Every spray system depends on three factors: nozzle type, operating pressure, and flow rate. When any of these are out of alignment, screening performance drops — regardless of pump capacity or system design.
Simaflex Engineering applies a system-level approach to spray optimisation, improving fines recovery while reducing water consumption and energy use.
Why the Right Balance Matters
Too much pressure
- Atomisation and evaporation losses
- Droplets miss the ore
- Increased pump energy demand
Too little pressure
- Incomplete coverage
- Coarse droplet formation
- Nozzle blockages
Wrong nozzle selection
- Uneven spray patterns
- Overspray and runoff
- Poor wash effectiveness
Common Spray System Errors in Mining
- Using the same nozzle across multiple applications
- Oversizing pumps to overcome clogged or damaged bars
- Failing to match spray pattern to screen, trommel or chute geometry
- Operating systems outside recommended pressure ranges
These issues reduce both efficiency and equipment lifespan.
Simaflex’s Engineering Approach
Nozzle Selection
- Flat fan, full cone, or hollow cone matched to ore type and duty
Flow Rate Calculation
- Based on required wash volume and ore throughput
Pressure Range Design
- Washing and classification systems typically operate between 100–400 kPa, delivering controlled coverage without excessive atomisation.
- Dust suppression applications require higher pressures (400+ kPa) to generate fine mist and effectively bind airborne particles.
System Integration
- Pumps, pipework, nozzles, and automation designed as a cohesive unit
Operational Results
Sites with properly balanced spray systems report:
- Improved fines separation and product consistency
- Lower water use per tonne processed
- Reduced pump loads and energy consumption
- Fewer maintenance shutdowns and system failures
Book a Spray System Assessment
Simaflex provides engineering audits to assess nozzle selection, pressure control, and flow rate efficiency. Get in touch to optimise your existing systems or plan upgrades for better performance.
Suggested Visuals
- Diagram: pressure vs droplet size and effectiveness
- Spray pattern comparison: flat fan vs full cone vs hollow cone
- Flowrate/pressure balance table