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Gas cooling

Spray nozzles and spray systems are used for gas cooling and conditioning to improve processes in the chemical and petrochemical industry, cement production, waste incinerators, power plants, etc.

Gas cooling protects equipment and create stable conditions for safe and efficient operation downstream.

How does gas cooling work?

The quickest and most effective way to cool a hot gas is to evaporate an injected liquid. Changing the phase of the injected liquid to gas consumes enormous amounts of energy.

As an example, heating water from 0 °C to 100 °C requires about 418 kJ/kg. Converting that same water from liquid at 100 °C to steam at 100 °C requires about 2320 kJ/kg, which is more than five times the energy. The energy used to vaporize the gas is taken from the hot gas, thus lowering the gas temperature.

When a volume of water is atomized into smaller droplets, more surface area is exposed, increasing the evaporation rate. The evaporation rate is often critical 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.

Factors to consider to optimise the gas cooling process

There are several key factors that are important to optimise a gas cooling process. Our experienced staff and engineers are happy to provide calculations and find the right solution.

Gas temperature - initial and final process gas temperatures
Process gas composition, including relative humidity (RH) of the incoming gas.
Available residence time for droplet evaporation
Available and required flow rate
Available liquid pressure drop (∆P) across the nozzle = supply pressure at nozzle inlet - process pressure outside nozzle
Required coverage - ensure complete contact/cooling of a gas stream whilst minimising potential wall contact
Required droplet size - the droplet size required to achieve complete or partial evaporation to obtain the required cooling
Required nozzle material - quench nozzles often require special materials to withstand the high temperature and corrosive environments present in these applications

Project review and proposed solution

To deliver the optimal solution, it is important to go through in detail various factors that affect product choice, type of solution, investment objective, and other requirements at an early stage of the project.

Robin Ryberg Spray nozzles & systems, Tank cleaning I look forward to providing product advice and solutions! Let's meet via a video call or a site visit. You can also phone or email us, of course.

Hans Linder Spray nozzles & systems, Tank cleaning, Safety showers, Tank storage equipment I look forward to providing product advice and solutions! Let's meet via a video call or a site visit. You can also phone or email us, of course.

Linda Caporicci Column internals, Droplet separation, Spray nozzles & systems, Other products I look forward to providing product advice and solutions! Let's meet via a video call or a site visit. You can also phone or email us, of course.

Alexander Bergman Droplet separation, Column internals, Spray nozzles & systems, Tank cleaning I look forward to providing product advice and solutions! Let's meet via a video call or a site visit. You can also phone or email us, of course.

Sol Millerv Dust control, Spray nozzles & systems, Tank cleaning I look forward to providing product advice and solutions! Let's meet via a video call or a site visit. You can also phone or email us, of course.

A start-up meeting is important to find out about various factors that will affect choice of equipment and solution in order to achieve the most efficient and sustainable solution. We are happy to set up the start-up meeting as a web meeting or a site visit, depending on your preference. All details and information from the start-up meeting we will summarise and go through with you to make sure we agree on project scope and objective.

Next step, we present a proposed solution, focusing on function, lifespan, quality, choice of material, operating and maintenance costs, and environmental impact. Our goal is to deliver a sustainable solution that creates added value to your company,