Process Gas Cooling/Quenching Nozzles

Cool hot flue or process gases prior to entering a scrubber, baghouse, or other temperature-sensitive equipment


BETE nozzles are used for quenching in commercial and industrial applications around the world. In many processes a gas is raised to temperatures that could easily damage downstream equipment. This can either be by direct combustion, as in the case of flue gas, or by secondary heating. The quickest and most effective way to cool a hot gas is through the evaporation of an injected liquid. Changing the phase of the injected liquid to gas consumes enormous amounts of energy compared to sensible/direct contact cooling. As an example, heating water from 32 °F to 212 °F (0 °C to 100 °C) requires about 180 BTU/lbm (418 kJ/kg). Converting that same water from liquid at 212 °F (100 °C) to steam at 212 °F (100 °C) requires about 1000 BTU/lbm (2320 kJ/kg), or more than 5 times the energy. The energy used to vaporize the gas is taken from the hot gas, thus lowering its temperature.

In evaporative gas cooling, a mist of water is sprayed into the hot gas. In many cases this is flue gas from a combustion process. The water then evaporates, cooling the system rapidly as the energy is used to change the water from liquid to gas. When a volume of water is atomized into smaller droplets, more surface area is exposed, allowing the evaporation rate to increase. The rate of evaporation 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.

Our applications engineers can confidently assess which nozzle to recommend with the information acquired through the BETE Gas Cooling/Quenching Application Intake Sheet. This data will also allow the engineer to calculate the amount of water, operating pressure, and drop size that is necessary for your application. It is important to note that since spray nozzles produce a droplet size spectrum rather than a single droplet size, expertise is needed to correctly choose between different types of nozzles. BETE engineers perform detailed thermodynamic calculations to determine the ideal nozzle, droplet size, and pressure for each system. For applications with precise requirements and/or complex geometry, BETE offers Computational Fluid Dynamics (CFD) analysis as a contract service to verify the suitability and effectiveness of a proposed quench system.
 

Selecting a Process Gas Cooling Nozzle:

Important factors to consider:

  • Initial/final process gas temperatures
  • Process gas composition (including initial water content)
  • Available residence time for droplet evaporation
  • Available and required flow rate
  • Available pressure drop (∆P) across the nozzle
    • ∆P = supply pressure at nozzle inlet - process pressure outside nozzle
  • Required coverage
    • Ensure complete contact/cooling of gas stream while minimizing potential wall contact
  • Required droplet size
    • Achieve complete or partial evaporation to obtain required cooling.
  • Required nozzle material
    • Quench nozzles often require special materials to withstand the high temperature and corrosive environments present in these applications.
  • Our experienced engineers can help determine which nozzle will perform as required with your design details.

Common Process Gas Cooling Nozzle Uses and Industries: 

  • Cooling process gases prior to scrubber/bag-houses
  • Cooling combustion exhaust gases
  • FGD quench systems
  • Emergency quench systems

Also recommended:

SpiralAir high flow air atomizing nozzles
 

PJ

  • BETE's P series of impingement style misting nozzles provides excellent atomization for efficient evaporation and cooling
  • Impingement style nozzle with external pin
  • No whirl vanes or internal parts
  • Lower flow rates than P series
  • Multiple filter options available
  • Optional safety wire hole available
Nozzle Type(s):
Impingement
  • Impingement nozzles provide some of the finest atomization of any nozzle type for lower flow rate applications making them ideal for many gas cooling applications.
Spray Pattern(s):
Mist
Flow Range:
.007 to 2.43 gpm
Typical Pressure Range:
50 to 3000 psi
Angle Range:
90°
Common Materials:
303, 316

