Proptec™ Air-Assisted Rotary Atomizer

Proptec™ & Penguin™ Rotary Atomizers

Hydraulic (Pressure) Nozzle

Air-Atomizing Nozzles

Clog Resistance

Virtually clog-proof.

Virtually clog-proof.

Highly sensitive to clogging.

Variable clog resistance.

Wear Resistance
(Flow Rate)

Wear does not affect flow rate.

Wear does no affect flow rate.

As nozzle wears, flow rate is largely affected.

Flow rate may be affected, depends on the design.

Wear Resistance
(Spray Pattern)

Wear does not affect spray pattern.

Wear does not affect spray pattern.

Wear highly degrades spray pattern.

Variable effects on spray pattern.

Small Droplet Spectra Applications

Good to a 50-micron average.

Good to a 50-micron average.

Works well with high pressure fogging nozzles. Many required for large quantities.

The best option for making large quantities of mist below 50 microns.

Medium Droplet Spectra Applications

The best option in the range of 60-150 micron.

The best option in the range of 60-150 micron.

Well-defined industry flow curves for nozzles within this range.

Average in this range, though spectrum may be wide with fine droplets.

Large Droplet Spectra Applications

Not advisable. Large droplets are not entrained in the airstream.

Functions well in applications requiring a radial spray pattern.

Well-defined industry flow curves for nozzles within this range.

Average in this range, though spectrum may be wide with fine droplets

Operational Life

Gets 1500-3000 hours on basket with mildly abrasive slurries, and nearly infinite hours with compatible fluids. Gets 8000+ hours on hydraulic motor if properly maintained.

Gets 1500-3000 hours on basket with mildly abrasive slurries, and nearly infinite hours with compatible fluids. Gets 8000+ hours on hydraulic motor if properly maintained.

Hours vary depending on the materials. Brass can be less than 100 hours, or ceramic nozzles can get 1000+ hours. Higher pressures reduce lifespan.

Long lifespan with compatible materials. Fluid exit nozzle is subject to abrasive wear.

Installation and
Start-Up Cost

Higher initial cost. May require high power hydraulic powersource, depending on model. Lower chemical pump cost. Fluid doesn't require high pressure for operation.

Higher initial cost. May require low power hydraulic powersource, depending on model. Lower chemical pump cost. Fluid doesn't require high pressure for operation.

Lowest initial cost, although may require a more expensive high-pressure pump. Often requires 3-8 nozzles to match capability of a single Proptec™ atomizer.

Highest initial cost. Requires continuous compressed air source and fluid pump. Often requires 3-8 atomizers to match capability of a single Proptec™ atomizer.

Operational and
Running Cost

Medium. Requires 1-6 horsepower per atomizer depending on airflow requirements. Consumable cost of eight cents per hour when spraying abrasives, four cents otherwise.

Low. Electric models consume 200-500 watts in operation, hydraulic models 800-1200. Consumable cost of eight cents per hour when spraying abrasives, four cents otherwise.

Requires low electricity to run the pump and nozzles replacement.

High. Compressed air is very expensive, and suffers a high amount of energy loss.

Maintenance

Basket may be removed and cleaned if residue accumulates, typically after hundreds of hours. Easy visual diagnosis of condition. Removal and replacement un under a minute. Change hydraulic filter seasonally, oil annually.

Basket may be removed and cleaned if residue accumulates, typically after hundreds of hours. Easy visual diagnosis of condition. Removal and replacement un under a minute. Change hydraulic filter seasonally, oil annually.

Very simple maintenance. Remove worn nozzle and replace, or clean if clogged. Difficult to visually diagnose wear until it becomes severe.

May require frequent maintenance to remove accumulated overspray. Can be as often as every 3-5 hours with some designs. Visual diagnosis of atomizer is difficult unless to make until condition is severe.

Comparative Air Volume

Up to 10,000 CFM (300 CMM) at velocities of 70 MPH (30 Meters Per Second.)

No air-assist.

No air-assist.

Low to medium volume. High velocities close to nozzle. Very low relative air volume (5-30 CFM).

Maximum Spray Distance

May carry over 100 feet in stationary applications. Will carry up to 30 feet in mobile applications depending on speed and configuration. Fan can be adjusted to increase or decrease air flow without affecting atomization.

Radial spray pattern of four to fifteen feet. Spray plume diffuses or travels with ambient air currents.

Gets 18-50 feet depending on nozzle and fluid pressure. Requires large droplets to carry any significant distance.

Gets 3-10 feet. Air diffuses rapidly from the nozzle. Tend to make small droplets that are carried by the air. Air volume and velocity cannot be adjusted without adversely affecting droplet spectrum.

Flow Range

Gets 0-6 gallons per minute, depending on configuration. All atomizers will atomize through entire rated flow range, which is independent of air volume.

Roughly 0-12 gallons per minute, depending on configuration. All atomizers will atomize through entire rated flow range.

Depends on nozzle type. Nozzles typically have narrow operational ranges. Slight variations in flow or pressure radically affect spray quality.

Depends on nozzle type. Nozzles typically have narrow operational ranges. Increases in fluid flow require adjustment of air to maintain consistency.

Noise Level

High. Up to 95 decibels.

Low. To 65 decibels.

Low. Variable.

High. Depends on nozzle design and air velocity.

Performance
(Viscous Fluids)

Able to spray fluids up to 10,000 CP.

Able to spray fluids up to 10,000 CP.

Viscosity radically degrades performance.

Viscosity can degrade performance.

Performance
(Abrasives)

Able to spray fluids with suspended agregate up to .05 inches (1.2mm) in diameter. Atomization not affected by basket wear.

Able to spray fluids with suspended agregate up to .125 inches (3.2mm) in diameter. Atomization not affected by basket wear.

Nozzle very limited by orifice size. Many nozzle materials highly erodable.

Nozzle often limited by orifice size. Many nozzle materials highly erodable, although wear is less of a factor here.

Performance
(Sensitive Materials)

Mechanical droplet formation minimizes interaction with ambient air, or can occur in controlled atmosphere. Relatively low fluid velocities inside atomizer preserve shear-sensitive fluids.

Mechanical droplet formation minimizes interaction with ambient air, or can occur in controlled atmosphere. Relatively low fluid velocities inside atomizer preserve shear-sensitive fluids.

Depends completely upon the nozzle type.

Potential for interaction and accelerated oxidation of droplets by compressed air (pyrolysis). Operation with compressed inert gasses can be costly.