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Cast Iron Pipe Manufacturer Eliminates Rework and Saves US$40,000 per Month with New Spray System Problem: A high-production foundry which manufactures cast iron products from recycled materials, needed to efficiently cool cast iron soil pipe from 350° to 100°F (177°C to 38°C) after dipping the pipe in hot asphalt. The asphalt coating, which acts as a corrosion inhibitor and fills in the porosity of the pipe, was chosen as a solvent-free coating but caused surface imperfections as it cooled on the pipe surface. Though the asphalt was an acceptable “green” alternative to previously used coatings, the surface flaws were unacceptable to customers and resulted in a significant number of returned products. Cooling by immersion in a water bath was tried first but caused blistering of the asphalt coating. Ambient air cooling gave a better finish but took much longer and required manual rotation of the large pipes to prevent bumps from forming where drips of asphalt cooled and hardened on the surface of the pipe. Both solutions resulted in excessive manual labor and overtime expense. Solution: Spraying Systems Co.’s solution was a simple cooling station comprised of two rows of six 1/4J air atomizing nozzles mounted 30” (762 mm) above the pipe to provide even coverage of the 4’ x 10’ (1.2m x 3m) area. Based on the specific heat of the cast iron and the pipe mass, a heat balance calculation provided the theoretical water flow and nozzle quantity required to complete the cooling in the desired time. Air atomizing nozzles are used because they provide nearly 100% evaporation, maximize cooling and resist plugging even when used with recycled water. water. 1/4J Air Atomizing Nozzles Mounted on Spray Headers Provide Cooling of Cast Iron Pipes spray.com | 1.800.95.SPRAY | Intel. Tel: 1.630.665.5000

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Page 1: Cast Iron Pipe Mfg Eliminates Rework and Saves US$40,000 ...Cooling of Cast Iron Pipes spray.com | 1.800.95.SPRAY | Intel. Tel: 1.630.665.5000 Cast Iron Pipe Manufacturer Eliminates

Cast Iron Pipe Manufacturer Eliminates Rework and Saves US$40,000 per Month with New Spray System

Problem:

A high-production foundry which manufactures cast iron products from recycled materials, needed to effi ciently cool cast iron soil pipe from 350° to 100°F (177°C to 38°C) after dipping the pipe in hot asphalt. The asphalt coating, which acts as a corrosion inhibitor and fi lls in the porosity of the pipe, was chosen as a solvent-free coating but caused surface imperfections as it cooled on the pipe surface. Though the asphalt was an acceptable “green” alternative to previously used coatings, the surface fl aws were unacceptable to customers and resulted in a signifi cant number of returned products.

Cooling by immersion in a water bath was tried fi rst but caused blistering of the asphalt coating. Ambient air cooling gave a better fi nish but took much longer and required manual rotation of the large pipes to prevent bumps from forming where drips of asphalt cooled and hardened on the surface of the pipe. Both solutions resulted in excessive manual labor and overtime expense.

Solution: Spraying Systems Co.’s solution was a simple cooling station comprised of two rows of six 1/4J air atomizing nozzles mounted 30” (762 mm) above the pipe to provide even coverage of the 4’ x 10’ (1.2m x 3m) area. Based on the specifi c heat of the cast iron and the pipe mass, a heat balance calculation provided the theoretical water fl ow and nozzle quantity required to complete the cooling in the desired time. Air atomizing nozzles are used because they provide nearly 100% evaporation, maximize cooling and resist plugging even when used with recycled water. water.

1/4J Air Atomizing Nozzles Mounted on Spray Headers Provide

Cooling of Cast Iron Pipes

spray.com | 1.800.95.SPRAY | Intel. Tel: 1.630.665.5000

Page 2: Cast Iron Pipe Mfg Eliminates Rework and Saves US$40,000 ...Cooling of Cast Iron Pipes spray.com | 1.800.95.SPRAY | Intel. Tel: 1.630.665.5000 Cast Iron Pipe Manufacturer Eliminates

Cast Iron Pipe Manufacturer Eliminates Rework and Saves US$40,000 per Month with New Spray System – Continued

Results:The cooling system has dramatically improved the foundry’s production, eliminating US$40,000 in monthly rework and overtime expense. This savings resulted in a payback of less than two weeks. In addition, the cooling system advances one of the company’s green initiatives.

J Series air atomizing nozzles are available in many sizes and confi gurations. Inlet connections range from 1/8

to 1” with fl ow rates ranging from 0.55 to 906 gph at 40 psi (2.08 to 343 l/hr at 2.8 bar). Users can choose pressure- or siphon-fed spray set-ups and a round, wide-angle round,

360° circular, fl at spray or defected fl at spray pattern.

A variety of Spraying Systems Co.’s accessories are part of the installation including t-style strainers, regulators, gauges, solenoid

valves, air fi lters and more.

o.’s accessoriies are partf S S C

A CLOSER LOOK AT THE SYSTEM

Experts in Spray Technology

Case Study No. 147A Printed in the U.S.A. ©Spraying Systems Co. 2014

North Avenue and Schmale Road , P.O. Box 7900, Wheaton, IL 60187-7901 USA

Tel: 1.800.95.SPRAY Intl. Tel: 1.630.665.5000Fax: 1.888.95.SPRAY Intl. Fax: 1.630.260.0842www.spray.com


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