered nozzles were constructed completely of corrosive-resistant Hastelloy®. Since it is a solid piece of Hastelloy, versus just a coating, the nozzle's wear life is extended. This reduced the frequent shutdown for nozzle replacement. In addition, all wetted parts are constructed of silicon carbide furthering the nozzle's wear life.
Although the nozzle unit cost is higher, the savings from extended wear life more than offsets the cost of the nozzles.
Hastelloy is a registered trademark of Haynes International, Inc.
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