Achieve Effective, Efficient Gas Cooling with an AutoJet® Gas Conditioning System

For paper mills, steel mills, power plants, waste incineration facilities and cement plants with gases to cool or condition, spray technology remains the most effective solution. Cooling prior to baghouse or ESP, NOx control and SO2 removal are areas where evaporative cooling via spray technology is ideally suited.

In recent years, evaporative cooling utilizing air atomization has become the preferred solution for a variety of reasons:

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

The patented three-stage atomization process used by FloMax® air atomizing nozzles is extremely air efficient and is the primary reason why it is the preferred nozzle for gas conditioning

Solutions that Have Worked for Your Peers and That May Help You Boost Performance, Too

Efficient Gas Cooling Improves Production

Small droplet sizes produced by FloMax air atomizing nozzles allow greater volumes of gas to be cooled without wetting and maintenance headaches.

Induct Gas Cooling Prior to ESP

High-efficiency FloMax air atomizing nozzles reduce gas temperature and correct opacity to improve ESP performance.

PulsaJet® Automatic Spray Nozzles Provide Unmatched Precision for the Most Demanding Coating, Sealing, and Marking Operations

• Speeds up to 10,000 cycles per minute
• Hydraulic or air atomizing spray tips, including selected quick-connect tips
• Flow rates up to 15.8 gpm (59.8 l/min)
• Fluid pressures up to 350 psi (24 bar)
• Intrinsically safe versions

Using an AutoJet® spray controller in conjunction with PulsaJet nozzles will maximize cycle speed, enable Pulse Width Modulated (PWM) flow control, allow spray operation validation and provide other advanced control options.
PulsaJet nozzles can help increase productivity and lower costs in many ways:

• High speed cycling means faster line speeds
• Accurate spray placement ensures the sprayed solution is delivered to the target with minimal waste
• Reduced overspray and misting improves worker safety
• High turndown ratio allows a wide range of flow rates without having to change spray tips
• Compact design allows smooth integration to most work environments
• Operating at low flow rates using clog-resistant larger tips can result in reduced maintenance time.

Compact WindJet® Air Control Nozzles: Designed for Use When Space is Tight

Standard Air Atomizing Spray Manifolds Help Ensure Proper Nozzle Placement and Optimal Performance

We offer a wide range of spray manifolds to simplify nozzle positioning, installation, and maintenance, and contribute to trouble-free operation.  Options include:

• Channel Manifold: Basic spray nozzle manifold incorporated in a C-channel for easy mounting. Nozzles can be spaced as needed for precise spray placement
• Pipe-in-Pipe Manifold: Conventional spray manifold mounted inside a slotted pipe to protect nozzles from the external environment and minimize maintenance time
• 53500 Manifold: Modular design manifold for industrial applications is lightweight, easy to assemble, and keeps tubes and fittings organized for easy service
• 54000 Manifold: Fully integrated manifold designed specifically for tablet coating applications offers the same benefits as the 53500 Manifold with mechanically polished and electro-polished surface finish, including internal flow passageways
• 58800 Manifold: Lightweight, compact manifold allows ability to service spray nozzles while keeping piping in place

Manifolds are available in a variety of lengths, nozzle spacing options, mounting options and are suitable for use with several types of air atomizing nozzles.

In many applications, the use of anti-bearding spray set-ups can help reduce clogging. These set-ups change the air current around the spray tip to prevent drops from falling back on the nozzle and causing build-up. In some cases, users can run their spray operations up to 20-times longer without shutting down.

The addition of a heat jacket can ensure trouble-free atomization of hard-to-spray liquids such as waxes, adhesives, starches and syrups and minimize maintenance due to clogging. When spraying an extremely difficult solution such as chocolate, an automated system may be required.

Heated automated systems use closed-loop temperature control to ensure liquid temperature is ensured all the way from the tank to the target. The pressure tank and liquid and air lines are usually jacketed or heated to ensure consistent flow rates and clog-free operation.

Dedicated spray controllers can automatically adjust spray performance to compensate for changes in operating conditions. This minimizes clogging in many applications. However, when spray nozzles do clog, it is detected immediately and operators are notified to minimize scrap and lost production time.