The cooling of gas flows by injecting water or other coolants is a very common application for our spray nozzles.  Correct nozzle selection is of critical importance in many spray cooling applications as the properties of the spray will determine how quickly heat is absorbed and where the spray will reach within a given gas flow.


Application Of Gas Cooling Nozzle

Material of Gas Scrubbing Nozzle
Air Inlet Cooling

Cooling Deluge

Process Gas Cooling

Pond Cooling

Cooling Tower

Nozzle selection

When spraying into a hot gas flow above the boiling point of the coolant most of the cooling is caused by taking heat from the gas to evaporate the fluid.  The rate of evaporation will depend on the average droplet size of the spray.  Sprays consisting of smaller droplets will evaporate far more rapidly than sprays containing larger droplets.  In fast moving gas flows this can be very important as often cooling needs to be achieved before the gas reaches another point in the process.  Correct nozzle selection can thus reduce the need for long quench chambers.

To learn more about which spray nozzle would be right for your gas cooling application, please explore the specific categories listed below, or contact our experienced engineers.

1. Air Inlet Cooling—-Air Atomizing Nozzles

Many facilities or processes in hot, dry areas can benefit from using spray nozzles to cool the inlet air streams.

Evaporating water into the inlet air can provide critical cooling of heat sensitive areas such as electronic server rooms or animal enclosures.

It can also provide significant increases in the efficiency of equipment such as gas turbines or air-cooled condensers by cooling the air and increasing the relative humidity level of the inlet air streams to these units.

Spray nozzles can provide an effective and economical alternative to the use of electric chillers in many applications.

Important factors to consider:

  • Air temperature & humidity
  • Available quench length
  • Available/required flow rate
  • The available pressure drop across the nozzle

2.Cooling Deluge—-Full Cone Nozzles

CYspray provides a range of high-quality nozzles that are useful for reducing the temperature of various components and parts using a deluge spray.

Many production processes require the product to be hot during work and then cooled back to ambient temperature.

In metal processing industries, castings, extrusions, and hot-worked products fall into this category, as do any components that have been heated treated. In the food industry, many products are packaged hot and must be cooled before storage and shipment.

Regardless of whether you are cooling steel or soup.

Important factors to consider:

  • Target final object(s) temperature
  • The shape of the object(s)
  • Specific heat of object(s) material
  • Speed of travel (if moving)
  • Required coverage
  • Available and required cooling media flow rate
  • Available liquid pressure drop across the nozzle

3.Process Gas Cooling—-Spiral Nozzles / Air Atomizing Nozzles

Nozzles are used for quenching in commercial and industrial applications around the world.

In many processes gas is raised to temperatures that could easily damage downstream equipment.

This can either be by direct combustion, as in the case of flue gas or by secondary heating.

The quickest and most effective way to cool a hot gas is through the evaporation of an injected liquid.

Changing the phase of the injected liquid to gas consumes enormous amounts of energy compared to sensible/direct contact cooling.

In evaporative gas cooling, a mist of water is sprayed into the hot gas.

In many cases, this is flue gas from a combustion process. The water then evaporates, cooling the system rapidly as the energy is used to change the water from liquid to gas.

When a volume of water is atomized into smaller droplets, more surface area is exposed, allowing the evaporation rate to increase.

The rate of evaporation is often criticized as the gas must reach its final temperature before a fixed point downstream.

The evaporation rate is dependent on the droplet size, temperature differential, and partial pressure among other variables.

Important factors to consider:

  • Initial/final process gas temperatures
  • Process gas composition (including initial water content)
  • Available residence time for droplet evaporation
  • Available and required flow rate
  • The available pressure drop across the nozzle
  • Required coverage: Ensure complete contact/cooling of the gas stream while minimizing potential wall contact
  • Required droplet size: Achieve complete or partial evaporation to obtain required cooling.
  • Required nozzle material: Quench nozzles often require special materials to withstand the high temperature and corrosive environments present in these applications.

4.Pond Cooling—-Spiral Nozzle

Cooling ponds are used to lower water temperature through contact cooling with the surrounding air.

Static ponds often have low cooling efficiency and require a lot of space as only the surface of the pond is in direct contact with the air, resulting in relatively expensive use of valuable land.

CYSpray offers a wide variety of spray nozzles which can dramatically lower the expense and footprint of cooling ponds.

By spraying and atomizing the water from the cooling ponds into the air, spray nozzles significantly increase the surface area of water exposed to the air, thus improving the cooling efficiency and decreasing the area needed for the pond.

In some cases, the use of spray nozzles can reduce the land required to 5% of the area needed for a static pond.

Important factors to consider:

  • Environment
    • Average temperatures, relative humidity, prevailing wind speeds, etc.
  • Nozzle placement
    • In general, spray nozzles are placed evenly around/over the pond at a height that maximizes residence times while taking droplet drift due to wind into account
  • Nozzle clog resistance
  • Available and required flow/cooling rates
  • Available pressure drop (∆P) across the nozzle
    • ∆P = supply pressure at nozzle inlet – process pressure outside nozzle
    • Typical operating pressures range from 10-20 PSI (0.7-1.4 bar) to produce a drop size capable of efficient cooling while minimizing evaporation losses and wind drift

5.Roll Cooling—-Flat Fan Spray Nozzles

Cooling & lubricating mill rolls used for the production of steel and aluminum

Important factors to consider:

  • Required coverage
  • Spray media density and viscosity
  • Ease of maintenance/replacement
  • Available nozzle mounting locations
  • Available and required flow rate
  • Available pressure drop (∆P) across the nozzle
    • ∆P = supply pressure at nozzle inlet – process pressure outside nozzle

More nozzle for cooling application:

  • Steel continuous casting
  • Skin coverage wire elongation project
  • Plastic pipe forming
  • Conveyor belt cooling
  • Heat treatment before quenching
  • Die casting cooling
  • PVC pipe extrude cooling
  • The secondary cooling of billet continuous casting machine in steel rolls cooling
  • Storage tank cooling
  • Chamber at kiln back end cooling
  • Roof cooling
  • Spiral condenser cooling
  • Chamber at kiln back and cooling
  • Aluminium ware angioclast cooling
  • Hoop rolling mill cooling
  • Tool and material cooling
  • before electrostatic precipitation cooling and humidifying
  • Draper-type muller cooling
  • Drinks cooling
  • Wire stretch project cooling
  • Plastic moldings cooling
  • Product direct and indirect cooling
  • Spray and temperature drop for equipment

Consult Your CYSpray Industry Nozzle Experts

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