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SPRAY NOZZLES FOR INJECTION OF FLUIDS

SENIOR DEVELOPER

Spray nozzles used for injecting additives into gas flows or other fluid streams are designed for precision and efficiency. Typically, these applications require small volumes of additives to be sprayed, but complete mixing must occur rapidly. When selecting nozzles for injection applications, various engineering factors must be considered to ensure optimal performance.
Sprays over Liquid Streams

Advantages of Using Sprays over Liquid Streams

Sprays, as opposed to continuous liquid streams, allow for greater control during heating or cooling processes. Nozzles significantly increase the surface area of the injected liquid, enhancing heat transfer and system efficiency. This results in reduced energy waste and improved overall performance.
Spraying Thick Liquids

Spraying Thick Liquids – Challenges & Solutions

Viscous fluids such as lubricants can pose challenges for spraying, particularly with air atomizing nozzles. The interaction of compressed air with thick liquids may lead to clogging issues. Using external mix air atomizing nozzles, where air is introduced after the liquid exits the nozzle, can effectively reduce clogging risks.


Injection into Liquids vs. Gases – Choosing the Right Nozzle

Whether the additive is being sprayed into a liquid stream or a gas stream influences the nozzle design. In liquid streams, nozzles that depend on surface impingement (twist or impingement designs) are unsuitable, as they fail to create a spray pattern once submerged. Instead, direct spray nozzles that maintain their pattern under immersion should be used.

Operating in Aggressive Conditions

Often, injection takes place in harsh environments — such as hot, chemically reactive, or corrosive gas or fluid streams. In such cases, the nozzle material must be compatible with these conditions. Synergy offers a wide range of nozzles manufactured from heat-resistant and corrosion-resistant materials to handle such environments reliably.

Spray Pattern & Flow Rate Considerations for Injection Applications

When a liquid is injected into a flowing gas or liquid stream, natural mixing will occur over time. However, faster and more uniform mixing can be achieved with finely atomized sprays and well-distributed spray patterns. In continuous flow systems, complete mixing may be required within a certain downstream distance — making nozzle selection critical.

Adjusting spray angle or achieving finer atomization can help improve dispersion, especially when injecting small volumes. Nozzle selection plays a key role in controlling these parameters to ensure rapid and efficient blending.

Low-Volume Injection Applications

For applications where only small amounts of additives are needed, maintaining low flow rates is essential. However, effective mixing at low volumes still demands fine atomization — which typically requires high pressure and, paradoxically, higher flow capacity. Choosing the right nozzle that balances both requirements is vital.

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