Evaporative Cooling:

The Best Way to Cool Hot Gases and Reduce Emissions

If you have gases to cool or condition, you know technology is advancing rapidly and you have more options than ever before. However, the basic need to cool hot gases and reduce volume quickly still remains. And, in the final analysis, spray technology remains the easiest and most effective solution.

• More efficient reduction of gas volume results in lower energy costs
• Maintenance is minimized
• Precise control of humidity prior to electrostatic precipitators (ESPs) improves dust collection efficiency and opacity correction
• Wet deposits and wet walls are eliminated
• Significant reductions in the creation and emission of toxic dioxins and furans are also possible, making compliance with government regulations less costly

Many pulp and paper mills, steel mills, power plants, waste incineration facilities and cement plants use air atomizing for evaporative cooling in a variety of applications. Cooling prior to baghouse or ESP, NOx control and SO2 removal are areas where evaporative cooling via spray technology is ideally suited.

FloMax® Air Atomizing Nozzles Offer Superior Performance

All air atomizing nozzles are not alike. In fact, very few are suitable for use in gas conditioning. High efficiency nozzles offer tight control of drop size and spray coverage. The goal is to minimize Dmax and achieve a finely-atomized spray with D32 less than 100 microns at 10 gpm (37.8 l/min). A multi-stage atomization process must be used to achieve this very small drop size. The patented three-stage atomization process used by FloMax Air Atomizing nozzle is extremely air efficient and is the primary reason why it is the preferred nozzle for gas conditioning.

Unlike competitive nozzles using single-step atomization, FloMax nozzles produce a D32 drop size that is 34% smaller utilizing 20% less air than competitive nozzles. [Flow rate of 10 gpm (37.8 l/min)]

Smaller drop size benefits:

• Lower installation and maintenance costs due to the wide range of flow rates per nozzle
• The liquid being sprayed generates more surface area per gallon for a more complete reaction and total absorption without wetting
• Lower energy costs
• Longer compressor life

• FloMax nozzles allow for a high turndown of flow rate so a set air pressure can be maintained while liquid pressure and flow varies
• A large flow rate per nozzle means that fewer nozzles are required for cooling resulting in a lower initial purchase cost and less maintenance
• Large free passage reduces clogging and allows flexibility in water sources
• Low maintenance since FloMax nozzles operate at low pressures
• FloMax nozzles are available in a variety of corrosion and erosion resistant materials, such as Hastelloy®, Stellite® and reaction-bonded silicon carbide, to ensure optimal performance in harsh environments

• Easy maintenance when required – no special tools are necessary
• Wide range of flow rates available – 0.5 gpm to 52 gpm (1.8 l/min to 197 l/min)
• Lances, manifolds and headers are available as installation options along with adapters, cooling jackets, purge tubes and protective tubes as needed
• Product line overview:
  • FloMax A Series
    • 0.7 to 30.0 gpm (2.6 to 114 l/min)
    • 55° and 20° spray angles
    • FloMax X Series
    • 0.03 to 1.5 gpm (0.11 to 1.89 l/min)
    • 20° spray angle (55° available in some sizes)

Our Gas Conditioning System is a total custom solution:

• It is easy to install, easy to operate and easy to maintain
• It is unsurpassed in energy efficiency and occupies minimal space
• The AutoJet Spray Controller, equipped with patent-pending SprayLogic® software, monitors and automatically adjusts system operation providing unmatched performance at a reasonable cost
• Technical information is readily available as is training and ongoing support
• Single-source convenience

Flowback nozzles feature a simple two-piece design for easy installation and maintenance. Competitive lances utilize a bellows design that is easily damaged during operation or maintenance. This results in internal leaking, poor atomization and wetting. These lances require special tools for installation and maintenance. Our Flowback nozzles are often selected to replace competitive nozzles in existing systems because of the advantages offered in installation and maintenance.

Our Flowback line is available with the largest selection of nozzle capacities. Sizes range from 1.2 to 45 gpm (4.5 to 170.3 l/min) at 600 psi (41.4 bar).

Hastelloy is a registered trademark of Haynes International Inc.
Stellite is a registered trademark of Deloro Stellite, Inc.