Precision Spray Nozzles
and Engineered Solutions
for the Power Plant Industry

Power Plant Industry

EFFICIENT COOLING AND CONDITIONINGWITH LECHLER NOZZLE LANCES AND SYSTEMS

Lechler is Europe’s No. 1 and is also one of the leading suppliers of nozzles and systems
worldwide. For over 140 years, we have pioneered numerous groundbreaking developmentsin the field of nozzle technology. We combine comprehensive nozzle engineering expertisewith a deep understanding of application-specific requirements to create products that offer
outstanding performance and reliability.

Innovative solutions
for a trending market

logies means that new competitors are arriving on themarket to which it is also
­necessary to react.

Power plant operators are
faced with many diﬀerent
challenges. On the one hand,
they must guarantee a reliable
and continuous supply of
power. On the other hand,strict emission requirements
are creating a constant pressure to invest and innovate.
In ­addition, the developmentof renewable energy techno-­Eﬃcient gas conditioning
oﬀers a wide range of approaches to reducing costs
and increasing efficiency.
A prerequisite is that the­respective processes arethoroughly understood andthat the gas conditioning is
adapted accordingly.

The right solution
for every requirement

1879

1893

1962

1978

Company founded by Paul Lechler

Patent for liquid atomization

Sales offices set up in Germany

Expansion to the USA andthen to other countries

2

With our wide range of nozzles,
gas conditioning systems anddroplet separators, we offer
the perfect solution for every
application. Every power plant
naturally comes with its own
set of challenges.

We rise to these challenges
and work with you to develop the best solutions foryour business. We support
you with comprehensive
consulting services ranging
from process analysis toturnkey solutions.

COMPETENCE –THE ADVANTAGE OF MULTIPLE PERSPECTIVESCUSTOMERADVANTAGES
Wide product
range

Process
optimization

Service
Process
reliability
ExperienceCostsavings

Custom madesolutions

For many years now, nozzles,
spray systems and droplet
separators for indus­trial gas
conditioning have been an
integral part of our Environmental Technologies portfolio.
An international team of outstanding engineers and process engineers continuously
develop new solutions andadapt them to new challenges.
Through the use of global
databases and close coopera­tion with external specialized
institutes and renowned plant
manufacturers, we have built
up an interdi­sciplinary know­
ledge base – and with it
optimal process integration.

Our constant exchange ofexperiences with power plant
operators means we are always in tune with the latest
developments and can react
proactively to them.
To provide you with local
support, we are represented
all around the globe – withlocations in the USA, GreatBritain, India, China, ASEAN,
France, Belgium, Italy,
Finland, Hungary, Spainand Sweden, as well as
sales partners in almost
every country.

CONTENTS

Page

Applications

4–9

Choosing the right nozzle

10

Spillback nozzles

11® nozzles

VarioJet

12

Laval nozzles

13

Special twin-fluid nozzles
for DeNOx applications

14–15

Nozzle lances

16–17

VarioCool ®
gas cooling system

18–21

Lechler Online Cleaning(LOC®)

22–23

Engineering and service

24–25

CFD Analysis

26–27

Nozzles for flue-gas
desulfurization

28–31

Droplet separator systems

32–35

Measuring technology

36–38

Quality with a system

38

Costs under control
In the flue-gas treatment installations of power plants­extreme ambient conditions
prevail. We manufacture ournozzles and droplet sepa­
rators from highly resistantmaterials with minimal wear.

Twin-fluid nozzles allow for
an application-optimized fine
droplet spectrum, whereas
spillback systems do awaywith compressed air alto­
gether to reduce the energy
consumption.

The long service life of ourhigh-quality components forvalve skid units and systems
does not just reduce the purecosts of spare parts, but also
decreases downtimes andmaintenance costs. In addition,customer-specific systems
lower the operating costs toa minimum.

Our job is to identify theappropriate solution ineach case and then adapt
it perfectly to the on-site
conditions.

1988

1995

2010

2016

Environmental Technologies
division founded

Production, sales and administration
are concentrated in Metzingen

Expansion of production with new
13,000 m² production hallOpening of the ultra-modern
Development and Technology
Center in Metzingen

3

OVERVIEW OF LECHLER APPLICATIONSIN POWER PLANTS

Flue-gas denitrification
DeNOx SCR, high dust
Atomization of aqueous ammonia for­catalytic reduction of nitrogen oxides.

Spray dryers
Atomization of liquids for waste
water-free operation.

