Spillback Nozzles

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    Spillback Nozzle Lances

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    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.

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    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.

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    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

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    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.

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    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

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    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

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    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

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    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)

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    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

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    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)

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    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

    E-mail

    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]