Cement Plant
Gas Conditioning System
Cement Plant Tower

Spray Applications for the Cement Industry

Optimizing spray performance can result in improved efficiency, increased throughput, reduced downtime and lower operating costs

Effective and efficient gas cooling has become a top priority for cement plants around the world. Increased concern about emissions and the need to boost production are the primary reasons why. Evaporative spray cooling remains the best way to gain control of gas temperature, reduce gas volume and provide humidification.

We have several solutions available to help you:

  • Achieve precise control of temperature and humidity to maximize dust collection and ESP performance
  • Reduce the maintenance time required to clean ducts, kiln feed hoods, tower walls/bottom and to monitor, repair and restart equipment
  • Significantly lower the volume of toxic dioxins and furans created and released
  • Lower energy costs as a result of optimized ESP performance

High-Efficiency Air Atomizing Nozzles Yield Best Results

Technological advancements in atomization have made high-efficiency air atomizing nozzles a better choice in most applications than hydraulic nozzles. In addition to better performance, air atomizing nozzles are less costly to operate and enable the use of smaller cooling towers since fewer lances are required.

Hydraulic vs. Air Atomizing Nozzle Comparison Chart

Hydraulic vs. Air Atomizing Nozzles and Cooling Tower Size

FloMax® Air Atomizing Nozzles: Becoming the Industry Standard

The patented multi-stage atomization process of FloMax nozzles produce a highly focused air stream that shears the liquid with minimal air. The benefits are many:

  • Smaller drops are produced using less air than competitive nozzles
  • Energy costs are lowered
  • Compressor life extended
  • Small drops require less dwell time for complete evaporation and reduce the risk of wetting and generates more surface area per gallon (liter) sprayed

FloMax Air Atomizing Nozzles vs. Other Air Atomizing Nozzles Comparison Chart

Watch How FloMax Nozzles Work

FMA

FMX

Maintaining a Hydraulic System? Flowback Nozzles Offer Several Advantages

You may be able to improve performance in your existing hydraulic gas cooling operations. Easily interchangeable with competitive products, these nozzles offer several benefits:

  • Consistent drop size by applying consistent pressure to the nozzle at all times. Once the desired gas temperature is achieved and a reduction in volume is needed, a valve is adjusted to alter the amount of fluid leaving the nozzle
  • 10:1 turndown ratio
  • Large selection of nozzle capacities
  • Unique two-piece design makes installation and maintenance quick and easy – no special tools required

Watch How Flowback Nozzles Work

AutoJet® Gas Conditioning Systems Provides Even Greater Efficiencies

If you're looking for a fully automated solution, optimal systems performance and lower operating costs, our AutoJet Gas Conditioning System is exactly what you need. It includes a proprietary control system to maximize the performance of FloMax nozzles. Patent-pending SprayLogic® firmware and software monitor and adjust the closed loop system. Liquid and air flow to the nozzles is regulated based on data gathered from temperature sensors to ensure optimal performance.

All system components – nozzles, pumps, sensors and other hydraulic and pneumatic devices – are controlled by the AutoJet controller. If a problem is detected that the controller can't resolve automatically, operator warnings will be displayed or sounded.

Watch How An AutoJet Gas Conditioning System Works

 Visit iSpray for selection assistance and easy online ordering.
Or, contact your local sales and engineering office.

 

 Gas Cooling and Conditioning in Cement Manufacturing, Bulletin 556B
Gas Cooling and Conditioning in Cement Manufacturing, Bulletin 556B

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References

Literature

  • Gas Cooling and Conditioning in Cement Manufacturing, Bulletin 556  · View   · Request
  • International Cement Review: The Use of Spray Technology for Gas Conditioning, Article ARCPROC1 · View   · Request
  • International Cement Review: Automated Gas Conditioning, ARCPROC4 · View   · Request
  • FloMax Air Atomizing Nozzles Bulletin 487C · View   · Request
  • Spray Technology Reference Guide: Understanding Drop Size, Bulletin 459B · View   · Request
  • Full-line catalog including spray nozzles and accessories, technical data and problem-solving ideas, Catalog 70   · View  · Request
  • Full-line catalog including spray nozzles and accessories, technical data and problem-solving ideas,
    Catalog 70-M - Metric   · View  · Request

Resources

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