Gas Cooling and Conditioning Guide - SGN Tekniikka Oy

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The Key to Effective Gas Conditioningand Cooling is ControlGas temperature, humidity and volume all needto be precisely controlled to avoid:• Unexpected, costly downtime caused by ESP overload• Decreased production levels due to gas volumes greaterthan the capacity of downstream equipment• Excessive maintenance time caused by wetting and sludgebuild-up in towers and ducts• Damage to downstream equipment from break away debris• High energy costs due to operational inefficiency of thegas cooling system and downstream equipment• Emissions exceeding environmental regulationsand significant fines and penalties• Tarnished reputation for not being a good corporate citizenEvaporative cooling using dual-fluid atomization technology,where water is mixed with compressed air, has become thepreferred method for gas conditioning because it typicallyoffers greater precision than hydraulic cooling and loweroperating costs. However, the performance of dual-fluid systemsvaries widely. It is important to understand the key system elementsthat determine the level of gas control you can achieve and to partnerwith a manufacturer that has all the resources to evaluate yourrequirements and help ensure performance goals are met.Spraying Systems Co. is uniquely qualified to help you with your gasconditioning needs. We have more than 70 years of experience and oursole focus on spray technology has enabled us to develop the broadestproduct line of spray nozzles and systems in the industry and uniquefabrication, research and testing services. As a result, we have solutionsfor NOx and SO 2 control, cooling in ducts and towers and cooling prior togas entry into baghouse, ESP, heat exchangers, kilns and more.On the pages that follow, you'll learn more about our:• High-efficiency FloMax ® air atomizing nozzles that outperform all other similar nozzles• Turnkey AutoJet ® Gas Conditioning Systems that provide total automation and optimize the performanceof FloMax nozzles• Performance testing services in the world’s largest spray laboratory and the use of Computational Fluid Dynamics(CFD) to predict spray performance using actual operating conditions• Standard and custom spray lances to ensure proper delivery of the liquid and gas to the spray nozzles1.800.95.SPRAY | Intl. 1.630.665.5000 | www.spray.com
FloMax ® NozzlesSuperior gas cooling requiressuperior air atomizing nozzlesThe most critical component in agas cooling system is the spray nozzle1If drop size and spray coverage aren't precisely right,problems like these can occur:2• Insufficient cooling• Inadequate reductions in gas volume3FloMax Aseries nozzles• Wetting• Increased energy consumptionAll air atomizing nozzles are not alikeIn fact, very few are suitable for gas conditioning.High-efficiency nozzles provide tight control of drop sizeand spray coverage. Very small drop sizes cannot beachieved with a single-step atomization process.A multi-stage process is required.FloMax Xseries nozzlesFloMax nozzles use a patented atomization principle toproduce a highly focused air stream that shears the liquidwith minimal air. The result of the unique process is thatFloMax nozzles use less air and produce smaller dropsthan competitive nozzles.321The benefits of small drop size are many:• Energy costs are lowered• Small drop size equals greater liquid surface areafor better chemical reactionFloMax operating principle• Dwell time for complete evaporation is reduced• The risk of wetting is reduced• The liquid being sprayed generates more surfacearea per gallon (liter)The uniformity of drop size distribution produced by FloMaxnozzles ensures precise, tight control of drop size. This isanother unique attribute – FloMax nozzles provide a narrowerRelative Span Factor (RSF)* than many other air atomizingnozzles at most air pressures.* RSF is a single number indicative of the uniformity of the drop size distribution.The closer the number is to 1, the more uniform the spray will be. 21 Stage one: primary fluid breakupAir and liquid converge at the annulus allowinghigh velocity air to shear the liquid column.3Stage two: secondary fluid breakupFocused stream impacts the target bolt forcingadditional mechanical breakup.Stage three: final mixingAir cap acts as a final mixing chamber. As liquidcrosses multiple orifices, an additional pressuredrop provides the final atomization.1.800.95.SPRAY | Intl. 1.630.665.5000 | www.spray.com
Page 1: SprayNozzlesSprayControlSprayAnalys
Page 5 and 6: Overview of FloMaxair atomizing noz
Page 7 and 8: FloMaxnozzleHow it works and how yo
Page 9 and 10: Computational Fluid Dynamics(CFD) a
Page 11 and 12: Solutions That Work for Your PeersM

Gas Cooling and Conditioning Guide - SGN Tekniikka Oy

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