{"id":7526,"date":"2025-01-28T13:42:10","date_gmt":"2025-01-28T04:42:10","guid":{"rendered":"https:\/\/www.dry-fog.com\/en\/?post_type=cases&#038;p=7526"},"modified":"2025-02-12T11:02:08","modified_gmt":"2025-02-12T02:02:08","slug":"nozzle-steel-001","status":"publish","type":"cases","link":"https:\/\/www.dry-fog.com\/en\/projects-technology\/cases\/nozzle-steel-001\/","title":{"rendered":"Extended Nozzle Lifespan with Wear-Resistant Materials: Reducing Maintenance Burdens"},"content":{"rendered":"<section>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<div style=\"margin-top:5rem;margin-bottom:3rem;width:100%;border-bottom:1px solid #E9E9E9\"><\/div>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<!-- \u82f1\u8a9e\u7248\u4eba\u7269\u4ed8\u304d\u3000\u3010\u304a\u554f\u3044\u5408\u308f\u305b\u306f\u3053\u3061\u3089\u30dc\u30bf\u30f3\u3011\u3053\u3053\u304b\u3089 --><\/p>\n<div style=\"float: left;padding-top:1.5rem;padding-left: 2rem\">\n<img decoding=\"async\" loading=\"lazy\" src=\"https:\/\/www.dry-fog.com\/jp\/wp-content\/uploads\/sites\/2\/2024\/10\/call-1.jpg\" alt=\"\" width=\"330\" height=\"296\" class=\"alignleft size-medium wp-image-5969\" \/>\n<\/div>\n<div style=\"float: right;margin-top: 4rem;margin-right: 3%\">\n<ul style=\"list-style-type: none;margin-left:0rem;font-size: 1.2rem;font-weight: bold;line-height:1.6rem\">\n<div style=\"margin-bottom:0.8rem;background:url(https:\/\/www.dry-fog.com\/jp\/wp-content\/uploads\/sites\/2\/2024\/10\/check.svg) no-repeat 0 0;background-size:auto 20px;padding-left: 30px\">\n<li>Not sure which product is right for you?<\/li>\n<\/div>\n<div style=\"margin-bottom:0.8rem;background:url(https:\/\/www.dry-fog.com\/jp\/wp-content\/uploads\/sites\/2\/2024\/10\/check.svg) no-repeat 0 0;background-size:auto 20px;padding-left: 30px\">\n<li>Curious about the total cost?<\/li>\n<\/div>\n<div style=\"margin-bottom:0.8rem;background:url(https:\/\/www.dry-fog.com\/jp\/wp-content\/uploads\/sites\/2\/2024\/10\/check.svg) no-repeat 0 0;background-size:auto 20px;padding-left: 30px\">\n<li>Wondering where to start?<\/li>\n<\/div>\n<div style=\"margin-bottom:0.8rem;font-size: 0.8rem;font-weight: bold;padding-left: 30px\">\n<li>We\u2019re here to help \u2013 reach out with any questions.<\/li>\n<\/div>\n<\/ul>\n<div style=\"text-align:center;margin-top:2rem;margin-bottom: 2rem\">\n<a style=\"margin-bottom:1rem;margin-left:2rem;justify-content: center;align-items: center;padding: 0.5rem 4rem;color: #fff;font-weight: 500;font-size:1.2rem;width:auto;background: #0C9B6F;border-radius: 30px\" href=\"https:\/\/www.dry-fog.com\/en\/contact\/\" target=\"_blank\" rel=\"noopener\">Contact Us<\/a>\n<\/div>\n<\/p><\/div>\n<div style=\"clear: both\"><\/div>\n<\/div>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto;margin-top:3rem;margin-bottom:3rem;width:100%;border-bottom:1px solid #E9E9E9\"><\/div>\n<p><!-- \u4eba\u7269\u4ed8\u304d\u3010Product Information\u30dc\u30bf\u30f3\u3011\u3068\u3010Contact Us\u30dc\u30bf\u30f3\u3011\u3053\u3053\u307e\u3067 -->\n<\/div>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<div style=\"text-align:center;font-size:1.2rem\">\n<h3 style=\"font-size: 1.2rem\">Case Study 1<\/h3>\n<\/div>\n<div style=\"margin-bottom:0.8rem;background:url(https:\/\/www.dry-fog.com\/jp\/wp-content\/uploads\/sites\/2\/2024\/10\/10px-45px.svg) no-repeat 0 0;background-size:auto 30px;padding-left: 20px\">\n<h3 style=\"font-size: 1.2rem\">Solutions or