 Solving Typical Gas Conditioning Problems in Cement Manufacturing with FloMax® Nozzles
Here are just a few examples of how cement plants are effectively using FloMax nozzles to gain control of gas temperature, gas volume and humidity.
Gas Cooling Operation at Cement Plant Improves with FloMax Nozzles and Lances
One cement plant was experiencing a number of problems during the gas cooling process. The existing atomizing nozzles were leaking. As a result, atomization was poor and wetting occurred on kiln walls. The wet walls produced excessive build-up, causing large chunks of concrete to break off and damage downstream equipment. In order to minimize the impact of the leaking nozzles, maintenance intervals were increased and valuable production time lost. The solution was to replace our competitor's nozzles with FloMax® air atomizing nozzles. The nozzles and lance assemblies are placed at opposite sides of the kiln and efficiently cool the gas from over 900°F (482°C) to below 400°F (204°C). Since the installation of the FloMax air atomizing nozzles, maintenance has been reduced to once every three months and lost production time due to damaged downstream equipment has been eliminated.
 FloMax nozzles enable increase in clinker throughput and production
A leading grey cement clinker producer uses a single dry process rotary kiln with ore calciner. This plant relies FloMax FM 25 nozzles to increase the capacity of the rotary coolers. Six lances are used for each cooler. Nearly 400,000 acfm of dust laden gases are cooled from 640° F to 270° F (338° C to 132° C). The 370° F (188° C) temperature reduction efficiently reduces gas volume enabling increased clinker throughput and production.FloMax nozzles replace less efficient air atomizing nozzles and return plant to full production
 To prevent damage to the baghouse, one cement plant was forced to reduce production by 20% during the hottest three months of the year. This was an unacceptable revenue loss and plant management quickly turned to Spraying Systems Co. to analyze the gas composition, volume and temperature range. Once we’d completed the testing and analysis, new lances equipped with FloMax nozzles, specialized lance assemblies and shuttle tubes were designed to fit existing entry points. The nozzles and lances shipped in a matter of weeks, helping the plant return to full production as quickly as possible.
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