SpillAir - Hybrid Spray Systems

The SpillAir™ nozzle is essentially a high volume, low pressure (HVLP) air assisted mechanical hybrid nozzle. The mixing between the air and the water takes place immediately outside of the spray orifice (external mixing), virtually at ambient pressure. A low-cost blower is installed for virtually maintenance free HVLP air.

Principal advantages of the BoldEco SpillAir nozzle:

• Improved Spray Cone Characteristics: By design, a high-velocity air shroud is produced around the mechanical atomization cone in order to improve droplet formation and to control the plume spray angle. This results in a constant angle of atomization and an optimized droplet size.
• Improved Gas-to-Spray Interaction: Flow vectors generated by the patented BoldEco Assist Air Annulus enable the naturally produced hollow-cone nozzle characteristics of the SpillAir™ nozzle to become a full-cone spray. This results in droplets that are more diffused within the gas stream, improving hot-gas-to-liquid-droplet interaction.
• Improved Evaporation Rates: The annular air shroud that is created at the edge of the BoldEco SpillAir™ nozzle entrains the liquid droplets into its high velocity flow field, increasing the velocity of the droplets, and therefore the droplet-to-gas differential velocity, reducing evaporation time.
• Lower Achievable Outlet Temperatures: With standard mechanical spill-back nozzles, the droplet sizes are randomly distributed within the spray cone. This results in the smaller droplets removing much of the heat from the gases, leaving the balance of the gases with insufficient heat capacity to evaporate the larger droplets. With the BoldEco SpillAir™ nozzle, the finer fraction of the droplets, having less inertia, is easily moved by the air jet into the center of the spray cone, while the larger droplets, having more resistance to being moved, remain on the outside periphery of the spray cone. This droplet distribution results in significantly improved nozzle performance, because once the gases evaporate the larger droplets on the outside of the spray cone, where they have the highest heat content, as they cool, they converge with the smaller diameter droplets, which are easier to evaporate with cooler gases. This phenomenon allows for lower spray tower outlet temperatures within a given spray tower volume.

• Improved quality of droplet distribution and heat exchange
• Improved turn-down capabilities
• Constant angle of atomization avoids interference with neighboring sprays
• Shield air protects nozzles from fouling
• Shield air reduces scaling in the presence of hard water
• Maintains low energy consumption while improving performance
• Requires shorter residence times for the same outlet temperature or lowers outlet temperature within the parameters of the existing residence time