Products Featured in This Case Study<\/h3>\n<\/div>\n<ul style=\"list-style-type: disc;margin-left:2.8rem;font-size: 1rem;line-height:1.6rem\">\n<div style=\"margin-bottom:0.8rem\">\n<li><a href=\"https:\/\/www.dry-fog.com\/en\/products\/noz-hyd-ajp-al92\/\" style=\"color: #00a273\">Alumina Ceramic Full Cone Spray Nozzles (92% Alumina) | AJP-AL92 Series<\/a><\/li>\n<\/div>\n<\/ul>\n<p><img decoding=\"async\" loading=\"lazy\" src=\"https:\/\/www.dry-fog.com\/en\/wp-content\/uploads\/sites\/3\/2024\/07\/ajp-al92_2.jpg\" alt=\"\" width=\"1600\" height=\"500\" class=\"aligncenter size-full wp-image-5966\" \/><\/p>\n<div style=\"margin-bottom:0.8rem;background:url(https:\/\/www.dry-fog.com\/jp\/wp-content\/uploads\/sites\/2\/2024\/10\/10px-45px.svg) no-repeat 0 0;background-size:auto 30px;padding-left: 20px\">\n<h3 style=\"font-size: 1.2rem\">Key Reasons for Implementation<\/h3>\n<\/div>\n<ul style=\"list-style-type: disc;margin-left:2.8rem;font-size: 1rem;line-height:1.6rem\">\n<div style=\"margin-bottom:0.8rem\">\n<li>Switching to spray nozzles made from highly wear-resistant materials achieved an extended lifespan.<\/li>\n<\/div>\n<div style=\"margin-bottom:0.8rem\">\n<li>The selected nozzles proved to operate reliably in harsh environments.<\/li>\n<\/div>\n<div style=\"margin-bottom:0.8rem\">\n<li>Even after three months of use, the nozzles demonstrated no significant deterioration in appearance or performance.<\/li>\n<\/div>\n<\/ul>\n<\/div>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<div style=\"margin-bottom:0.8rem;background:url(https:\/\/www.dry-fog.com\/jp\/wp-content\/uploads\/sites\/2\/2024\/10\/10px-45px.svg) no-repeat 0 0;background-size:auto 30px;padding-left: 20px\">\n<h3 style=\"font-size: 1.2rem\">Challenges Faced by the Customer<\/h3>\n<\/div>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">At a sintering plant in a steelworks, <span style=\"font-weight:bold;font-size: 1rem\">significant wear on the spray nozzles used for spraying slurry<\/span> inside the drum mixer had become a major concern.<\/p>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">Iron ore, coke fines, and lime\u2014the raw materials for sintered ore\u2014are mixed in a drum mixer and granulated to a size suitable for sintering before being fed into the sintering machine. During this process, spray nozzles are used to apply slurry, enhancing granulation efficiency.<\/p>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">However, the powdered iron oxide in the slurry caused significant wear on the nozzles. After being replaced with new ones, the nozzles were severely damaged and became unable to spray properly after only 300 hours (about one month) of use.<\/p>\n<div style=\"margin: 1rem, 0\">\n<img decoding=\"async\" src=\"https:\/\/www.dry-fog.com\/en\/wp-content\/uploads\/sites\/3\/2024\/07\/noz-AJP-AL92-case1_1R.png\" alt=\"\" width=\"820\" class=\"aligncenter size-full wp-image-6304\" \/>\n<\/div>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">Consequently, the drum mixer had to be shut down every month for nozzle replacement, substantially increasing the burden of maintenance and upkeep. In search of <span style=\"font-weight:bold;font-size: 1rem\">spray nozzles capable of maintaining a long lifespan even in harsh environments<\/span>, the customer reached out to us for a solution.