Upload
aaron-flowers
View
364
Download
10
Embed Size (px)
Citation preview
7/21/2019 Spillback Nozzles
1/12
Spillback Nozzle Lances
7/21/2019 Spillback Nozzles
2/122
Efficient Gas Conditioning
made by Lechler
For over 125 years, Lechlerhas pioneered developmentsin spray technology for allindustries, designing, develop-ing and manufacturing prod-ucts of outstanding reliabilityand performance. All accom-
panied by expert advicebased on a thorough know-ledge gained through experi-ence in providing both con-ventional and innovativesolutions.
Wherever you are, Lechlerseeks to establish a partner-ship, helping you to enhanceproduct quality through theapplication of advanced fluidsengineering expertise.
From development, throughmanufacture to installation,
Lechler products are subjectto continuous quality manage-ment. State of the art test andinspection methods, often inexcess of our ISO 9001 certifi-cation, reliability and longevityof Lechler spraynozzles andsystems.
VarioCoolsystem
Lechler offers you complete gas conditioning sys-
tems VarioCool, including nozzle lances, pumps,
regulation units and electronic controls. As the only
manufacturer worldwide Lechler supplies gas condi-
tioning systems equipped with spillback nozzle
lances as well as twin fluid nozzle lances.
The coupled with the engineers experience gained
through numerous installations worldwide, enables
tailor-made solutions to be designed and imple-
mented.
7/21/2019 Spillback Nozzles
3/123
Pump and regulation unit
Computer aided data capture
Lechler uses the most modernmeasuring technology which
was partly developed byLechler. Data from our mea-suring laboratory is availableon request. A further serviceoffered by Lechler is our seriesof gas cooling calculations.
Measuring technologyFor the design of an engineer-
ed system or plant it is neces-sary to obtain a multitude ofnozzle specific data thatpermits exact statementsabout flow rate, pressure,spray width, droplet size anddroplet velocity. In order tomeasure these parameters
Complete system from one source with guar-
anties on system and process.
Guarantee on full evaporation.
Lechler offers spillback and twin fluid lances.
Extensive engineering support, e.g. gas cool-ing calculations.
Modern measuring technology guarantees
high product quality.
Applications
Lechler VarioCool
gas conditioning systems have beenused successfully in the following processes of gastreatment:
Cooling / Humidifying (conditioning) in front of ESPas an example in waste incinerators, in cement works, incoal fired power stations in front of ESP/baghouse.
DeNox ProcessIn accordance with the SNCR (high temperature DeNoxprocess) or SCR (low temperature DeNox process with cat-
alytic converter) technology e.g. in municipal waste inciner-ators and power stations.
Spray dry FGD(for drying of reacted limestone slurry), such as in municipalwaste incinerator plants.
Spray adsorptionas in flue gas desulphurization sections of smaller blocktype coal fired power stations.
Atomizing of residues into burning chambers,for instance in waste and special waste incinerator plants.
7/21/2019 Spillback Nozzles
4/124
Gas Conditioning with
Lechler Spillback Nozzle Lances
Anywhere where exhaust ga-ses have to be cooled in con-ditioning towers before theyare conveyed into the electro-static precipitators, such as cement industry refuse incineration plants sponge iron plants blast furnaces and oxygen
vessels in steel plants glass plants the varying
temperatures and chang-ing volumes of the exhaustgases pose a problem:
How to atomize a variable flowof liquid with consistent fine-ness?
Lechler Spillback NozzleLances provided the ans-
wer.
The liquid is always pumpedto the nozzle at a constanthigh pressure regardless ofthe sprayed volume.
All the nozzles which atomizeby liquid pressure only are fed
from the same supply line witha joint return pipe to the reser-voir. The flow rate of thesprayed liquid is only con-trolled by a motorised regulat-ing valve in the joint returnline. Maximum injectionoccurs when the return line isclosed.
The feed pressure in the sup-ply line remains always con-stant. The turn down ratio is10:1 (max.: min. flow rate withno change of number of noz-zles) maintaining a constantfine atomization over the fullrange.
The Lechler Spillback NozzleSystem ensures good pro-cess results due to precisecooling of the exhaust gaseswith the optimum of coolingliquid.
Variable factors
Spillback pressure P2
Spillback flow rate V.
2
Sprayed volume V.
1
Constant factors
Return line
Supply line
Pump delivery V.
