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Comparison between Two-Fluid Ultrasonic Spray Humidification Systems and High-Pressure Micro-Mist Humidification Systems
Release time:
2023-04-28 09:46
Source:
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Two-fluid ultrasonic spray humidification system |
High-pressure micro-mist humidification system |
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Project/Type |
Two-fluid ultrasonic spray humidification system |
High-pressure micro-mist humidification system |
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Humidification Principle |
Mist humidification (isenthalpic humidification) |
Mist humidification (isenthalpic humidification) |
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Working principle |
Compressed air passes through a Venturi tube and strikes the water flow vertically, atomizing the water into tiny droplets that are ejected from the spray nozzle at an ultra-high velocity approaching the speed of sound. It once again directly impacts the ultrasonic resonance amplifier positioned at the nozzle’s front end, generating an ultrasonic resonance phenomenon. Achieve secondary atomization, thereby achieving the purpose of cooling and humidifying. |
The water is pressurized to around 5 MPa by a high-pressure pump and then sprayed out through a specially designed nozzle. Generate mist droplets around 20 micrometers in size, which mix with the air. Humidification is achieved through thermal and moisture exchange. |
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Spray particle size |
Compressed air is mixed with water to create an atomized mist, resulting in very small particle sizes (mostly between 5 and 10 microns). Visible to the naked eye (with video) |
It relies solely on water pressure for atomization, resulting in relatively large particle sizes (mostly around 20 microns). Visible to the naked eye (with video) |
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Humidification efficiency |
High, around 75% |
Higher, around 60% |
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Air enthalpy Absorption distance |
Sufficient air enthalpy is required; Sufficient absorption distance is required; |
Sufficient air enthalpy is required; Sufficient absorption distance is required; |
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Water quality requirements |
Pure water (deionized water); if the on-site environment permits the use of ion-containing water, Municipal tap water with a filtration level of 5 microns or higher can also be used. Using pure water (deionized water), the equipment requires virtually no maintenance. |
Pure water (deionized water) must be used; The nozzle orifice diameter is only about 0.1 to 0.3 mm, and the water supply containing ions can easily clog the nozzle due to scaling. |
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Use water pressure |
The pressure requirement is greater than 3 bar; the higher the water pressure, the better. The higher the water pressure, the greater the amount of water atomized. The higher the water pressure, the lower the unit air consumption required per unit of water for atomization. |
2~6 Bar |
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Motor |
Not needed |
Need |
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Compressed air |
Need |
Not needed |
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Control method |
Proportional control or on-off control. Because the system primarily consists of proportional water flow control valves and on/off air valves, It consists of a water-gas valve assembly with a fixed differential pressure function and adjustable ultrasonic atomizing nozzles. By controlling the water flow rate and the pressure difference between the water flow and the air, direct proportional control is achieved. Not only does it ensure proportional control and atomization quality, but it also genuinely saves compressed air, achieving the goal of energy conservation. |
Control, or several sets of on-off control (segmented proportional control). Divide the number of nozzles into several groups, with each group controlled by a single on-off solenoid valve. Open the corresponding number of solenoid valves according to the signal magnitude to achieve segmented proportional control. |
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Main components |
Proportional control box, water-gas valve assembly with fixed differential pressure function, and adjustable ultrasonic atomizing nozzles with backflushing function, among others. |
Motor, high-pressure plunger pump, high-pressure solenoid valve, frequency converter, water tank, pressure sensor, micro-mist nozzle, and others. |
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Reliability Stability |
Only medium-pressure compressed air (operating pressure 4 bar) and low-pressure water supply (operating pressure greater than 3 bar) are required. The nozzle orifice diameter is 2.5–3.0 mm, and compressed air is used for auxiliary atomization. Additionally, the nozzle features a backflushing function, making it less prone to clogging. |
Because it uses water pressure of around 50 kilograms, the nozzle has a high wear rate. The nozzle orifice diameter is 0.1–0.3 mm and is prone to clogging. |
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Construction and installation |
It features quick-connect fittings for simple, convenient, and rapid installation. Small in size, it can be mounted on air handling unit panels or walls, saving installation space. |
Due to the high water pressure, the piping system has very strict installation requirements. It is bulky and cannot be mounted; it requires a large installation space. If used in conjunction with ceiling-mounted air conditioning systems in the attic space, a dedicated operating platform needs to be constructed. |
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Maintenance, consumables |
Meets usage requirements with virtually no maintenance needed. |
Oil and nozzles need to be replaced regularly, and the equipment requires inspection, cleaning, and maintenance. |
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Lifespan |
Long-lasting (4–6 years), no consumables. |
The nozzle needs to be replaced; the engine oil must be changed regularly. If it is not changed in a timely manner, the high-pressure plunger pump could be damaged. |
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Warranty |
Two-year warranty provided. |
One-year warranty provided. |
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Usage cost |
Requires medium-pressure compressed air. |
Due to its relatively low humidification efficiency, there is significant waste of water resources. |
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It is recommended to choose. |
There is ample medium-pressure compressed air available on site; it is recommended to select this option. |
The humidification demand is very high (over 200 kg/h), and there’s no compressed air available on-site. We recommend using... |
Conclusion:
1. The nozzle aperture used in high-pressure micro-mist humidification systems ranges from 0.1 to 0.3 mm. Such nozzles are highly susceptible to clogging by scale, so only pure water can be used. In contrast, the nozzle aperture used in dual-fluid ultrasonic misting systems is 2.5 to 3 mm—considerably larger than that of micro-mist nozzles. Moreover, these systems employ compressed air to assist atomization and feature a back-flushing function, making their nozzles much less prone to clogging. As a result, the requirements for water quality are not as stringent as those for micro-mist nozzles; municipal tap water with a filtration level of 5 microns or higher can be used without issue. If pure water is available on-site, maintenance can be virtually eliminated. For further comparison, please refer to the videos demonstrating the atomization performance of the nozzles for these two products. Although the high-pressure micro-mist humidification system uses imported ceramic nozzles, the water droplets produced are relatively large and are ejected almost in a straight line. On the other hand, despite the larger aperture of the nozzles used in the dual-fluid ultrasonic misting system, the atomized droplets can be clearly seen floating in the air. Thus, it’s evident that the micro-mist system has lower humidification efficiency compared to the dual-fluid ultrasonic misting system.