<\/p>\n<\/div>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<div style=\"margin-bottom:0.8rem;background:url(https:\/\/www.dry-fog.com\/jp\/wp-content\/uploads\/sites\/2\/2024\/10\/10px-45px.svg) no-repeat 0 0;background-size:auto 30px;padding-left: 20px\">\n<h3 style=\"font-size: 1.2rem\">Proposals from IKEUCHI<\/h3>\n<\/div>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">The nozzles previously in use were made of stainless steel 303 (SUS303). To maintain the same performance while greatly enhancing wear resistance, we proposed switching to the AJP-AL92 series, crafted from alumina ceramic with a 92% purity, which <span style=\"font-weight:bold;font-size: 1rem\">offers far superior wear resistance<\/span> compared to SUS303.<\/p>\n<p><img decoding=\"async\" src=\"https:\/\/www.dry-fog.com\/en\/wp-content\/uploads\/sites\/3\/2024\/07\/noz-AJP-AL92-case1_2R_E.png\" alt=\"\" width=\"820\" class=\"aligncenter size-full wp-image-6304\" \/>\n<\/div>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<div style=\"margin-bottom:0.8rem;background:url(https:\/\/www.dry-fog.com\/jp\/wp-content\/uploads\/sites\/2\/2024\/10\/10px-45px.svg) no-repeat 0 0;background-size:auto 30px;padding-left: 20px\">\n<h3 style=\"font-size: 1.2rem\">Benefits Achieved<\/h3>\n<\/div>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">The switch to the AJP-AL92 series was promptly implemented, and an interim inspection conducted after 150 hours of use revealed no signs of deterioration in either the nozzles&#8217; appearance or performance. A final inspection three months later also demonstrated no significant changes in appearance or performance, confirming that the <span style=\"font-weight:bold;font-size: 1rem\">nozzle lifespan had more than tripled<\/span> compared to the previous model. This resulted in a substantial reduction in maintenance and upkeep burdens.<\/p>\n<\/div>\n<p><!-- \u3010Product Information\u30dc\u30bf\u30f3\u3011\u3068\u3010Contact Us\u30dc\u30bf\u30f3\u3011\u3053\u3053\u304b\u3089 --><\/p>\n<div style=\"max-width: 800px;margin-left: auto;margin-right: auto;margin-bottom:1rem\">\n\t<span><\/p>\n<div class=\"page-bottom_contacts\" style=\"float: left;padding-top:0;padding-bottom:0\">\n<div style=\"margin-left: 1rem;margin-right: 1rem\">\n<div style=\"text-align: center\"><a class=\"content-ttl__sub\" style=\"margin-bottom: 1rem;justify-content: center;align-items: center;padding-top: 1rem;padding-bottom: 1rem;color: #fff;font-weight: 500;font-size: 1.2rem;background: linear-gradient(20deg, rgba(31,207,158,1) 0%, rgba(27,217,168,1) 35%, rgba(19,222,173,1) 100%);border-radius: 10px\" href=\"https:\/\/www.dry-fog.com\/en\/products\/noz-hyd-ajp-al92\/\" rel=\"noopener\">Product Information<\/a><\/div>\n<\/p><\/div>\n<\/p><\/div>\n<div class=\"page-bottom_contacts\" style=\"float: right;padding-top:0;padding-bottom:0\">\n<div style=\"margin-left: 1rem;margin-right: 1rem\">\n<div style=\"text-align: center\"><a class=\"content-ttl__sub\" style=\"justify-content: center;align-items: center;padding-top: 1rem;padding-bottom: 1rem;color: #fff;font-weight: 500;font-size: 1.2rem;background: linear-gradient(20deg, rgba(31,207,158,1) 0%, rgba(27,217,168,1) 35%, rgba(19,222,173,1) 100%);border-radius: 10px\" href=\"https:\/\/www.dry-fog.com\/en\/contact\/\" rel=\"noopener\">Contact Us<\/a><\/div>\n<\/p><\/div>\n<\/p><\/div>\n<p>\t<\/span><\/p>\n<div style=\"clear: both\"><\/div>\n<\/div>\n<div style=\"margin-top:0rem;margin-bottom:3rem;width:100%;border-bottom:1px solid #E9E9E9\"><\/div>\n<p><!