Customer pain: Thermal damage to downstream equipment.
Requirement: Fine atomization, rapid evaporation.
Gas Treatment Spray Nozzles
High-efficiency nozzles for flue gas cooling, SO₂/NOx removal, scrubbing, and wet dust collection. Corrosion-resistant materials for harsh chemical environments.
Common Gas Treatment Challenges & Solutions
High-Temperature Flue Gas Cooling
Chemical Corrosion in Scrubbers
Customer pain: Equipment degradation from acidic gases.
Requirement: Corrosion-resistant materials.
Clogging from Particulate-Laden Gas
Customer pain: Nozzle blockage and system downtime.
Requirement: Non-clogging, large passage design.
Power · Waste-to-Energy · Chemical
Flue Gas Cooling
Quenching and cooling of flue gases from incinerators, power plants, and industrial furnaces to protect downstream equipment. Effective cooling also helps control emissions.
Associated Industries: Power · Chemical
Gas Treatment Challenges:
- Extremely high temperatures (600-1000°C) requiring rapid cooling
- Complete evaporation required before droplet impingement
- Corrosion from acid gases (SO₃, HCl) in cooled gas
Recommended Products:
SPJT Spiral Nozzle – 60°–170°, 5.5–4140 L/min
DP Max Passage Full Cone – 60°–120°, 8180 L/min
1/8-AA Hollow Cone – 51°–144°, 0.2–7 bar
💡 Engineering Tip: For flue gas quenching, use SPJT (79) with 316SS for high-temperature resistance. For large ducts, use multiple DP (86) nozzles for full cross-section coverage. Ensure water pressure is sufficient for fine atomisation.
Power · Marine · Chemical
SO₂ Removal (Desulfurization)
Spray nozzles for wet FGD systems using lime/limestone slurry to remove SO₂ from flue gas. Efficient absorption requires optimum droplet size and distribution.
Associated Industries: Power · Marine
Gas Treatment Challenges:
- Handling abrasive lime/limestone slurry
- Achieving high SO₂ removal efficiency (95%+)
- Preventing nozzle clogging from slurry solids
Recommended Products:
DP Max Passage Full Cone – 60°–120°, 8180 L/min
BBS Short Type Full Cone – 110°–120°, 1415 L/min
BG-W Wide Angle Full Cone – 110°–120°, 7370 L/min
💡 Engineering Tip: For FGD systems, use large passage nozzles like DP (86) or BG-W (88) to handle slurry without clogging. For marine scrubbers, use 316L construction for saltwater corrosion resistance.
Power · Industrial
NOx Control
Selective Non-Catalytic Reduction (SNCR) and Selective Catalytic Reduction (SCR) systems using ammonia or urea spray. Precise atomization ensures effective NOx reduction.
Associated Industries: Power
Gas Treatment Challenges:
- Precise control of reagent flow for NOx reduction efficiency
- Avoiding ammonia slip through proper atomization
- High temperature zones (800-1100°C) for SNCR
Recommended Products:
D-1/4-303SS Air Atomizing – fine mist, 0.7–4 bar
D Series Air Atomizing – adjustable, stainless steel
DE101 Large Flow Air Atomizing – 316SS, 20°, 3.3mm droplets
💡 Engineering Tip: For SNCR applications, use D-1/4-303SS (99) with fine atomization for maximum surface area. For large boilers, DE101 (152) provides higher capacity. Ensure correct nozzle placement in the temperature window for optimal NOx reduction.
Chemical · Environmental · Mining
Gas Scrubbing
Venturi scrubbers, packed towers, and spray towers for removal of particulates and acid gases. Nozzles must provide high liquid coverage with fine droplets.
Associated Industries: Chemical · Environmental
Gas Treatment Challenges:
- Fine droplet generation for high mass transfer efficiency
- Resisting chemical attack from aggressive scrubbing liquids
- Maintaining performance under varying gas flow rates
Recommended Products:
BB Narrow Angle Full Cone – 15°/30°, Stainless Steel
BB Standard Full Cone – 43°–106°, Brass/SS
AF Hollow Cone – 120°–180°, SS
💡 Engineering Tip: For venturi scrubbers, use BB Narrow Angle (83) for high impact. For packed towers, use AF Hollow Cone (127) for uniform liquid distribution over the packing material.
Waste · Food · Chemical
Deodorization
Odor control in waste treatment, food processing, and chemical plants using chemical or biological scrubbers. Fine atomization of chemical reagents ensures effective odor neutralization.
Associated Industries: Environmental · Food
Gas Treatment Challenges:
- Neutralizing a wide range of odorous compounds (H₂S, NH₃, VOCs)
- Minimizing chemical consumption through efficient atomization
- Operating in corrosive environments from odorous gases
Recommended Products:
SPJT Spiral Nozzle – 60°–170°, 5.5–4140 L/min
AD Hollow Cone – 50°–90°, 145 L/min
D-1/4-303SS Air Atomizing – fine mist, 0.7–4 bar
💡 Engineering Tip: For odor control, use D-1/4-303SS (99) for fine chemical atomization. For high-volume scrubbers, use SPJT (79) with chemical injection. Regular cleaning is essential to prevent biological fouling.
Mining · Cement · Environmental
Wet Dust Collection
Wet scrubbers and dust collectors using water spray to capture particulates from industrial exhaust. Effective for both coarse and fine dust with high collection efficiency.
Associated Industries: Mining · Environmental
Gas Treatment Challenges:
- High dust loading requiring efficient particle capture
- Preventing nozzle clogging from dust-laden water
- Minimising water consumption and waste treatment
Recommended Products:
SPJT Spiral Nozzle – 60°–170°, 5.5–4140 L/min
BG-W Wide Angle Full Cone – 110°–120°, 7370 L/min
LC-200 Large Flow Hollow Cone – 70°–90°, carbide silicone
💡 Engineering Tip: For wet dust collectors, use SPJT (79) for clog resistance. For high dust loading, use LC-200 (129) with carbide construction for wear resistance. Install strainers upstream to protect the system.
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Frequently Asked Questions
How do I size a nozzle for flue gas cooling?
Calculate the required evaporation rate based on gas flow and temperature drop. Select a nozzle with adequate flow rate and fine atomization to ensure complete evaporation before contact with duct walls.
Which materials resist sulfuric acid dew point corrosion?
316L and 904L stainless steels are suitable. For severe conditions, use Alloy 20 or Hastelloy. Ceramic‑lined nozzles are also available for extreme environments.
What is the difference between full cone and hollow cone for scrubbing?
Full cone provides even coverage across the entire spray area, ideal for absorption. Hollow cone creates a ring‑shaped spray, better for cooling and dust capture in venturi scrubbers.
Can I use spiral nozzles for SO₂ removal?
Yes, spiral nozzles (like SPJT) offer large, clog‑free passages and are widely used in FGD systems for slurry spraying.
What is the typical nozzle spacing in a scrubber?
Spacing depends on spray angle and duct size. Typically 300–600 mm to ensure overlapping coverage. Consult CYCO engineering for precise layout.
How do I prevent nozzle clogging from particulate-laden gas?
Use spiral or large full cone nozzles. Install strainers and maintain proper water quality. The DP series offers the largest free passage.
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