2. The high-pressure micro-mist humidification system uses a high-pressure plunger pump, which requires frequent oil changes. If the oil is not changed in a timely manner, the high-pressure plunger pump could be damaged. Therefore, maintenance personnel at the user’s site must demonstrate a high degree of responsibility.
3. Understand the system’s actual configuration and performance: Micro-mist systems are not true proportional control systems; rather, they employ on-off control—or a combination of several on-off control stages.
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Related applications
Offshore platform, ship, marine engineering, nuclear power, satellite launch center
To ensure worker comfort, enhance work efficiency, or prevent static electricity from interfering with the normal operation of equipment, it is essential to maintain appropriate temperature and humidity levels in the working environment. Typically, temperature control involves either cooling or heating. When cooling is required, some moisture is removed from the air; conversely, when heating is needed, the outdoor air often has a very low moisture content. Therefore, these environments invariably require humidification.
Humidifying the air can prevent damage to collectibles caused by the drying and cracking of fibers due to excessively low relative humidity from air conditioning. Many priceless manuscripts, books, artworks, floppy disks, magnetic tapes, and other items housed in museums—without being stored in spaces with proper temperature and humidity control—can easily suffer severe damage. However, environments suitable for these items often have lower temperatures, which can be uncomfortable for visitors. Generally, the lower limit for relative humidity for paper-based collections in museums is 40%; for items such as floppy disks and magnetic tapes, which need to be protected from drying out and becoming brittle, the lower limit is 36%. Organic collections, on the other hand, require even lower-temperature environments. Moreover, museum collections typically alternate between display areas and storage rooms; it’s important to note that even in environments with controlled temperature and humidity, heat conduction from outside walls or radiation from switching lights can still cause fluctuations in surface temperature, leading to moisture evaporation and structural damage to the collections. Furthermore, when a collection is moved from a cooler storage room into a warmer display area, its surface temperature gradually rises, causing internal moisture to migrate toward the surface and condense there—a phenomenon known as "moisture transfer." This process can accelerate the deterioration of the collection. The following temperature and humidity levels are recommended for museum environments:
Modern agricultural edible mushroom preservation and refrigerated food processing
The normal growth of edible fungi and other plants requires appropriate temperature and humidity conditions. To store foods such as fruits and vegetables, it is necessary to control the temperature and humidity of the air in order to maintain the quality and freshness of agricultural products. Generally, the humidity should be kept between 70% and 95% RH. Low relative humidity can lead to increased moisture loss in fruits, resulting in a decline in their quality grade and ultimately affecting profitability. In food processing—such as baking bread, cakes, and confectionery—both the production process and storage must prevent food cracking caused by excessively low relative humidity.
Data center computer room, programmable control room
Increased static electricity can easily damage integrated circuit chips. In data centers, preventing service interruptions is critical, and humidification systems must ensure both reliability and redundancy.
Spray painting workshop (for industries such as aerospace and automotive)
If the relative humidity of the air is too low, the adhesion of the paint will decrease. On the other hand, if the relative humidity is too high, the glaze layer sprayed onto the product may become excessively diluted, forming tiny liquid bubbles. As these bubbles evaporate during the drying process, they can lead to poor spraying results and the formation of fine pits on the sprayed surface.
Textile printing cigarette factory, wood processing, precision machining, detonator plant
Air humidification can prevent fiber cracking and static electricity caused by excessively low relative humidity in the air, thereby avoiding disruptions in the production process and ensuring good product quality. The recommended temperature and humidity levels are as follows:
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