Mist

Select a nozzle number below for performance graph, drawings, and to request a quote.
Nozzle Number Connection Sizes Spray Angles gpm @ psi     (density: 1 SG)
10 psi 40 psi 100 psi 1000 psi 2000 psi 3000 psi
PJ 6 1/8″, 1/4″ 90° - - .010 .030 .042 .052
PJ 8 1/8″, 1/4″ 90° - - .018 .057 .080 .099
PJ 10 1/8″, 1/4″ 90° - .017 .027 .085 .120 .147
PJ 12 1/8″, 1/4″ 90° - .023 .036 .115 .163 .199
PJ 15 1/8″, 1/4″ 90° - .037 .058 .185 .262 .320
PJ 20 1/8″, 1/4″ 90° .034 .067 .106 .335 .474 .581
PJ 24 1/8″, 1/4″ 90° .050 .100 .158 .500 .707 .865
PJ 28 1/8″, 1/4″ 90° .065 .130 .206 .651 .921 1.13
PJ 32 1/8″, 1/4″ 90° .090 .180 .285 .901 1.27 1.56
PJ 40 1/8″, 1/4″ 90° .140 .280 .443 1.40 1.98 2.43

These values are filtered based on search criteria or application and do not represent the full range of nozzles for this series. Click here to see all available series offerings.

TF

  • Thirty percent finer atomization than an equivalent whirl nozzle
Nozzle Type(s):
Spiral
  • Spiral nozzles provide some of the finest atomization of any nozzle type for medium to high flow rate applications making them ideal for many gas cooling applications
Spray Pattern(s):
Full Cone
Flow Range:
.494 to 335 gpm
Typical Pressure Range:
10 to 400 psi
Angle Range:
90 - 120°
Common Materials:
316, 347, 310

Full Cone

Select a nozzle number below for performance graph, drawings, and to request a quote.
Nozzle Number Connection Sizes Spray Angles gpm @ psi     (density: 1 SG)
5 psi 20 psi 40 psi 60 psi 100 psi 400 psi
TF 6 1/8″, 1/4″, 3/8″ 90°, 120° .494 .988 1.40 1.71 2.21 4.42
TF 8 1/8″, 1/4″, 3/8″ 90°, 120° .919 1.84 2.60 3.18 4.11 8.22
TF 10 1/4″, 3/8″ 90°, 120° 1.41 2.83 4.00 4.90 6.32 12.6
TF 12 3/8″ 90°, 120° 2.12 4.24 6.00 7.35 9.49 19.0
TF 14 3/8″ 90°, 120° 2.86 5.72 8.10 9.91 12.8 25.6
TF 16 3/8″ 90°, 120° 3.76 7.51 10.6 13.0 16.8 33.6
TF 20 3/8″ 90°, 120° 5.84 11.7 16.5 20.2 26.1 52.2
TF 24 1/2″ 90°, 120° 8.52 17.0 24.1 29.5 38.1 76.2
TF 28 1/2″ 90°, 120° 11.7 23.3 33.0 40.4 52.2 104
TF 32 3/4″ 90°, 120° 14.8 29.7 42.0 51.4 66.4 133
TF 40 1″ 90°, 120° 23.7 47.4 67.0 82.1 106 212
TF 48 1″ 90°, 120° 33.5 67.1 94.9 116 150 300

These values are filtered based on search criteria or application and do not represent the full range of nozzles for this series. Click here to see all available series offerings.

TF

  • Thirty percent finer atomization than an equivalent whirl nozzle
Nozzle Type(s):
Spiral
  • Spiral nozzles provide some of the finest atomization of any nozzle type for medium to high flow rate applications making them ideal for many gas cooling applications
Spray Pattern(s):
Hollow Cone
Flow Range:
.494 to 335 gpm
Typical Pressure Range:
10 to 400 psi
Angle Range:
90 - 120°
Common Materials:
316, 347, 310

