GAS CONDITIONING TOWERS

Gas conditioning towers (GCT) are used in industrial applications to cool gases upstream, ahead of bag filters (baghouses),
electrostatic precipitators or our Dual-Action Filters. They are considered to be the most effective type of cooling systems
in treating exhaust process gases. Our GCTs offer unequalled effectiveness: our team has three decades of experience
designing these towers and customizes every one to suit our customers’ specific process parameters.

WHY CHOOSE OUR

GAS CONDITIONING TOWERS?
Unparalleled efficiency
Reduced energy costs
We use model tests and CFD simulations
to calculate the ideal timing and gas Our optional Dual-Nozzle System
distribution parameters. Even mixing allows you to reduce the number
of nozzles in operation when
We have mastered our Gas Distribution
operating with lower gas volumes.
System (GDS) to ensure even gas/water
mixing, avoiding the creation of mud.

Smaller tower size

Our special nozzles, coupled with our GDS, increase
evaporation, reducing the gas retention time in the tower
Optimized control system and thus the tower’s size. Our GDS can even be applied as a
retrofit to improve our competitors’ installations.
Our Temperature Control System is designed to optimize
reaction times, allowing you to cope with new process
conditions at the tower inlet rapidly to ensure continued
efficiency.
GAS CONDITIONING TOWERS: SYSTEMS & FEATURES
Our Gas Conditioning Towers are used to lower the temperature and increase the moisture level of the dusty exhaust gas OUR GAS DISTRIBUTION SYSTEM
before it passes through a bag filter (baghouse), electrostatic precipitator (ESP) or our Dual-Action Filter. Its purpose is to
We constantly search for new ways to further
cool the flow and optimize the uniformity of the gas and its temperature, in order to make the air filtration device more
improve our market leading Gas Conditioning
effective at extracting the dust.
Towers’ (GCT) flow distribution. We use model tests
We offer two models, based on different water injection systems: a Spillback Injection System, based on spillback nozzles, and computer simulations to optimize timing and
and a Dual-Media Injection System, in which water is atomized by water pressure and compressed air. gas distribution. Our GCT design is distinctive due to
our carefully designed inlet deflectors that optimize
the distribution of the gas in the tower.
Hot gas
Our Gas Distribution System design:
OUR SPILLBACK INJECTION SYSTEM
1• Reduces the evaporation height and therefore
Our Spillback Injection System works with a high-pressure centrifugal your tower height, without risk of creating mud
pump, which forces water through our special nozzles located inside the in the hopper, as the hot gases are properly
conditioning tower, producing a fine mist. mixed
Gas distribution system
2• Evenly distributes the gas flow to reach the
required outlet temperature of the GCT and to avoid mud at the bottom
OUR DUAL-MEDIA INJECTION SYSTEM 3• Prevents condensation, as our gas distribution liner prevents the spray from reaching the casing of the GCT
Dual-Media Injection
System nozzles Our Dual-Media Injection System uses both water and
compressed air to produce an extra fine mist. This
is our highest-efficiency model, allowing for an even OUR OPTIMIZED TEMPERATURE CONTROL SOLUTION
Second set of Dual-Media smaller conditioning tower size as the gas has a shorter
Injection System nozzles required retention time in our GCT.
(optional) Common Weaknesses in Other Gas Conditioning
Towers
Our Dual-Media Injection System The gas treatment time (from a few to 10-12 seconds)
uses both water and compressed air causes a change in the thermal inertia of the system
to produce a fine mist, resulting in Water since there is a time gap between what is happening at
a shorter retention time in our the tower outlet and inlet. This affects the temperature
conditioning towers. control of the tower. In certain plants using an
electrostatic precipitator (ESP), such a delay would
Air
cause unsettled conditions and poor ESP performance.
For some systems with a bag filter, these transient
conditions could negatively affect filter bags.
OUR DUAL-NOZZLE SYSTEM (OPTIONAL)
For both our Spillback and Dual-Media Injection Systems, we offer the
Our Innovative Solution
option of our Dual-Nozzle System, which reduces energy costs and
prolongs the lifespan of your equipment. Since a lower volume of gas Our Temperature Control System overcomes this
requires less cooling water, you may not always need all nozzles in time lag by controlling the amount of water required
Cooled gas operation. The system therefore entails installing two nozzle levels on based on the gas conditions at the inlet. The control
your system: system analyzes the incoming gas mass’s temperature,
pressure and I.D. fan speed. Once the enthalpy of the
1• One set of nozzles, preferably close to the tower centre, is used gas mass is entered, the system calculates the amount
when the gas and water volume requirements are low of water to be sprayed. In our system, the gas outlet
2• A second set of nozzles is put into operation to supply additional temperature is only used to adjust any possible under-
water when the system is operating at higher capacity or over-regulation effects.

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DETERMINING TOWER SIZE
DESIGN PARAMETERS
Our engineering team has 30+ years of experience in
surveying the output and needs of various plants, and will
study your plant and its gas flow to find an appropriate
solution to reach your desired emissions reductions. The
size of your GCT depends on the process data. The amount
of water injected per area unit and the gas velocity along
the shell of the tower are the key parameters to consider.

The gas enthalpy will be calculated based on gas

temperature, and therefore on the amount of water
needed. The tower size required is based on the amount
of water necessitated. To avoid the risk of mud at the
bottom of the tower, the gas must remain in the tower long
enough for the sprayed water to completely evaporate.
Nozzle design is essential to perform a complete cooling
process without risk of mud. We use top quality nozzles.

We customize every Gas

Conditioning Tower to suit your
specific process parameters.

MODELLING
We use Ansys’s well-respected Fluent software to accurately
design and study every solution for each customer. The Fluent
program allows us to engineer and analyze the system’s broad
physical capabilities, optimize the fluid dynamics and study
the efficiency of pollutants removal. In certain circumstances,
when a computerized simulation is not sufficient, we
undertake a physical simulation on a 1:7 scale. All physical
models are made and tested in Redecam’s workshop.

Redecam offers a comprehensive portfolio of air filtration, flue gas treatment (FGT), gas conditioning and transportation,
handling & storage products. Please contact us to see how we can take care of all your air pollution control needs.

ITALY (HEADQUARTERS) U.S.A.

 +39 02 243491  +1 704 969.8811
[email protected] [email protected]

Visit our website to learn more at BRAZIL CHILE

www.redecam.com  +55 11 3044.4125  +56 2 2789 0358
or scan this code: [email protected] [email protected]