4

Wet flue-gas desulfurization
DeSOx
Atomization of suspensions for­separation of SO2.

Highly efficient
droplet s­ eparator systems
For wet flue gas
desulfurization.

Atomization of waterfor emergency cooling
Wall and floor rinsing withflat fan and tongue-type nozzles
to remove deposits

5OVERVIEW OF LECHLER APPLICATIONSIN POWER PLANTS

Spray absorbers
Semi-dry process for DeSOx
Atomization of lime slurry suspensions
for binding SO2.

6

Flue-gas denitrification
DeNOx SCR, low dust/tail end
Atomization of aqueous ammonia
for catalytic reduction of NOx.

7

OVERVIEW OF LECHLER APPLICATIONSIN POWER PLANTS

CFB
Dry process DeSOx
Injection into circulating fluidized bed forhumidification and reaction acceleration.

8

Flue-gas denitrification
DeNOx SCR, low dust/tail end
Atomization of aqueous ammonia forcatalytic reduction of nitrogen oxides.

9

CHOOSING THE RIGHT NOZZLEBest results are achieved in gas cooling and conditioning processes only
when detailed knowledge of process-specific requirements is available toassist in the choice of nozzles.
We will provide you with comprehensive advice taking your systemand the applications you require into account. Our portfolio includes
nozzles made of different materials for a wide range of droplet
sizes and spray angles. The combination of your specific process
requirements and our decades of experience results in a tailor-madesolution for your needs.

Spillback nozzles
Atomization without compressed air

Lechler spillback nozzles
atomize liquids as a fine hollow
cone.
This special single-fluid nozzle
works according to thepressure atomization principle.
The water is sent to the nozzle
with a relatively constant feed
pressure, independent of theatomized flow rate.

Spillback line
Supply withconstant feed
pressure
Spray pattern of asingle spillback nozzle

The amount of liquid injectedis adjusted via a control valve
in the spillback line, whereby
part of the flow is taken fromthe inlet flow rate and returnedto the tank. The maximum­atomized flow rate is achieved
with the control valve closed.

Hollow cone

Uniform and fine liquid atomi­
zation is achieved across theentire control range.

.
Vpump

Constant feed pressure
p1 = 35 bar, gFeed flow rate.
Feed flow rate V [l/min]

The atomized flow rate can be
distributed over cluster heads
with up to six small nozzles.
This results in a total spray
angle of approximately 120°.
This wide distribution of liquid
over the entire duct is ad­vantageous for reducing thenumber of lances.

Spray pattern of acluster spillback nozzle lance

Scheme of the spillback nozzle

.
V2
.
V1

.
V3 max.
V3.
V3 min.
V1: feed flow rate.
Vpump: max. feed flow rate.
V2: return flow rate.
V3: atomized liquid rate.
.
.
V3 = V1 – V2.
V3 min: min. atomized liquid(return line open).
V3 max: min. atomized liquid(return line closed)
p1: constant feed pressure
p2: return pressure.
.
Turn down ratio: V3 max/V3 min

Atomized liquid
Return pressure p2 [bar, g]Use:Gas cooling in medium-­
sized and large gas
cooling towers

Properties

V1
V2

Spray angle of theindividual nozzles
90° or 60°
as hollow cone

Low operating
costs as noa­ tomizing airr­ equiredHigh turn-downr­ atioof up to 12:1

Even and finel­ iquid atomization
over the entirec­ ontrol range

Execution
as single or cluster
nozzle lances pos­
sible

bar

Typicalpressure rangeof 35 bar, g in the
supply line at thenozzle11

VarioJet® nozzles
Twin-fluid nozzles with low air consumption
despite large outlet angle

Lechler VarioJet® nozzles
atomize according to the­principle of internal mixing.
With this twin-fluid nozzle,
the water is fed in axially via
a bore hole.

LiquidAtomizing air

Two-phasemixtureAfter arriving at the cone tip,
the liquid is split up into athin liquid film. This thin liquidfilm is split into finest dropletsby the atomizing air in the
mixing chamber. The resulting
two-phase mixture is thenatomized a second time when
exiting via several bore holesarranged in a circular fashion.

Secondaryatomization

Thanks to the innovative­design of the nozzle, a spraywith a large outlet angle isachieved. This is characte­rized
by an even liquid dis­tribution
as well as a fine droplet spectrum with a low specific air
consumption.

The large free cross-sectionsin the nozzle keep the risk of
clogging and the maintenanceeffort to a minimum.