Hollow Cone

Select a nozzle number below for performance graph, drawings, and to request a quote.
Nozzle Number Connection Sizes Spray Angles gpm @ psi     (density: 1 SG)
5 psi 20 psi 40 psi 60 psi 100 psi 400 psi
TF 6 1/4″ 90°, 120° .494 .988 1.40 1.71 2.21 4.42
TF 8 1/4″ 90°, 120° .919 1.84 2.60 3.18 4.11 8.22
TF 10 1/4″ 90°, 120° 1.41 2.83 4.00 4.90 6.32 12.6
TF 12 3/8″ 90°, 120° 2.12 4.24 6.00 7.35 9.49 19.0
TF 14 3/8″ 90°, 120° 2.86 5.72 8.10 9.91 12.8 25.6
TF 16 3/8″ 90°, 120° 3.76 7.51 10.6 13.0 16.8 33.6
TF 20 3/8″ 90°, 120° 5.84 11.7 16.5 20.2 26.1 52.2
TF 24 1/2″ 90°, 120° 8.52 17.0 24.1 29.5 38.1 76.2
TF 28 1/2″ 90°, 120° 11.7 23.3 33.0 40.4 52.2 104
TF 32 3/4″ 90°, 120° 14.8 29.7 42.0 51.4 66.4 133
TF 40 1″ 90°, 120° 23.7 47.4 67.0 82.1 106 212
TF 48 1″ 90°, 120° 33.5 67.1 94.9 116 150 300

These values are filtered based on search criteria or application and do not represent the full range of nozzles for this series. Click here to see all available series offerings.

ST

  • Spray tip constructed from extremely abrasion resistant material
  • Thirty percent finer atomization than an equivalent whirl nozzle
Nozzle Type(s):
Spiral
  • Spiral nozzles provide some of the finest atomization of any nozzle type for medium to high flow rate applications making them ideal for many gas cooling applications
Spray Pattern(s):
Full Cone
Flow Range:
.919 to 335 gpm
Typical Pressure Range:
10 to 400 psi
Angle Range:
90 - 120°
Common Materials:
316, Cobalt Alloy 6
  • Cobalt Alloy 6 provides an excellent balance between thermal and wear resistance, making it ideal for gas cooling applications

Full Cone

Select a nozzle number below for performance graph, drawings, and to request a quote.
Nozzle Number Connection Sizes Spray Angles gpm @ psi     (density: 1 SG)
5 psi 20 psi 40 psi 60 psi 100 psi 400 psi
ST 8 1/4″ 90°, 120° .919 1.84 2.60 3.18 4.11 8.22
ST 10 1/4″ 90°, 120° 1.41 2.83 4.00 4.90 6.32 12.6
ST 12 3/8″ 90°, 120° 2.12 4.24 6.00 7.35 9.49 19.0
ST 14 3/8″ 90°, 120° 2.86 5.72 8.10 9.91 12.8 25.6
ST 16 3/8″ 90°, 120° 3.76 7.51 10.6 13.0 16.8 33.6
ST 20 3/8″ 90°, 120° 5.84 11.7 16.5 20.2 26.1 52.2
ST 24 3/4″ 90°, 120° 8.52 17.0 24.1 29.5 38.1 76.2
ST 28 3/4″ 90°, 120° 11.7 23.3 33.0 40.4 52.2 104
ST 32 3/4″ 90°, 120° 14.8 29.7 42.0 51.4 66.4 133
ST 40 1″ 90°, 120° 23.7 47.4 67.0 82.1 106 212
ST 48 1″ 90°, 120° 33.5 67.1 94.9 116 150 300

These values are filtered based on search criteria or application and do not represent the full range of nozzles for this series. Click here to see all available series offerings.

