The Sonicom nozzle tip is the core component of the Sonicom ultrasonic atomising system. Available in eight models, the range covers a wide variety of flow rates and spray patterns, from wide angle coverage to more forward projecting configurations, allowing the most suitable nozzle to be selected for each application.
The nozzle tip is available as a standalone component but requires either a non-drip valve or an adaptor to complete the installation. Details of both options are covered elsewhere in this section.
Operating principle
Sonicom nozzles are powered by compressed air, although steam can be used in certain applications. As air passes through the nozzle's inner bore, it accelerates through a convergent/divergent section at high velocity before expanding into a resonator cavity. Here it is reflected back to complement and amplify the primary shock wave, creating an intensified field of sonic energy concentrated between the nozzle body and the resonator cap.
Any liquid fed into this acoustic field is vigorously sheared into fine droplets, not by pressure, but by sound. The result is exceptionally consistent atomisation with none of the wear and blockage problems associated with high-pressure liquid nozzles.
Spray characteristics
Droplets leave the nozzle carried downstream by the bypassing airflow in a soft, controlled plume. Because they have low mass and low forward velocity, they exhibit low impingement characteristics, behaving very differently to pressure-atomised sprays. This makes Sonicom nozzles particularly well suited to humidification and dust suppression applications, where uniform distribution and minimal overspray are critical requirements.
Orifice design and service life
Sonicom nozzles operate at very low liquid pressures and feature large liquid orifices, typically many times larger than those found in comparable pressure nozzles. Orifice wear is virtually eliminated as a result, and the quality of atomisation does not deteriorate over time. Service life is significantly extended compared to conventional nozzle designs.
Flow range and turndown
One of the most significant advantages of the Sonicom system is its ability to maintain consistent atomisation quality across a wide range of flow rates. Turndown ratios of up to 50:1 are achievable, giving operators considerably greater flexibility than conventional nozzles allow.
By varying air and liquid pressures, droplet size can be adjusted from a coarse spray of 50 to 300 microns down to an ultra-fine dry fog of 1 to 10 microns, without changing the nozzle or interrupting the process.
Nominal operating pressures
For the majority of applications, optimum atomisation and spray pattern are achieved at 5 bar air pressure and 1 bar liquid pressure at the nozzle. These pressures can be adjusted to suit specific application requirements if needed.
