Advantages of Using Spray Nozzles for Gas Cooling & Conditioning

May 1, 2023
A image depicting how gas cooling and conditioning works.

How Spray Nozzles Improve Gas Cooling And Conditioning

Spray nozzles improve gas cooling and conditioning by introducing appropriately sized liquid droplets into the gas stream to increase efficiency and achieve process goals. Here are some specific ways that spray nozzles can improve gas cooling and conditioning:

Temperature control: Spray nozzles in addition to process control systems can precisely control the gas
temperature by adjusting the amount and temperature of the liquid being introduced. For example, if a gas stream is too hot, a spray of cool water can be introduced to lower the temperature.

Humidity control: Spray nozzles can also be used to control the humidity of the gas by introducing a fine mist of water. Nozzles can be useful in industrial applications where precise humidity control is needed.

Particulate removal: Spray nozzles can remove particulate matter and other contaminants from the gas stream by introducing appropriately sized liquid droplets that can capture and carry away the particles.

Gas scrubbing: In some cases, spray nozzles can be used to scrub the gas with a liquid that reacts with or absorbs certain gases or components. For example, a gas stream could be scrubbed with caustic soda to remove carbon dioxide.

Heat recovery: Spray nozzles can also be used for heat recovery, where the liquid introduced into the gas stream absorbs heat and is then used in a secondary process, such as for heating water.

Overall, spray nozzles provide a versatile and efficient way to control the temperature, humidity, and cleanliness of gas streams in various industries, including petrochemical, chemical, cement, waste-to-energy, and more.

What Types Of Spray Nozzles Optimize Gas Cooling And Conditioning Processes

There are many different types of spray nozzles that can be used for gas cooling and conditioning:

Atomizing spray nozzles: These nozzles use compressed air or other gases to break up a liquid into fine droplets. BETE’s XAAD hollow cone air atomizing nozzles are commonly used in industrial applications to cool hot gases and remove pollutants. Liquid and air streams come together inside the nozzle, are mixed internally, and exit the orifice to produce very fine atomization.

Fogging or misting nozzles: These nozzles produce a fine mist or fog that can be used for humidification or evaporative cooling. Impingement misting nozzles like the PJ series use an external pin to distribute a mist of water sprays into the hot gas for effective evaporation. These misting nozzles produce the finest fog of any direct pressure nozzles.

Fan nozzles: These nozzles produce a flat, fan-shaped spray pattern that covers large areas. They are often used in gas cooling applications where a wide coverage area is needed.

Full cone nozzles: These nozzles produce medium to large-size droplets ideal for cooling and gas scrubbing applications where the gas needs to be treated with a liquid. Full cone whirl style nozzles like the MaxiPass® provide great coverage with even spray distribution. Two unique S-shaped internal vanes allow maximum free passage of particles for reliable performance in extreme conditions.

Hollow cone nozzles: A special type of single-fluid nozzle called a spillback, atomizes liquids into a fine hollow cone spray. Without changing the pump pressure, these nozzles ensure uniform droplet size over the entire controlled flow range. Spillback nozzles have a high turndown ratio of 10:1 and are highly reliable in extreme environments. These nozzles do not require compressed air and can lower operating costs.

Spiral full cone nozzles: The spray pattern of these nozzles is formed by the fluid shearing along the turns of the spiral, which produces multiple concentric cones. These cones form two to three bands of relatively coarse droplets surrounded by wider bands of relatively fine droplets producing very fine atomization. The larger droplets concentrate at the edges of each concentric ring of spray and take the small droplets with them into a fast-flowing gas. Spiral full cone nozzles, like the TF series, are ideal for gas scrubbing because they can deliver fine droplets to areas that other nozzle designs would not reach.

Spray Lances and Injectors: Spray lances and injectors include a spray nozzle and can spray a single fluid or multiple fluids into a vessel, pipe, duct, or tower. These fabricated solutions are ideal for precise placement of the nozzle into a process stream. BETE spray injectors are designed to optimize gas cooling and conditioning processes.

Learn More About Selecting Gas Cooling and Conditioning Nozzles

When selecting a spray nozzle for gas cooling and conditioning, it is important to consider factors such as the size of the droplets produced, the spray pattern, the flow rate, and the pressure of the gas and liquid streams. The appropriate nozzle will depend on the specific application and the desired results.

BETE offers Advanced Spray Engineering Services to solve more challenging and critical problems, including the ability to do CFD studies and physical testing. By combining our comprehensive in-house resources with our customers’ knowledge, BETE spray technology can proficiently solve complex gas cooling and conditioning requirements to ensure reliable and cost-effective results.

Let's Connect Today

Ready to improve your process with BETE Spray Technology?

Contact our spray experts to find the perfect nozzle for your application.