Scheme of the VarioJet® nozzle

Variable control concepts of twin-fluid nozzles
1  2A
Constant
atomizer air pressure
1  2B
Constantm
μ0
atomizer air
=6
m
D32
μ
volume flow
= 70
m
D32
μ
= 80
2
3
D
μm
1  2C= 90m
D32
Constant
00 μ
2A
1
=
m
droplet diameter
D32
10 μ
1
=
m
D32
20 μ
1
m
μ
=
0
D32
μm
= 13
D32 32 = 140 150 μm
2B
1
=
D
0 μm
2
3
D
= 16
D32
2C
p(air) = 6 barp(air) = 5 barp(air)=
4barp(air) = 1 barp(air) = 2 bar p(air) = 3 bar

Air flow rate [m³/h STD]

The fineness of the droplet
spectrum is decisively in­fluenced by the air/liquid ratio
and by the pressure levelof the two flow rates. As ageneral rule: the higher the
air/liquid ratio and the higher
the pressure level of atomizing
air and liquid is, the finer the
droplet spectrum.

Spray pattern of the VarioJet®
­ ozzlen

Water flow rate [l/min]Use:
Gas cooling in gas
cooling towers as well
as gas-bearing pipes(ducts)Properties

V1
V2

12

Large spray angle(60°, 90°) for goodcoverage of the cross-­
section of the duct

Adjustment of thedroplet spectrum
by changing the air/fluid ratio

High turn-down­ratioup to 20:1

Low air
consumption

Clog-resistant
thanks to large freecross-sections without internal fittingsbar

Typicalpressure range
Liquid 1–9 bar, gAtomizing air 1–6 bar, gLaval nozzles
Twin-fluid nozzles for a wide droplet
spectrum in special applications

Lechler Laval nozzles­atomize liquids as a fine
full cone. These twin-fluid
nozzles work according to
the supersonic principle.

Atomizing air

LiquidA dual-phase mixture is createdfrom atomizing air and liquidin the mixing chamber inside
the nozzle. The shape of thenozzle causes this mixture
to be accelerated to supersonic speed, resulting in an
extremely fine atomizationof the droplets.

Constriction accelerates mixture tosupersonic speed
Two-phasemixtureBy changing the air/liquid­ratio, the droplet size andthe droplet spectrum canbe adapted within a wide
range. The large free crosssections of the nozzle also
­allow atomization of viscousor solids-laden liquids.

Scheme of the Laval nozzle

Operating point of a twin-fluid nozzle

D32

=

m
50 µ

Air flow rate [m³/h STD]

D

Use:

Gas cooling in gasbearing pipes (ducts)
and medium-sized
and small gas cooling
towers
Injection of solids-ladenwaterIntroduction of lime
water in the desulfuri­
zation processInjection of aqueous
ammonia or urea solution for the DeNOx process (SNCR/SCR)
Chemical processengineering (spraydryers etc.)

Water pressure [bar, g]

Choosing the right material
prevents wear even whereabrasive media are present,
and enables use at high­temperatures.

Spray pattern of the Laval
nozzle

60
32 =

µm

D

70
32 =

p(air) = 6 barp(air) = 5 barp(air) = 4 bar

pWaterp(air) = 3 barp(air) = 2 barp(air) = 1 bar

µm

D32

= 80
D

µm

90
32 =

Water flow rate [l/min]

µm

D32

.
VWater

= 10

0 µm
D32

= 11

0 µm
D32

.
VAir

= 12

0 µm

p(air)== 66bar
p(air)barp(air)barp(air)== 55barp(air)barp(air)== 11barp(air) =22bar
bar
p(air)=.
VWasserp(air)== 44barp(air)barp(air)== 33barp(air)
bar
d32==130µm
D32
130 µmd32==150µm
D32
150 µmWater flow rate [l/min]

Properties

V1
V2

Small spray angle(15°), suitable forsmall cross-sections
and horizontal ducts

Adjustment of thedroplet spectrum
by changing the air/fluid ratio

Very large
turn down ratioof 20:1 (in somecases up to 40:1)

Very fine
droplet spectrum

Clog-resistant
thanks to large freecross-sections without internal fittingsbar

Typicalpressure range
Liquid 1–6 bar, gAtomizing air 1–6 bar, g

13

Special twin-fluid nozzles for DeNOx applications

Special properties

Laval nozzle
In DeNOx applications with
SNCR processes, small Laval
nozzles are usually used.
These nozzles are charac­terized by a high discharge
velocity, enabling the optimum droplet spectrum to be
introduced into the reactor
with a great penetration depth.