-- \u3010Product Information\u30dc\u30bf\u30f3\u3011\u3068\u3010Contact Us\u30dc\u30bf\u30f3\u3011\u3053\u3053\u307e\u3067 -->\t<\/p>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<div style=\"text-align:center;font-size:1.2rem\">\n<h3 style=\"font-size: 1.2rem\">Case Study 2<\/h3>\n<\/div>\n<div style=\"margin-bottom:0.8rem;background:url(https:\/\/www.dry-fog.com\/jp\/wp-content\/uploads\/sites\/2\/2024\/10\/10px-45px.svg) no-repeat 0 0;background-size:auto 30px;padding-left: 20px\">\n<h3 style=\"font-size: 1.2rem\">Solutions or Products Featured in This Case Study<\/h3>\n<\/div>\n<ul style=\"list-style-type: disc;margin-left:2.8rem;font-size: 1rem;line-height:1.6rem\">\n<div style=\"margin-bottom:0.8rem\">\n<li><a href=\"https:\/\/www.dry-fog.com\/en\/products\/noz-pne-bimv\/\" style=\"color: #00a273\">Pneumatic flat spray nozzles BIMV (made from hardened steel)<\/a><\/li>\n<\/div>\n<\/ul>\n<p><img decoding=\"async\" loading=\"lazy\" src=\"https:\/\/www.dry-fog.com\/en\/wp-content\/uploads\/sites\/3\/2024\/07\/bimv_2.jpg\" alt=\"\" width=\"820\" height=\"500\" class=\"aligncenter size-full wp-image-6304\" \/><\/p>\n<div style=\"margin-bottom:0.8rem;background:url(https:\/\/www.dry-fog.com\/jp\/wp-content\/uploads\/sites\/2\/2024\/10\/10px-45px.svg) no-repeat 0 0;background-size:auto 30px;padding-left: 20px\">\n<h3 style=\"font-size: 1.2rem\">Key Reasons for Implementation<\/h3>\n<\/div>\n<ul style=\"list-style-type: disc;margin-left:2.8rem;font-size: 1rem;line-height:1.6rem\">\n<div style=\"margin-bottom:0.8rem\">\n<li>Switching to spray nozzles made from highly wear-resistant materials achieved an extended lifespan.<\/li>\n<\/div>\n<\/ul>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<div style=\"margin-bottom:0.8rem;background:url(https:\/\/www.dry-fog.com\/jp\/wp-content\/uploads\/sites\/2\/2024\/10\/10px-45px.svg) no-repeat 0 0;background-size:auto 30px;padding-left: 20px\">\n<h3 style=\"font-size: 1.2rem\">Challenges Faced by the Customer<\/h3>\n<\/div>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">A sand molding machine manufacturer had adopted a design that utilized spray nozzles to apply release agents in an environment where sand particles circulated inside the equipment. However, nozzle wear became a significant issue. <span style=\"font-weight:bold;font-size: 1rem\">Continuous impacts from the sand particles on the nozzle tips caused severe damage, leaving the nozzles heavily deteriorated within just six months<\/span> and making it difficult to maintain stable application of the release agents.<\/p>\n<\/div>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">This situation made it impossible for machine users to maintain stable operations. The manufacturer sought spray nozzles capable of delivering a long lifespan even in harsh environments and reached out to us for a solution.<\/p>\n<div style=\"margin-bottom:0.8rem;background:url(https:\/\/www.dry-fog.com\/jp\/wp-content\/uploads\/sites\/2\/2024\/10\/10px-45px.svg) no-repeat 0 0;background-size:auto 30px;padding-left: 20px\">\n<h3 style=\"font-size: 1.2rem\">Proposals from IKEUCHI<\/h3>\n<\/div>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">The material of the nozzles in use was stainless steel 303 (SUS303), with a hardness of HRB90 (equivalent to HRC11). In response, we proposed manufacturing nozzles made from stainless steel 440 C (SUS440C), which offers a hardness of HRC58.