3
Feed pressure P1
Droplet size
7/21/2019 Spillback Nozzles
5/125
The pressure flow rate dia-gram shows the quantity ofsupply flow rate atomized inrelation to the return pressure(P2). It also shows what thereturn pressure must be inorder to obtain a specific
spray flowrate V. 1 at constantfeed pressure. Maximumatomized flow rate V
.1max. is
attained when the return iscompletely closed. As the re-turn is opened, the flow rate ofatomized liquid reduces.At part load, the sum of theatomized liquid and the return
flow is greater than the maxi-mum atomization flow.
Consequently, the capacity ofthe h. p. supply pump must becorrespondingly higher(approx. 40 - 50 %). The deli-
very curve of the pump shouldbe as flat as possible in theworking range.
An accurately matched controlcharacteristic must be chosenfor the regulating valve inorder to guarantee the turndown ratio of 10 : 1.
Pressure-Flow Diagram
Spillback pressure P2 [bar]
Flowrate[l/min]
P1
V.
2
V.
1 V.
1max V.
3
V.
Pump
PSV.
1min
V.
1 = Sprayed volume
V.
1max. = Max. sprayedvolume
(return line closed)V.
1 min. = Min. sprayedvolume(return line com-pletely open)
V.
2 = Spillback flow rate
V.
3 = Pump delivery
V.
Pump = Pump delivery pernozzle
P1 = Constant feedpressure
P2 = Spillback pressure
PS = Spillback pressure atV.
1max.(Pmax for controlvalve)
Turn down ratio = V.
1max./ V.
1min.
7/21/2019 Spillback Nozzles
6/126
Examples of configuration
Supply ring main
Vessel wall
Return ring main
Barrier air
Spillback Nozzle Lance with accessories
Spillback Cluster Lance
Lechler Spillback NozzleLances of this type can bedelivered with various spraypositions of the nozzles. Thecompact construction allowseasy mounting. The robustconstruction made from high
quality stainless steel providessignificant safe operation ofthe spray lance. Lechler Spill-back Nozzle Lances are de-livered as a complete sprayunit. All components are de-signed to exactly match eachother. This ensures minimumdown time when installing andconnecting.
Advantages:
Compact construction Robust design Maintenance friendly
construction Functional and safe opera-
tion
The nozzle lance illustrated isdesigned with a compactshield. This shield reduces theflow resistance in the gas ductcompared with the lance itself.At high gas velocity in particu-lar, this results in an improvedprocess result. The air barrier
protects the nozzle from clog-ging and protects the interiornozzle lance against corrosionand overheating. The conicaldesign of the front barrier aircap effectively ensures that thenozzle is evenly surroundedby an air barrier. This guaran-tees reliable, low-maintenanceoperation. The front barrier aircap can be quickly dismantledin order to inspect the nozzle.
Advantages:
Robust and compactdesign High safety in operation
Spillback Nozzle Lance with small shield and barrier air
7/21/2019 Spillback Nozzles
7/127
Examples of configuration
If the object is to atomize rela-tively large quantities of cool-ing water, spillback nozzlelances with cluster head canbe installed as an alternativeto several individual lances atdifferent levels. The control-
lable atomization rate is 10:1.Each multiple sprayer cancomprise 3, 4 or 6 nozzles.Spillback nozzle lances of thistype are available in differentlengths for axial, ascendingand descending atomizingcones (45).
Main merits
robust, compact design wedge-flanging for easy
installation and removal
Materials:
The standard material is stain-less steel 316/1.4571. Highalloy steels, such as chrome-nickel steels (Hastelloy) arealso available for specialprocesses. Lances made fromplastic materials, such as PVC,PVDF, PTFE and temperatureresistant FRP have proved tobe highly efficiant for somespecial applications.
Standard delivery scope:
Pressure resistant andflexible hoses
Shut off valve Mounting devices, coupling
devices Special accessories up to
complete systems includ-ing control units (seepage 11).
Spillback Cluster Lance
Spillback Nozzle Lance
7/21/2019 Spillback Nozzles
8/128
Selecting the nozzles
The choice of the nozzle andits flow rate depends on thetotal flow of liquid to be spray-ed and on the type and num-ber of lances respectively.
There are six standard spill-
back nozzle sizes available.All nozzle sizes do fit on everylance. The nozzles are inter-changeable . However, clusterlances should always beequipped with only one nozzlesize on a particular lance.A minimum feed pressure of30 bars is recommended.The maximum allowable feedpressure for the standardlances is 50 bars.
Explanations:Spray angle: 30, 45, 60, 90Spray pattern: Hollow coneTurn down ratio 10 : 1(max. flow : min. flow)
7* Smallest and largest valueis mentioned, to show thespectrum of flow rates.
