Spray bar clogging on a steel galvanising line
Spray bar clogging was interrupting production on the galvanising line of a major steel manufacturer in Ontario. Six spray bars cooled the product with recycled liquid pumped through a 3-inch header at 500 US gallons per minute, and its high load of dissolved solids and contaminants left deposits in the bars, nozzles and pipework. The bars were changed every three weeks and the supply line was reported 65% blocked. One HydroFLOW® i100 was fitted to the pump output line for a three-month trial. Supply-line clogging fell to 10%, the sprays had almost no deposits at three weeks, and no shutdowns or blockages were reported for the following year.
The Challenges
- Spray bar clogging meant all six bars were changed every three weeks
- The supply pipe was reported 65% blocked
- Nozzle and pipe blockages interrupted production
- Frequent mechanical and chemical cleaning was needed
- Maintenance was costing around $35,000 a year
The Solution
- Unit installed: one HydroFLOW® i100
- Installation point: output pipe downstream of the system pump
- System flow: 500 US gallons per minute through a 3-inch header
- Trial: three months on site, inspected every three weeks
To tackle spray bar clogging at the source, the i100 went on the output pipe after the system pump, so all the recycled liquid passed the unit before reaching the header and the six spray bars. The system was inspected every three weeks during the trial, and the deposits that remained were described as loose and fluffy rather than concrete-like.
