Synergy Spray Systems, we specialize in Spray Performance Analysis using advanced tools like Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA). These techniques help industries improve fluid dynamics, optimize spray coverage, and reduce prototyping costs.
What Is Spray Performance Analysis?
Spray Performance Analysis involves evaluating how well a spray system meets its intended goals. Key performance factors include:
Droplet size and distribution
Spray coverage and uniformity
Flow rate and velocity
Spray angle and pattern
Impact force and atomization quality
This ensures the system meets application goals — whether it’s cleaning, cooling, coating, or suppression.
CFD for Spray Systems: Virtual Testing Without the Downtime
Computational Fluid Dynamics (CFD) allows us to simulate:
Fluid flow behavior inside pipes, nozzles, and tanks
Spray angle and droplet trajectory
Temperature and heat transfer effects
Multi-phase flows (liquid + air/mist)
By analyzing the system in a virtual 3D environment, we can predict issues like turbulence, flow separation, and mist drift before they happen.
Applications: Cooling towers, fire suppression systems, chemical dosing, cleaning systems
CFD for Spray Nozzles: Optimize Without Trial & Error
With CFD, we simulate spray nozzle behavior to optimize:
Droplet size (for misting vs coating)
Spray cone shape and angle
Atomization efficiency
Turbulence and flow path within the nozzle
This helps improve:
Fluid efficiency (less waste)
Coverage uniformity
Performance at different pressures
For example, CFD helped one client reduce overspray in a bottle washing system by 22%, cutting water usage and improving cleaning performance.
CFD FOR SPRAY SYSTEMS
cfd for agitator tank
Key Metrics We Analyze
- Droplet Size: Affects cooling/misting vs. coating/cleaning
- Spray Angle: Determines coverage width
- Flow Rate: Impacts delivery volume and force
- Spray Pattern: Full cone, flat fan, hollow cone
- Impact Force: Critical in cleaning and industrial stripping
- Atomization Quality: Ensures fine mist or even coating
Industries That Benefit from Spray Analysis
Agriculture: Improve pesticide coverage
HVAC: Optimize evaporative cooling
Manufacturing: Enhance cleaning systems
Food & Pharma: Ensure uniform coating
Fire Suppression: Verify coverage areas
Our Process
Input Requirements (system layout, fluid type, nozzle specs)
Run CFD/FEA Simulations
Analyze Spray Performance Metrics
Generate Reports with Visuals & Recommendations