25 bar
2,80
7*
17,90
22,40
7*
70,44
260.38x
7*
260.68x
260.72x
7*
260.92x
RS 3
RS4
Nozzle
size
Flow V (l/min) at pressures p (bar)
Flow rates of nozzles for spillback nozzle lances
Nozzle
type30 bar 35 bar 40 bar 45 bar 50 bar
3,05
7*
19,60
24,50
7*
77,15
3,30
7*
21,15
26,45
7*
83,34
3,55
7*
22,65
28,28
7*
89,10
3,75
7*
24,00
30,00
7*
94,50
3,95
7*
25,30
31,62
7*
99,61
Component
Materials available
Material
Insert
Gasket
Swirl disc
Mouth piece
Housing
Insert - 316 SS
- SS,
hardened
Gasket - 316 SSSwirl disc - 316 SS,
- SS
hardened
Mouth piece - 316 SS
- SS,
hardened
- T itan
- Hastelloy
- SS, heat
resistant
- Ceramic
- Tungsten
carbide
Housing - 316 SS
- Hastelloy
- 314 SS
7/21/2019 Spillback Nozzles
9/129
M
Typical Spillback Nozzle Lances Arrangement
and its Control System
Choice of control system
Depending on the requiredactuating time and response
time the control valve caneither be electric or electro-pneumatic.
A typical control system for agas conditioning tower of a refuseincineration plant.
Gas inlet (t1)
Setpoint controller
Return ring main
Return line
Regulating valve
Solenoid valve
Fresh water
Level gauge
Water storagetank
Filter
Overflow tank
Supply ring main
Supply line
Pressure switch
Gas outlet (t2)
Non-return valve
Electricallydriven h.p.centrifugalpumps(1 x service,1 x stand by)
7/21/2019 Spillback Nozzles
10/1210
Complete solutions with
pump and regulation units
and electronic controls
Lechler supplies complete,pre-assembled pump andregulator stations. The designof these stations is adapted tosuit the function and mode ofoperation of the nozzle lances.The control valve, for example,
is designed to match thespecial operating characteris-tics (required control range) ofthe installation. The choice ofmaterials used for the com-ponents is determined by themedium to be sprayed.
Our range of engineeringservices includes:
Gas cooling computations(evaporation distance andwater quantity)
Selection of nozzle (type,number and size)
Design of pump, controlvalves, etc.
Detail designs of water andbarrier air pipe lines
Designing flow sheets Designing drawings for
nozzle lances, pump- andregulation units
Documentation
The pump and regulationunits can be equipped with
the following components:
Filters Contact pressure gauges Pressure gauges Pumps Control valves Flowmeters Non-return valves Overflow valvesetc.
The measuring and monitoringinstruments for the unit (flowmeasurements, pressure
monitoring) are established incooperation with the customer.The correct choice of instru-mentation ensures that therequired operational reliabilityand safety are achieved. Thecomponents and interconnect-
ing pipework are mounted ona stable rack. Pressure- andfunction-test and precom-missioning at Lechler factoryenables us to put the systeminto operation in a minimum oftime after shipping the compactunit on site. In order to offercomplete solutions, we canalso supply the PLC requiredfor temperature control. Theswitching cabinet can beintegrated onto the valve rack.
Our complete engineeringpackage includes:
Designing the controlsystem
Flow charts Preparing the program for
the PLC CAD circuit diagrams Documentation
Our complete system solutionoffers you a prefabricatedinstallation tailored to yourneeds.Large numbers of completesystems of this type have beenbuilt and installed for a range ofapplications throughout theworld and have proved theirworth in continuous operation.
We would be pleased to sendyou copies of our product- andcountry-specific reference lists.
Advantages:
Complete solution froma single source includingprocess guarantees
No interfaces Systems adapted to suit
operational requirements Minimal installation and
commissioning times
Compact units
Example of pump and regulation unit
7/21/2019 Spillback Nozzles
11/1211
Company:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Date: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Address: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Complement: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Department: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Phone/Fax: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Projekt no.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas flow [Nm3/h*, humid] t inlet [C] t outlet [C]
max.: min.: max.:
nominal: min.: max.: min.: max.:
min.: min.: max.:
If there are other design cases, please note separately
Gas composition [Vol. %]H2O CO2 O2 N2
1. Gas data
Gas flow rate (under standard conditions,* humid)
Other components of gas (HCI, HF, etc.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [mg/Nm3*, humid]
Critical cooling limit temperature (dew point) Yes, at . . . . . . . . . . . . . . . . . . . . C System pressure (in the reaction area) . . . . . . . . . . . . bar (g)
2. Conditions on site
Are gas cooling tower dimensions fixed? Yes . . . . . . . . . . . . . . . . dimensions . . . . . . . . .