<\/p>\n<p><img decoding=\"async\" src=\"https:\/\/www.dry-fog.com\/en\/wp-content\/uploads\/sites\/3\/2024\/07\/noz-BIMV-case2_3R_E.png\" alt=\"\" width=\"820\" class=\"aligncenter size-full wp-image-6304\" \/>\n<\/div>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<div style=\"margin-bottom:0.8rem;background:url(https:\/\/www.dry-fog.com\/jp\/wp-content\/uploads\/sites\/2\/2024\/10\/10px-45px.svg) no-repeat 0 0;background-size:auto 30px;padding-left: 20px\">\n<h3 style=\"font-size: 1.2rem\">Benefits Achieved<\/h3>\n<\/div>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">As a result of switching to SUS440C nozzles, <span style=\"font-weight:bold;font-size: 1rem\">no significant damage affecting the spraying of release agents was observed even after one year of use<\/span> following replacement. This ensured that the machine provided users with stable and reliable operation.<\/p>\n<\/div>\n<p><!-- \u3010Product Information\u30dc\u30bf\u30f3\u3011\u3068\u3010Contact Us\u30dc\u30bf\u30f3\u3011\u3053\u3053\u304b\u3089 --><\/p>\n<div style=\"max-width: 800px;margin-left: auto;margin-right: auto;margin-bottom:1rem\">\n\t<span><\/p>\n<div class=\"page-bottom_contacts\" style=\"float: left;padding-top:0;padding-bottom:0\">\n<div style=\"margin-left: 1rem;margin-right: 1rem\">\n<div style=\"text-align: center\"><a class=\"content-ttl__sub\" style=\"margin-bottom: 1rem;justify-content: center;align-items: center;padding-top: 1rem;padding-bottom: 1rem;color: #fff;font-weight: 500;font-size: 1.2rem;background: linear-gradient(20deg, rgba(31,207,158,1) 0%, rgba(27,217,168,1) 35%, rgba(19,222,173,1) 100%);border-radius: 10px\" href=\"https:\/\/www.dry-fog.com\/en\/products\/noz-pne-bimv\/\" rel=\"noopener\">Product Information<\/a><\/div>\n<\/p><\/div>\n<\/p><\/div>\n<div class=\"page-bottom_contacts\" style=\"float: right;padding-top:0;padding-bottom:0\">\n<div style=\"margin-left: 1rem;margin-right: 1rem\">\n<div style=\"text-align: center\"><a class=\"content-ttl__sub\" style=\"justify-content: center;align-items: center;padding-top: 1rem;padding-bottom: 1rem;color: #fff;font-weight: 500;font-size: 1.2rem;background: linear-gradient(20deg, rgba(31,207,158,1) 0%, rgba(27,217,168,1) 35%, rgba(19,222,173,1) 100%);border-radius: 10px\" href=\"https:\/\/www.dry-fog.com\/en\/contact\/\" rel=\"noopener\">Contact Us<\/a><\/div>\n<\/p><\/div>\n<\/p><\/div>\n<p>\t<\/span><\/p>\n<div style=\"clear: both\"><\/div>\n<\/div>\n<div style=\"margin-top:0rem;margin-bottom:3rem;width:100%;border-bottom:1px solid #E9E9E9\"><\/div>\n<p><!-- \u3010Product Information\u30dc\u30bf\u30f3\u3011\u3068\u3010Contact Us\u30dc\u30bf\u30f3\u3011\u3053\u3053\u307e\u3067 --><\/p>\n<\/div>\n<\/section>\n","protected":false},"featured_media":0,"template":"","cat_cases":[87],"tag_cases":[539,542,540,543,378,538,537],"acf":[],"_links":{"self":[{"href":"https:\/\/www.dry-fog.com\/en\/wp-json\/wp\/v2\/cases\/7526"}],"collection":[{"href":"https:\/\/www.dry-fog.com\/en\/wp-json\/wp\/v2\/cases"}],"about":[{"href":"https:\/\/www.dry-fog.com\/en\/wp-json\/wp\/v2\/types\/cases"}],"wp:attachment":[{"href":"https:\/\/www.dry-fog.com\/en\/wp-json\/wp\/v2\/media?parent=7526"}],"wp:term":[{"taxonomy":"cat_cases","embeddable":true,"href":"https:\/\/www.dry-fog.com\/en\/wp-json\/wp\/v2\/cat_cases?post=7526"},{"taxonomy":"tag_cases","embeddable":true,"href":"https:\/\/www.dry-fog.com\/en\/wp-json\/wp\/v2\/tag_cases?post=7526"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}