EcoSpray™ Advanced Gas Cooling Spray Systems

State-of-the-art Evaporative Gas Cooling and Conditioning Systems

Available Features
• Downflow/upflow spray cooling tower design
• Dual-fluid compressed air systems
• Single-fluid mechanical atomization systems
• Hybrid low-pressure assisted single fluid systems

Design Benefits
• 30% Lower power consumption than nearest competitor
• Single or multiple nozzle spray lances
• CFD designed spray cooling chambers
• No need for water tanks

EcoSpray™ Advanced Spray Cooling Systems

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EcoSpray™ Downflow Evaporative Gas Cooling Tower
Applications: Cement, Lime, Incineration

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EcoSpray™ Upflow Evaporative Gas Cooling Tower
Applications: Steel EAF, Steel BOF


Two of Several EcoSpray™ Gas Cooling Spray Chamber Arrangement Layouts


EcoSpray™ Atomizing Technology Spectrum


OptiVap™ Evaporative Gas Cooling Systems (EGC)

Spray Cooling Tower Applications
Cooling towers are used to cool and humidify hot gases in order to improve the efficiency of the dust collector or to allow the use of lower priced filter media.

BoldEco implements low maintenance dual fluid air+water injection systems to drastically shorten the evaporation time, resulting in dry bottom operation.

A sophisticated water regulation system coupled with rapid temperature sensors provides a quick response to temperature variations to achieve precise tower outlet gas temperatures.

Detailed analyses, including model studies and computer simulations of gas distribution and tower geometries are carried out to prevent gas turbulence or poor gas / water interaction.

BoldEco offers the following evaporative gas cooling solutions for air pollution control applications:

OptiVap™ Dual-Fluid Spray Systems


The OptiVap™ dual-fluid evaporative gas cooling system utilizes a newly developed dual-fluid (air atomized) nozzle technology that uses 2.3 m3/h of air for every l/m of water injected. For the same droplet size generation, the closest competitive system utilizes almost 3.2 m3/h of air for every l/m of water injected, or 36% MORE AIR. That means that the OptiVap nozzle is over 30% more efficient than its nearest competitor!

Advantages of the OptiVap™ DF System:

30% less compressed air consumption
Able to operate at air deficit without droplet size degradation
• Single or multiple nozzle spray lances
• CFD designed spray cooling chambers
• Low-cost point-of-use compressor systems
• No need for water tanks

SpillAir™ Hybrid Spray Systems


BoldEco’s patented SpillAir™ nozzle combines the advantages of mechanical atomization with those of air atomization. This unique hybrid nozzle makes possible a low-cost retrofit of poorly operating spray cooling towers. The SpillAir™ nozzle can also reduce the cost of new installations requiring mechanical atomizers by allowing for much smaller evaporative gas cooling towers than with mechanical atomization alone.
The SpillAir™ nozzle is essentially a high volume, low pressure (HVLP) air assisted mechanical hybrid nozzle. The mixing between the air and the water takes place immediately outside of the spray orifice (external mixing), virtually at ambient pressure. A low-cost blower is installed for virtually maintenance free HVLP air.

Principal advantages of the BoldEco SpillAir™ nozzle:
• Improved Spray Cone Characteristics: By design, a high-velocity air shroud is produced around the mechanical atomization cone in order to improve droplet formation and to control the plume spray angle. This results in a constant angle of atomization and an optimized droplet size.
• Improved Gas-to-Spray Interaction: Flow vectors generated by the patented BoldEco Assist Air Annulus enable the naturally produced hollow-cone nozzle characteristics of the SpillAir™ nozzle to become a full-cone spray. This results in droplets that are more diffused within the gas stream, improving hot-gas-to-liquid-droplet interaction.
• Improved Evaporation Rates: The annular air shroud that is created at the edge of the BoldEco SpillAir™ nozzle entrains the liquid droplets into its high velocity flow field, increasing the velocity of the droplets, and therefore the droplet-to-gas differential velocity, reducing evaporation time.
• Lower Achievable Outlet Temperatures: With standard mechanical spill-back nozzles, the droplet sizes are randomly distributed within the spray cone. This results in the smaller droplets removing much of the heat from the gases, leaving the balance of the gases with insufficient heat capacity to evaporate the larger droplets. With the BoldEco SpillAir™ nozzle, the finer fraction of the droplets, having less inertia, is easily moved by the air jet into the center of the spray cone, while the larger droplets, having more resistance to being moved, remain on the outside periphery of the spray cone. This droplet distribution results in significantly improved nozzle performance, because once the gases evaporate the larger droplets on the outside of the spray cone, where they have the highest heat content, as they cool, they converge with the smaller diameter droplets, which are easier to evaporate with cooler gases. This phenomenon allows for lower spray tower outlet temperatures within a given spray tower volume.

Benefits of the SpillAir™ nozzle
• Improved quality of droplet distribution and heat exchange
• Improved turn-down capabilities
• Constant angle of atomization avoids interference with neighboring sprays
• Shield air protects nozzles from fouling
• Shield air reduces scaling in the presence of hard water
• Maintains low energy consumption while improving performance
• Requires shorter residence times for the same outlet temperature or lowers outlet temperature within the parameters of the existing residence time

SpraySentinel ES™ Supervisory Systems


The SpraySentinel ES controller is an automatic spray system supervisory system designed to monitor spray systems performance and alert plant personnel to any potential problems that might be hampering spray system performance.

The SpraySentinel ES carries out a self-learning period to record how the installed lances and nozzles are respond to varying operating conditions. After a short learning period, the controller starts to detect all critical deviations of the working parameters of the cooling system and, when appropriate, to provide the operators with an alarm.
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Spray Cooling Lances on Steel EAF

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SpraySentinel ES™ Installed on a Cement Plant GCT

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310 Stainless Steel Upflow Gas Cooling Tower
on Steel Electric Arc Furnace