No Favorite-. . . . . . . . dimensions . . . . . . . . .
Available reaction distance . . . . . . . . . . . . . . . . . . . . m. Reaction distance to be determined.
Direction of gas
Dust content in gas . . . . . . . . . . . . . . . . . . . . . . . . mg/m3
i. N.
Nozzle type: Single fluid Twinfluid Both types possible
Complete evaporation required? Yes No
Is water injection system always in operation? Yes No
In case the operation is interrupted, running time . . . . . . . . . . . . . . . . . . %
3. Coolant data
Coolant water Inlet temperature . . . . . . . . . . . . . .C
(max. over pressure . . . . . . . . . . bar) . . . . . . . . . . Content of solids . . . . . . . . . . . .
Medium (Twin fluid nozzles)
Air Over pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar (g)
Steam Over pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar (g)
Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C
4. If available, please attach
Process flow sheet Sketch/drawing of GCT
* T0 = 273 K (0C), P0 = 1 bar
Dear customer,
to comment on your gas conditioning problem, we would require all data known to you and indispensable for computing. The moreprecise your indications are, the more reliable our calculations can be.
Questionnaire for calculation of your
gas conditioning requirements
Please reply to Lechler (Fax or e-mail see following page)
7/21/2019 Spillback Nozzles
12/12
Lechler GmbH
Precision Nozzles Droplet Separators
P.O. Box 13 23
72544 Metzingen / Germany
Phone: +49 (0) 71 23 962-0
Fax: +49 (0) 71 23 962-301
E-Mail: [email protected]
Internet: www.lechler.de
Edition
01/06
GB1.000LEC05075www.walliser-partner.deM
SSubjectt
otechnicalmodifications
Lechler is your competentpartner when it comes toexhaust-air cleaning and gasconditioning plants.Know-how from over 125 yearsof experience is available toall companies which manufac-
ture or operate such plants.
Dont settle for less than thebest when it comes to protect-ing the environment. Consultwith the specialists fromLechler for the best applicationof nozzles, nozzle lances ordroplet separators. A series ofbrochures is available toprovide you with an initial in-sight. These brochures containthe comprehensive data andperformance specificationswhich you will require inplanning and maintaining yourplant.
I am interested in
Lechlers compo-
nents for effective
environmental
protection.
Please send me the
marked information.
Company
Department
Name
Function
Street/P.O. Box
Post code/Town
Telephone
Telefax
Twin Fluid NozzleLances
VarioCool
Gas ConditioningSystems
Nozzles forFlue GasDesulphurisation
Belgium: Lechler S.A./N.V. Avenue Mercatorlaan, 6 1300 Wavre Phone: (10) 225022 Fax: (10) 243901 [email protected]: Lechler Intl. Trad. Co., Ltd. Beijing Office Rm.1812 CTS Plaza No.2 Bei San Huan Dong Lu Phone: (86) 1064661986, Fax: (86) 1064660196 [email protected]
Finland: Lechler Oy Kalliotie 2 04360 Tuusula Phone: (358) 98709844 Fax: (358) 98709847 [email protected]
France: Lechler France, S.A. Bt. CAP2 B51 66-72, Rue Marceau 93558 Montreuil cedex Phone: (1) 49882600 Fax: (1) 49882609 [email protected] Britain: Lechler Ltd. 1 Fell Street, Newhall Sheffield, S9 2TP Phone: (0114) 2492020 Fax: (0114) 2493600 [email protected]
India: Lechler (India) Pvt. Ltd. Plot B-2 Main Road Wagle Industrial Estate Thane (W) - 400604 Phone: (22) 25811196 Fax: (22) 25821262 [email protected]: Lechler AB Box 158 68324 Hagfors Phone: (46) 56325570 Fax: (46) 56325571 [email protected]
Spain: Lechler S.A. Avda. Pirineos 7 Oficina B7, Edificio Inbisa I 28700 San Sebastin de los Reyes, Madrid Phone: (34) 916586346 Fax: (34) 916586347 [email protected]
USA: Lechler Inc. 445 Kautz Road St. Charles, IL. 60174 Phone: (630) 377-6611 Fax: (630) 377-6657 [email protected]