Spray Insights
FOCUS ON COOLING
Cooling plays a critical role in a wide range of applications across many industries. Spray technology is used to cool gas streams, steel, cattle, race car brakes and more. The consequences of cooling too quickly or too slowly can be very costly:
- Product quality problems resulting in increased scrap and rework
- Downtime to remove excess water and sludge
- Damage to or reduced efficiency of downstream equipment
- Fines due to inadequate emission control
- Increased energy and water use
To achieve optimal cooling efficiency of gasses or solids, it is important to partner with a spray technology manufacturer that has expertise in heat transfer, drop size analysis, process modeling capabilities to simulate your operating environment and an extensive product line that includes spray nozzles, lances and injectors.
Cooling Solids
Solid objects are typically cooled using spray nozzles and headers, especially in food processing and metalworking. Examples include cooling jam and jelly jars after steam sterilization, cooling and curing concrete blocks, and poultry grow-out house cooling. If you have a product that requires cooling, consult with a spray expert to optimize coverage and minimize waste.
Product Feature: HHX FullJet® Full Cone Nozzles: HHX FullJet nozzles provide consistent spray distribution to ensure uniform cooling and high heat transfer in the steel industry. They are ideal for secondary cooling operations such as billets, blooms, rounds and slabs.
Product Feature: Quick FloodJet® Flat Spray Nozzles: Quick FloodJet nozzles form a flat spray pattern that is evenly distributed from the center of the spray. The deflector surface enables wider spray angles compared to other flat spray nozzles.
Case Study: Cast Iron Pipe Manufacturer Eliminates Rework and Saves US$40,000 per Month with New Spray System
Case Study: New Spray Nozzles Save 2.7 million Gallons of Water for Beef Processor
Gas Cooling
Gas cooling can be complicated and challenging due to high temperatures and extreme environments. It’s imperative to determine the exact drop size required to achieve the desired cooling effect without wetting. The process stream and operating conditions have a big impact on spray performance, so Computational Fluid Dynamics (CFD) is often used to identify the best spray nozzle type, drop size, placement in the gas stream and spray direction.
Gas cooling is widely used in refineries, power plants and chemical processing. Typical applications include in-duct cooling, pollution abatement, emergency quench and more.
Product Feature: Precision Spray Injectors: Precision Spray Injectors consist of a pipe with one or more customizable spray nozzles that can be tailored to deliver a specific volume of fluid at a specified pressure drop. The use of spray nozzles on the injector enables precise control over the distribution of the injected liquid into the receiving process fluid.
Product Feature: FloMax® Air Atomizing Nozzles: FloMax Air Atomizing nozzles produce very small drops with exceptional efficiency. The nozzles offer significantly higher turndown ratios than standard two-fluid nozzles for maximum operating flexibility.
Case Study: Switching Nozzles Saves Waste-to-Energy Plant US$100,000 per Year
Case Study: Ethylene Plant Doubles Production and Increases Profitability with New Gas Cooling Injectors