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How does an Apollo dual induction blasting system/blast nozzle work?

Updated: May 9

Apollo Blasting systems utilize unique, patent pending technology, that offers direct pressure blast performance - without the use of a welded pressure vessel, offering over 30% less energy consumption, +30% faster stripping and complete elimination of downtime.


It's Rocket Science - Applied to Surface Cleaning Technology.


Apollo Sandblasting Nozzle
Apollo (V-Series) 10mm Cobra Blast Nozzle Mach Velocity CFD @ 100psi

Old Technology Explained:


In a traditional suction blast nozzle, the outlet nozzle (ID) is typically twice the ID of the air blast jet, to create ample suction to draw abrasive particles from a hopper or silo, shown below in Fig.1.

 

 

Fig.1 Typical Suction Blast Nozzle



Suction Blast Nozzle For Sandblaster

SUCTION BLAST NOZZLES RELY ON A VACUUM TO INDUCT ABRASIVE PARTICLES AT THE NOZZLE - APOLLO BLASTING SYSTEMS DO NOT.


With a larger outlet nozzle - to create a Venturi suction to draw abrasive media particles directly from a hopper through a suction hose (which is limited to light weight/lower density abrasive media) - These type of blast systems cause abrasive media to be carried through the outlet nozzle largely separated to the air jet flow - (mostly not mixed within the central air core) - due to coanda effect separation, causing abrasive/air separation, which causes abrasive particles to stick or “adhere” to the outlet nozzle walls during through flow and glide over the outlet flow air jet stream, gathering friction on the outlet nozzle walls, as the abrasive particles are propelled through the outlet nozzle (as opposed to within it), so in comparison, suction blast abrasive particle velocity is vastly reduced in comparison with a direct pressure blast nozzle:


Fig.1A - CFD Analysis showing abrasive media particle seperation (on a typical suction blasting nozzle).

Note the conical flow at the nozzle exit and flow seperation.


Suction Blast Nozzle Flow Analysis













A technical reference that backs up our research is evident in this paper:

 

Now, to differentiate and highlight the difference between Apollo dual induction blasting systems and (suction) type blasting systems!

 

In all Apollo dual induction blasting systems, a unique blast nozzle is utilised, namely the cobra blast nozzle, which is novel blasting technology that permits pressure blast performance without the use of a pressure vessel.

 

The Apollo Cobra blast nozzle accelerates abrasive particles, working similarly (in principle) to a water jet cutting nozzle, shown below:

 

 

Fig.2 Water Jet Nozzle



Water Jet Nozzle - Blast Nozzle
Waterjet Nozzle


Although using (compressed air), as the accelerating fluid medium, as opposed to incompressible water in a water jet nozzle, with working principles similar, in that the outlet nozzle size is not much larger than the (air jet) size, with no reliance on venturi or suction from the nozzle itself to induce abrasive media (as abrasive flow is introduced via positive eductor air flow conveyed from the abrasive hopper at atmospheric pressure) - the corresponding (fusion nozzle) within the cobra blast nozzle (post air jet) - (ID) is matched to the cobra air jet with unique geometry that limits expansion of post flow convergent (vortex flow) from the (cobra air jet) and ensures 100% mixing of abrasive particles induced from the eductor feed via the Coanda effect through the fusion nozzle.

 

Separately, positive air feed from the eductor, carrying abrasive media is separated and vented through vents located within the fusion nozzle, drawn through to the outlet nozzle liner via suction created at the fusion nozzle, at an opposing angle to induced abrasive momentum during through flow.

 

In contrast, Apollo dual induction blast nozzles accelerate abrasive media at the same velocity in comparison with direct pressure blast nozzles, as the abrasive media is mixed directly at the point of highest acceleration from the convergent nozzle flow (from the air jet), and mixed directly within the accelerated air flow (without an increase in nozzle diameter), through a secondary fusion nozzle - which concentrates abrasive particles within the dense, vortex air flow from the air jet, enabling abrasive particles to be mixed adequately, to enable maximum abrasive velocity through the outlet nozzle.

 

 


Fig.3 Apollo Cobra Blast Nozzle

















I’m not a rocket scientist, tell me how the Apollo Blast Nozzle works in simple terms?


The Apollo Cobra Blast nozzle forces abrasive media into a "fusion nozzle" with a matched diameter to a convergent nozzle jet, and at the same time; separates conveying air into a 2nd stage Venturi to expand the nozzle outlet airflow (to propel abrasive media at high-velocity), and create a wide blast pattern.


Result:


  • Direct Pressure Blast Performance

  • +30% FASTER STRIPPING

  • 30% Less Energy Consumption


 

To standardise our unique technology, Apollo Cobra blast nozzles utilise a standardized outlet liner with a variety of nozzle size options to suit all applications.

 

As no abrasive media is conveyed with high flow air on Apollo dual induction blasting systems, there is a significant gain in efficiency, due to the absence of abrasive friction within the blast hose, and additionally as the main air hose used can therefore be reduced to 3/4” (19mm) from 11/4” (on a direct pressure blast pot), to enable the same nozzle performance (pressure), a significant reduction in air consumption is achieved typically (~30%) less in comparison.

 

Additionally, the blast pattern of a dual induction system (in comparison to direct pressure) is significantly larger (30%) - permitting faster production rates as a result, with a greater rate of expansion and acceleration, with less wastage of compressed air (energy).

 

 

Fig.5 Blast Pattern Analysis, Direct Pressure and Apollo Cobra:



Abrasive Blasting Profile Comparison for coating applications


Blasting Pressure: 100psi

Blasting Distance: 10 Inches

 

SA2.5 Blast Profile for Primer application for marine application, achieve the performance of a ½” blast nozzle (12.7mm) with a 10mm Cobra Blast Nozzle, whilst also using less air than a 3/8” direct pressure blast nozzle.

 

 

Several other benefits of dual induction systems vs direct pressure include:

 

  1. Fill/empty hopper of abrasive anytime, even during use - In blast room installations, The Apollo-V1 system replaces older welded pressure blast pots, to allow for 24/7 production and zero downtime.

  2. Ball valve on side of hopper allows for abrasive empty/change out anytime.

  3. Lightweight hopper – typically half the weight of a comparable sized welded pressure pot - easy to transport and ideal for mobile blasting applications.

  4. Simplicity in design – ultra reliable. Easy to maintain.

  5. No moving parts within the blasting system.

  6. Solid S/S N/C pinch valve ensures no abrasive surges saving money on jobs, maximum control of abrasive flow from 70kg-180kg per hour (typically).

  7. Only 1 main wear item (Cobra Fusion Nozzle), which is made from Tungsten carbide, lasts between 1,000-1,500 hours. (typically).- longer if wet blasting.

  8. Zero downtime with blockages due to compressed air, as the abrasive hopper is atmospheric, no air moisture can accumulate with abrasive.

  9. No pressure vessel regulations to comply with.

  10. Apollo blast hose weighs less than ¾ the weight of a conventional 1” (25mm) direct pressure blast hose assembly = less operator fatigue & more productivity!

  11. Apollo Blast hose does not wear out, unlike direct pressure blast hose.

  12. ~30% less air consumption than direct pressure blast pots, for the same nozzle size used - more productivity at reduced costs.

  13. ~30% wider blast pattern, compared to welded pressure vessel blast pots using a standard double venturi nozzle. 

  14. Multiple outlet blast pots available from our V-Series blasting systems.

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