Our research has shown thatthe discharge velocity has agreater effect on the denitri­
fication process. Moreover,these nozzles without internals
are extremely insensitive toclogging and can be precisely
controlled.

Small spray angle(15°), suitable forsmall cross-sections
and horizontal
ducts
V1
V2

Turn-down ratioof 20:1 (in somecases up to 40:1)

bar

Typicalpressure range
Liquid 1–6 bar, gAtomizing air 1–6 bar, gVery fine
droplet spectrum
Adjustment of thedroplet spectrum
by changing the air/liquid ratio

Spray pattern of a Laval nozzle

For SCR processes and special SNCR processes there are special nozzles which have been developed to meet the
specific requirements. The same principles regarding control and operation apply for all twin-fluid nozzles, irrespectivelyof the type.
Special properties

Laval flat fan nozzle
The Lechler Laval flat fan
nozzle atomizes according to
the principle of inside mixing.
The air/fluid mixture exits via
three outlet holes creating awide and flat spray with aneven better surface coverage.

The droplet spectrum and thepulse of the droplets can beadapted by changing the air/fluid ratio.
V1
V2

bar

Wide and flat jet,spray angle 60°

Spray alignment
possibleTurn-down ratioof over 10:1

Adjustment of thedroplet spectrum
by changing the air/liquid ratio

Typicalpressure range
Liquid 1–5 bar, gAtomizing air 1–5 bar, gSpray pattern of a flat fan nozzle

14

MasterNOx® for DeNOx processes
The Lechler MasterNOx®
nozzles are usually used in the
non-catalytic denitrification offlue gases (SNCR process).
They are usually designed asflat fan nozzles and achieve ahigh spraying range to makethe liquid penetrate as far as
possible into the boiler. The

nozzle specially developed forthe retrofitting of existing power
plants is characterized by asmall outer diameter, so that it
can fit between the pipes ofthe boiler wall. It can also havea protective flow of barrier air
around it without the need forthe pipes to be bent aside.

Special properties
Spray angle
15°, 30°, 60°

V1
V2

bar

Turn-down ratioof over 50:1

Typicalpressure range
Liquid 1–10 bar, gAtomizing air 1–6 bar, g
Adjustment of thedroplet spectrum
by changing the air/liquid ratio

Spray pattern of a MasterNOx® nozzle 30°

Special properties

1AW nozzle
The Lechler 1AW nozzle
works according to a newly
developed and patented
atomization principle. It divides
the supplied atomizing air intoa primary and secondary air
flow. Thanks to the specific inflow geometry, the secondary
air exits through an annulargap causing a very fine atomization in the edge region of
the spray.

This twin-fluid nozzle enables
finest droplet spectra andshortest evaporation distances
while also allowing very good
controllability of the flow rate.
Cluster heads designed
specifically for these nozzles
multiply the flow rates andadapt the spray pattern to therequirements at the point of
injection.

V1
V2

bar

Spray angle of theindividual nozzle
15° as full cone

Particularly fine
droplets thanks totertiary atomization

Turn-down ratioof 10:1

Designas single or bundle
nozzle lances

Typicalpressure range
Liquid 1–5 bar, gAtomizing air 1–5 bar, g

Adjustment of thedroplet spectrum
by changing the air/liquid ratio

Single nozzle without barrier air
Spray angle 15°; full cone

Cluster head withthree nozzles with barrier air
Spray width approx. 55°, spray depth approx. 15°; flat fan
Spray pattern of 1AW nozzles

15Nozzle lances
Highest spraying accuracy in the flue gas duct

Connection options
Accessories
Option 1: Q uick release
couplings
Option 2: Flange connector
 onical screw
Option 3: C
connection

Spillback nozzles
Option 1: Single nozzle
Option 2: C luster head with
3 to 6 single nozzles

Lechler nozzle lances
ensure optimal spray placement and alignment in flue gas
ducts. The choice of nozzles
and the conside­ration of local
conditions and process-related
matters means they can be
individually adapted to therespective requirements.
The nozzles themselves havea low-maintenance designand can be quickly cleaned
or exchanged with minimal­effort.

