As sellers of dust and odour suppression systems, we get asked about air-atomising nozzle systems and what differentiates them from a conventional fan-assisted rotary atomiser system. We understand that our AtomisterAiro air-atomising nozzle system doesn't suit all situations, which is why we decided to make an in-depth comparison between air-atomising nozzle systems and conventional fan-assisted rotary atomisers to highlight the key differences between them.

We hope that by the end of this article you'll understand the main factors that differentiate an air-atomising nozzle system from a fan-assisted rotary atomiser system so you can choose the best system for your site.

Let's review how air-atomising nozzle systems compare to fan-assisted rotary atomiser systems across the following categories:

1. Effectiveness of Dust Particle Capture
2. Coverage and Application
3. Safety Considerations
4. Environmental Impact
5. Flexibility
6. Price
7. Which Should I Choose?

Effectiveness of Dust Particle Capture

An Air-Atomising System Producing Extremely Fine Droplets

Fan-Assisted Rotary Atomiser Systems

Principle: Rotary atomiser systems employ spinning mesh disks to break down a liquid into tiny droplets. Fans then propel these droplets and disperse them to capture the dust particles or odour molecules through envelopment.

Dust Particle Capture: Rotary atomisers produce fine to moderately-sized droplets. While these droplets can capture dust particles, the variability in droplet size can lead to less consistent dust suppression. Larger droplets may not envelop smaller dust particles as effectively, reducing overall efficiency.

Air-Atomising Systems

Principle: Air-atomising systems rely on compressed air to shatter water droplets into finer, mist-like droplets. The compressed air is also used to propel and disperse the mist droplets to capture the dust particles or odour molecules through envelopment.

Dust Particle Capture: Air-atomising systems generate extremely fine droplets, often in the micron range. This precise control over droplet size enhances their ability to capture and suppress dust particles. The smaller, uniformly sized droplets can more effectively envelop and capture dust, leading to a more effective dust suppression performance.

Coverage and Application

A Rotary Atomiser System in an Outdoor Environment

Fan-Assisted Rotary Atomiser Systems

Proximity to Source: Rotary atomiser systems provide mist from one position, limiting the even distribution and effectiveness of the treatment. Rotary atomiser systems produce a heavier mist which can result in wetting when placed within close proximity. This may result in an increase in moisture content in sensitive areas and the unintentional binding of the material being treated. However, a fan-assisted rotary atomiser system may be more suited to an outdoor application where heavier wetting is preferred.

Wind Resistance: Rotary atomisers produce larger droplets that are less prone to wind dispersion than finely-atomised air-atomising mist.

Ideal Use: Rotary atomiser systems are typically well-suited for a wide range of applications, both indoors and outdoors, where moderate coverage is required. They provide more indiscriminate blanket coverage so are typically less effective for targeted treatment. They are more suited to outdoor treatment than air-atomising systems as they are less prone to wind dispersion.

Air-Atomising Systems

Proximity to Source: Air-atomising technology enables nozzles to be distributed around the source in multiple areas providing wide coverage and targeted treatment. The nozzles can also be mounted close to the dust or odour source as the air-atomising technology results in an ultra-fine mist with minimal wetting.

Wind Resistance: Air-atomising systems may struggle more in windy conditions, as their ultra-fine mist can be readily carried away by strong winds, potentially reducing their effectiveness outdoors.

Ideal Use: Air-atomising systems excel in indoor settings, especially where precise control and minimal moisture are essential. By using multiple air-atomising nozzles, they provide widespread and uniform coverage. Due to the use of a compressed air 'jet' rather than fan-induced movement, they are typically more efficient than rotary atomiser systems for targeted coverage or coverage in enclosed spaces.

Safety Considerations

An Air-Atomising System Producing Minimal Wetting in an Indoor Environment

Fan-Assisted Rotary Atomiser Systems

Electrical Hazards: Fan-assisted rotary atomiser systems may require electrical cabling routing around your building, in conjunction with the water supply, to power the atomisers. This increases the risk of electrocution or fire, necessitating careful routing and maintenance to prevent these electrical hazards. However, rotary atomising cannons also come as a part of some self-contained mobile dust suppression units, which have no requirement for fixed electrical cabling.

