Any EGC system is only as good as the gas flow field it is injected in.
BoldEco suggests that a full CFD model be carried out in order to ensure that the interaction between the injected droplets and the gases results in complete evaporation.
In Cement, spray coolers have been applied almost universally to dry process cement plants. This was due to the relatively high resistivity of the raw meal and to the steady-state conditions of the cement process.
The problem arises when the process transitions from compound operation to direct operation, and vice versa. Additionally, the need to reach lower temperatures in order to help existing ESPs function more efficiently has been difficult to accomplish with water-only mechanically atomized systems.
BoldEco evaporative gas cooling systems greatly improve the reliability of spray cooling as it applies to cement. Gone are the wet bottoms by way of improved gas flow, droplet generation and control algorithms. Low air consumption, one of the many favorable characteristics of BoldEco nozzles not only helps to improve emissions, but helps to save energy as well.
Spray coolers are being applied more and more to various processes in order to reduce dioxin and furan formation as well as to avoid operational problems associated with traditional heat exchangers. Spray cooling towers can be designed to withstand high negative pressures, high temperatures and high dust loads, such as those found in the operation of steel mill furnaces.
A special gas cooling tower design is available that promotes uniform gas flow distribution to ensure that the sprays are well distributed with respect to the gas flow for properly balanced gas cooling and to maintain predictable performance throughout the varying gas flow range of any process.
Thanks to new advanced technological advances, evaporative coolers can be installed in steel mill Electric Arc Furnace applications where previously it was thought that spray coolers were not practical.
BoldEco has numerous installations where the successful implementation of a spray cooling tower has resulted in capital and operational savings to the customer.
BoldEco offers the following evaprative gas cooling solutions for air pollution control applications:
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 most efficient competitive system utilizes almost 3.2 m3/h of air for every l/m of water injected, or 36% MORE AIR.
Advantages of the OptiVap DF System:
• Lowest compressed air consumption
• Single or multiple nozzle spray lances
• CFD designed spray cooling chambers
• Low-cost point-of-use compressor systems
• No need for water tanks
BoldEco Environment also offers OptiVap single-fluid evaporative gas cooling system as an option for those who don't require the high efficiency or the low evaporation times offered by a dual-fluid system.
BoldEco Enviroment has a long legacy in the design and supply of air-to-air heat exchangers. Lately, we have been asked to develop a non-fouling heat exchager for cement and steel processes, but it is reallly well suited for any process that may have condensables in the gases that can foul the heat exchange surfaces.
BoldEco Environment air-to-air heat exchangers are designed and manufactured according to the individual requirements for various custom applications. The EcoVent heat exchanger series is designed with our own proprietary technology to produce heat exchangers with the following characteristics:
• Non-fouling
• Removable Tubes
• Direct Drive Fans
• Single-fan Multi-stage Cooling
• Single-pass
• Double-pass
• With or without heat recovery
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