16

The robust, high-quality stainless steel construction ensuresa high degree of functional­reliability. Lances are available
in a variety of material to suitspecific process requirements.
Lechler nozzle lances areavailable with many options,
including but not limited to:Protection tube to increase
the service life in case ofhigher temperatures, highdust loads and aggressive
gases, with barrier air as
an option

Wedge flange, standard
flange and special flange inaccordance with customer
requirementsGuide rail to facilitate lance
installation
Shifting device to change
the insertion lenght – withor without gastight sealing
Expansion joint or stuffing
box for expansion compensation at high temperatures

Assembly connecting
piece with flange connector
for welding onto flue gas
duct
Further special customi­
zations including wear
­ rotection, insulation,p­water cooling or coatingPre-assembled accessory
kits for process media
connections (e.g. quick­release couplings, shut-offball valves, strainers)
Lechler nozzle lances are
manufactured in line withultramodern production
processes and according
to the state of the art.

Flange connections
Option 1: Wedge
Option 2: Standard flange e.g. DIN, ANSI etc.
Option 3: Special flange according to customers­ pecification

VarioJet ® nozzle

1

2

3

Option 1: W ithout protection tube
and without protection cap
Option 2: With protection tube andwith protection cap... !

Material
Lances are manufactured fromstainless steel (316/316L) as
standard, but depending on requirements can also be madeof chemical and high-tempe­
rature resistant materials.

Accessories are available ingalvanized steel or stainlesssteel and the hoses are available in rubber or stainlesssteel.

Talk to us
Each gas cooling tower and flue gas duct is different.
Which is why standard solutions do not always makesense. Speak with us and let us work together to findthe best solution for your purposes.

17VarioCool ® gas cooling system
For a perfectly tailored solution

Our valve skid units for regulating the flow rates of water and atomizing air are individual customer-specific­solutions. Based on the requirements in each case, our first step is to design an overall concept and select thebest components in order to create a perfectly tailored solution.

First-class engineering
To perform our engineering, we determine all relevant parameters and define the plant’s design. This includes determining
the nominal widths and pressure levels as well as designing the pumps and control valves. We draw up the P&I diagram
and make detailed equipment and signal lists as an option. Of course, the project is fully documented to ensure that technology and processes can be quickly traced even after years of use.

High-quality components
An exact knowledge of of the characteristic properties of our nozzles is key here. For only a complete system that is co­ordinated to how the nozzles function and operate will ensure smooth and economical operation of the gas cooling system.
The service life of the products used is key to a power plant’s profitability. Unexpected failures can quickly lead to plant
stoppages and costly production outages. Which is why we fit our valve skid units with high-quality components from wellknown manufacturers as standard and the most important functional components are even realized in redundant design.
The components are interconnected with pipes and mounted on a stable base frame with eyelets for crane transportation,at the same time ensuring that all components for operation and maintenance are arranged in an easily accessible manner.

Tested quality
The design (e.g. dimensioning of nominal widths) and production are in line with the latest state of the art and comply withall relevant standards. They are equally subject to the Lechler quality management system certified to DIN EN ISO 9001,
as is the final acceptance. Before delivery, the valve skid unit undergoes a pressure and tightness test and is checked byour experienced engineers. This will avoid any problems during commissioning.

Control concept from the nozzle specialist
Numerous installations of VarioCool ® systems, years of commissioning experience, plus expertise in nozzle techno­logy
all contribute to the constant improvement and optimization of Lechler control systems. By installing a control solution
from Lechler you will benefit considerably from this wealth of experience. The flexible and fully automatic concept canbe perfectly adapted to your process. You will have start-up and shut-down scenarios and dynamic process conditions
under perfect control with our solution.

Option packages for our VarioCool ® valve skid units
Electrical wiring of the components:

Control cabinet with complete PLC
All components including the pumps are wired toa control cabinet. The control cabinet is integrated
into the base frame of the valve skid unit.
The complete injection control is tested in accordancewith valid electrical standards and regulations andallows all relevant process parameters to be visualized over a control panel on the control cabinet.
Junction box
All components except the pump
­motors are wired to a junction box­within the valve skid unit.

Specific configuration and extensive testing makecommissioning much faster. Communication andthe exchange of signals (setpoint, plant status,
error messages) with the customer’s logic system
is carried out via PROFIBUS or PROFINET.

This assures that the customer
has a central connection point for all
electrical components and measuring­devices for further processing in thehigher-level control.

The control has several modes of operation such as
automatic mode and manual mode for tests during
plant downtimes. In the event of faults, our engineers
can quickly perform a remote diagnosis via the installed modem without the need for an on-site visit.

19

VarioCool ® gas cooling system
For a perfectly tailored solution

Extended scope of delivery

20

Ring mains

Purge air connection

Ring mains are usually used to supply thelances. Lechler supplies ring mains andheaders together with the corresponding
brackets for welding onto the flue gas
duct. Accessories such as pressuretransmitters and manometers plus theappropriate connections for the lancesand supply lines are also included in thescope of delivery.