Slip Hazards: Rotary atomisers tend to distribute more water due to their design, which can create slip hazards in the immediate area. Adequate drainage and safety measures are essential to mitigate this risk.

Air-Atomising Systems

Electrical Hazards: Air-atomising systems typically have no electrical supply to the atomisers and only require an electrical supply to the central controls, reducing the risk of electrical hazards.

Slip Hazards: Air-atomising systems, due to their finer mist and lower water usage, tend to disperse less water, which can result in fewer slip hazards on surfaces. However, proper drainage and safety precautions are still recommended because the system can still increase humidity levels, especially in low temperatures.

Environmental Impact

A Rotary Atomiser System Producing Mist

Fan-Assisted Rotary Atomiser Systems

Water Efficiency: Fan-assisted rotary atomiser systems can vary in water consumption depending on the system's design but generally consume more water than air-atomising systems. This is because the quickly-rotating disk or wheel, which works using centrifugal energy, requires a high energy consumption for one kilogram of liquid compared to air-atomising systems.

Air-Atomising Systems

Water Efficiency: Air-atomising systems are known for their water efficiency, consuming only 1-10 litres/hour of water or fluid in the dust suppression process. Nozzles using air-atomising technology consume a much smaller volume of water or consumable product, such as an odour neutraliser. This is due to the mixture of air and water/consumable product needed to produce the finer mist being minimal in comparison to a system that works on the principle of centrifugal energy. This eco-friendliness can lead to long-term cost savings.

Flexibility

An Air-Atomising System For Use in a Number of Different Applications

Fan-Assisted Rotary Atomiser Systems

Mist Control: Fan-assisted rotary atomiser systems rotate giving wide coverage and the flow-rate can also be adjusted. This provides a good mist plume and treatment for just the area surrounding the fan, however, multiple areas cannot be treated simultaneously. Despite this, fan-assisted rotary atomiser cannons can also come as a part of some mobile dust suppression units which increases flexibility of use.

Air-Atomising Systems

Mist Control: The nozzles of air-atomising systems can be individually controlled, resulting in flexibility regarding how the mist plume can be applied. This increases the number of applications an air-atomising system is suited to, as groups of nozzles treating different applications can run simultaneously. Due to the fine droplet size, air-atomising systems are also excellent for neutralising odours. However, air-atomising nozzle systems, once installed, cannot be as easily repositioned in comparison to rotary atomiser cannons on mobile units.

Price

A Rotary Atomiser System Installed in an Indoor Environment

Fan-Assisted Rotary Atomiser Systems

A fan-assisted rotary atomiser system can be sold as an individual cannon which may seem like a cost-effective option. However, a set of multiple rotary atomising cannons is much more efficient in treating dust than one single rotary atomising cannon. A single rotary-atomiser cannon can only target dust from one source and has limited coverage and also limits the number of applications it is suitable for, as well as its effectiveness. The price of a set of rotary atomising cannons rivals that of a air-atomising nozzle system, depending on the options selected.

Air-Atomising Systems

Air-atomising nozzle systems are often sold in sets of multiple nozzles which enables treatment of the dust source from multiple angles or treatment of multiple sources at one time. In comparison to a single rotary atomiser, a set of air-atomising nozzles would cost more. However, this is balanced by the effectiveness of the treatment you receive when using multiple nozzles as opposed to one cannon, as well as the efficiency of the system.

Which Should I Choose?

Only you know the priorities for your site.

Carefully consider each characteristic to determine which system best suits your site and its dust suppression needs. Maybe you want to prioritise having a more effective, targeted treatment over a slightly more cost-effective solution. Or maybe you'd prefer a mobile system with the flexibility of movement and better wind resistance over a system that provides minimal wetting, excellent water efficiency and comes with long-term cost savings.

If you're still not sure, but you'd like further advice on which system is best suited for your needs, get in touch with our team or give us a call on +44 (0)1785 229300.