Air Mist Cooling
When your cooling process requires small drops, air mist cooling solutions from Spraying Systems Co. deliver with efficiency. Our air mist cooling solutions play a critical role in ensuring product quality and operational efficiency. Engineered specifically for slab caster cooling, our air mist cooling systems deliver precise cooling where it’s needed most.
Why Air Mist Cooling Matters
Air mist cooling technology ensures high heat transfer rates during the continuous casting process. This makes it essential for maintaining optimal temperatures while preventing defects in the final product. By distributing fine droplets across key areas, air mist cooling helps you maintain operational efficiency and avoid water buildup on steel surfaces. Our air mist cooling solutions provide a highly effective method of cooling using advanced nozzle designs and patented atomization technology.
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Continuous Casting Cooling with Air Mist
Our air mist continuous casting cooling solutions are specifically designed for highly efficient secondary cooling in the caster.
- High heat transfer rates are achieved using patented atomization technology.
- A wide variety of nozzle configurations and spray patterns are available.
- Easy tip and tube replacement minimizes downtime when breakouts occur.
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Shown: 50070 (59780) NCJ CasterJet Nozzles; efficient slab cooling, reduced consumption. D41968 Anti-Pulsing CasterJet® Nozzles; large spray, reduced air/water use.
The Power of NCJ CasterJet® Nozzles
NCJ CasterJet nozzles allow for better heat transfer in slab caster cooling.
- Unique atomization process increases mixing efficiency and requires less compressed air and water.
- Usage may reduce the size or number of compressors required on caster lines.
- The 25:1 turndown ratio enables lower flows to be used without a loss in performance.
- Wide operating range and consistent drop size across the spray pattern allow for more variation in line speed and grades of steel.
Shown: 50070 NCJ CasterJet® Nozzles, efficient slab cooling, reduced consumption.
Key Features of Air Mist Nozzles
Our air mist nozzles are specifically designed for use in the demanding environments of steel production. Featuring flat spray patterns, these nozzles optimize zone cooling by distributing fine droplets that evaporate quickly. This rapid evaporation prevents water from accumulating on the steel surface, enhancing cooling efficiency while reducing the likelihood of surface defects.
Durability is essential in steel mill operations. Our air mist nozzles are built from robust materials, such as brass and stainless steel, providing corrosion resistance and ensuring long-lasting performance even in the harshest environments. These materials resist wear, extending the life of the nozzles and reducing maintenance needs, which in turn helps lower total operational costs over the long term.
Custom Flow Rates and Spray Angles
One of the most significant advantages of our air mist nozzles is their customizable flow rates. Cooling needs vary from operation to operation, and our nozzles are designed to meet these varied demands with ease. Water flow rates range from 0.5 GPM to 12 GPM (1.9 to 45.4 LPM), allowing operators to control the cooling intensity based on the specific needs of the steel casting process.
Additionally, air flow rates range from 0.8 SCFM to 23 SCFM (1.3 to 36.9 Nm³/h), providing operators with the flexibility to tailor cooling for different zones within the continuous casting operation. Coupled with spray angles ranging from 30° to 140°, these nozzles provide broad coverage, allowing for customizable cooling solutions tailored to each section of the casting process. This level of control ensures precise cooling for slabs, billets, and blooms alike, meeting the unique demands of each stage in production.
The Benefits of Air Mist Technology
Choosing air mist cooling nozzles offer several benefits: reduced water usage through quick evaporation, precise control over the cooling process with customizable settings, longer equipment life due to durable materials, and energy savings by reducing air and water consumption. The result: fewer compressor needs and reduced operational costs.
Applications in Continuous Casting
Air mist cooling is widely applicable across the continuous casting process, making it ideal for various steel production needs. The precision and flexibility of our nozzles ensure consistent temperatures and prevent surface defects in the steel, even as production conditions vary.
- Slab Casting: NCJ CasterJet® nozzles are perfect for slab casting operations. By providing reliable, high-efficiency cooling they maintain consistent temperatures throughout the process.
- Billet and Bloom Casting: For smaller shapes such as billets and blooms, air mist nozzles adapt to different steel grades and casting speeds, ensuring that cooling is precisely controlled no matter the conditions.
Tailored Cooling Solutions for Your Operation
At Spraying Systems Co., we understand that every casting operation has its own unique needs. We work with you directly and offer a wide range of customizable air mist cooling systems to meet your operational needs. Whether you need high-impact cooling for slab casting or a more adaptable solution for billet and bloom casting, our air mist nozzles are designed to deliver reliable, efficient performance.
View technical resources for spray technology for steel mills