MaxiPass

  • The design features of the MaxiPass provide high reliability when recycling cooling water or in other harsh conditions
  • BETE's unique, clog resistant S-vane design gives the MaxiPass the largest free passage available for a given flow rate, making it resistant to clogging, efficient, and reliable
  • Easily handles liquids with a high solids concentration
  • High reliability spray performance under the most difficult conditions
Nozzle Type(s):
Whirl
Spray Pattern(s):
Full Cone
Flow Range:
.697 to 325 gpm
Typical Pressure Range:
10 to 80 psi
Angle Range:
30 - 120°
Common Materials:
316, Cobalt Alloy 6
  • Cobalt Alloy 6 provides an excellent balance between thermal and wear resistance, making it ideal for gas cooling applications

Full Cone

Select a nozzle number below for performance graph, drawings, and to request a quote.
Nozzle Number Connection Sizes Spray Angles gpm @ psi     (density: 1 SG)
3 psi 5 psi 10 psi 20 psi 50 psi 80 psi
MP 125 3/8″ 60°, 90°, 120° .697 .886 1.23 1.70 2.62 3.26
MP 156 3/8″ 60°, 90°, 120° 1.11 1.41 1.95 2.70 4.16 5.18
MP 187 3/8″, 1/2″ 60°, 90°, 120° 1.60 2.03 2.82 3.90 6.00 7.48
MP 218 1/2″ 60°, 90°, 120° 2.55 3.24 4.49 6.21 9.56 11.9
MP 250 1/2″ 60°, 90°, 120° 2.87 3.64 5.05 6.99 10.8 13.4
MP 281 3/4″ 30°, 60°, 90°, 120° 3.52 4.47 6.20 8.58 13.2 16.5
MP 312 3/4″ 30°, 60°, 90°, 120° 4.26 5.41 7.50 10.4 16.0 19.9
MP 343 3/4″ 30°, 60°, 90°, 120° 5.21 6.63 9.18 12.7 19.6 24.4
MP 375 3/4″, 1″ 30°, 60°, 90°, 120° 6.15 7.82 10.8 15.0 23.1 28.8
MP 406 1″ 30°, 60°, 90°, 120° 7.37 9.37 13.0 18.0 27.7 34.5
MP 437 1″, 1 1/4″ 30°, 60°, 90°, 120° 8.61 11.0 15.2 21.0 32.3 40.3
MP 500 1 1/4″ 30°, 60°, 90°, 120° 11.1 14.1 19.5 27.0 41.5 51.8
MP 531 1 1/4″ 30°, 60°, 90°, 120° 12.3 15.6 21.7 30.0 46.2 57.6
MP 562 1 1/4″, 1 1/2″ 30°, 60°, 90°, 120° 13.5 17.2 23.8 33.0 50.7 63.3
MP 593 1 1/2″ 30°, 60°, 90°, 120° 15.4 19.5 27.1 37.5 57.7 71.9
MP 625 1 1/2″ 30°, 60°, 90°, 120° 16.4 20.8 28.9 40.0 61.5 76.7
MP 656 1 1/2″ 30°, 60°, 90°, 120° 19.9 25.4 35.1 48.6 74.8 93.3
MP 687 1 1/2″ 30°, 60°, 90°, 120° 20.9 26.6 36.9 51.1 78.6 98.0
MP 750 2″ 30°, 60°, 90°, 120° 25.5 32.4 44.9 62.1 95.6 119
MP 812 2″ 30°, 60°, 90°, 120° 27.8 35.4 49.0 67.9 104 130
MP 875 2″ 30°, 60°, 90°, 120° 34.4 43.7 60.5 83.8 129 161
MP 937 2″ 30°, 60°, 90°, 120° 38.5 49.0 67.9 94.0 145 180
MP 1000 2″ 30°, 60°, 90°, 120° 45.1 57.3 79.4 110 169 211

These values are filtered based on search criteria or application and do not represent the full range of nozzles for this series. Click here to see all available series offerings.

XAAD

  • Internal mix air atomizing nozzle
  • Wide variety of hardware configurations
  • Available with clean out and shut off capabilities
  • Nickel alloy and other 300 series stainless steels available by request
Nozzle Type(s):
Air-Atomizing
  • Air-atomizing nozzles provide the fine atomization and high turndown rates often required for gas cooling applications
Spray Pattern(s):
Hollow Cone
Angle Range:
20 - 90°
Common Materials:
316, 321 / 347, 310, Alloy 625