In order to increase the injection­turn-down ratio, individual lances orlance groups can be connected or­disconnected. If the disconnected­lances are in the flue gas duct, therest of the fluid should be purged.
­Vaporization and deposits in the lancecan be prevented in this way.

Water tankA water tank made of steel or plastic
serves as a reservoir for the valve skid
unit and guarantees injection operation
for a certain period of time in the eventof the water supply failing. Its size isadapted to the injection quantity. The
components for tank filling and levelmonitoring are included in the scopeof delivery.

Temperature measurement
For a constantly regulated outlett­emperature, it is very important for
the response characteristics of thetemperature sensors to be adapted tothe ambient conditions. Lechler provides
the appropriate thermometers andassists you in defining the installation
position.
Barrier air fan
In order to protect the nozzles and ­lancesfrom dust deposits and/or high temperatures, barrier air is frequently applied tothem. For this purpose, Lechler supplies
fans geared to the specific application
with various optional attachments such asa throttle valve, suction filter and silencer.

... !
Talk to us
Do you require an option that is not listed? Or are you
having planning issues? No problem. Tell us what yourrequirements are. We will find the appropriate solution
and ensure a seamless integration.

21

Lechler Online Cleaning (LOC®)
Cleaning-in-Place system for twin-fluid nozzle lances

In the semi-dry flue gas cleaning processes used in power plants, an alkaline washing suspension, usually lime
­slurry, is injected into the hot flue gas in spray towers. The droplets injected by twin-fluid nozzles are evaporated
by the transferred heat. At the same time, pollutants such as SO2, HCl and HF react with the reactants in the­washing fluid.
The washing suspension frequently causes damaging deposits and blockages in the nozzles, nozzle lances and pipelines. In thepast, reliable long-term plant installation was often not possible without regularly dismantling and cleaning the nozzle lances.
Good process results frequently came at the cost of high maintenance effort.
The Lechler LOC® Cleaning-in-Place system eliminates the need for complex disassembly, unnecessary downtimes
and personnel costs.

Spray absorbers/dryers

Ring mains with LOC® unit

LOC® reference installation with maximum equipment configuration

LECHLER
ONLINE
CLEANING®

LOC® makes your plant more economically efficient
Lechler offers an online cleaning system tailored to the respective application which allows reliable continuous operation and inexpensive cleaning of the nozzle lances.
The nozzles are made of wear-resistant hard metal and have been optimized for atomizing suspensions. The individual lances arecleaned cyclically during ongoing operation using precisely metered quantities of cleaning agents. In many cases, minimum useof diluted citric acid (10 %) and compressed air is sufficient for reliable cleaning while at the same time ensuring compliance withthe process limit values.

Blocked air holes

A visible difference:
Nozzles before and after LOC® treatment

Advantages
High availability of the spray reactor/dryer
Uninterrupted operation

Minimum maintenance effort
Low costs through the controlled use of cleaning
agentsCyclical cleaning with citric acid doped in compressed air... !
Talk to us
Lechler Online Cleaning (LOC®) is a tailor-made solution.
The better we know your requirements and operating
conditions, the more efficiently your processes will run.
Let’s talk to each other – about efficiency, cost savingsand success.
Cleaned nozzle

23

ENGINEERING AND SERVICE

Our experience for your success

From digital to realWith our experienced engineering team, you have acompetent contact for your project at all times – fromtechnical design and detail engineering to com­missioning
and replacement of spare and wearing parts. You will
benefit from direct contact and fewer communication
channels to enable smooth completion of your project.

Each individual design of gas cooling and conditioning
systems is based on innovative software. CFD calcu­
lations are used for flow optimization. Using a 3D tool,
we identify the optimum liquid distribution in the duct
together with the necessary lance arrangement.

Exclusive solutions

Extensive documentation

Lechler offers a system solution tailored to your appli­
cation and plant-specific conditions. We use only high-­
quality components from renowned manufacturers for ourvalve skid units. If you choose a system with a control,
you will get a complete solution for your gas cooling andconditioning requirement from a single source.

Our nozzle lances and systems are designed andmanufactured in line with the current standards andregulations. New plants are always delivered withproject-related documentation containing all relevant
information for commissioning, operation and maintenance. Lechler will also provide a verbal descriptionof the function and control concept where desired.

Reliable service is part of ouragreement

Future-proof

Lechler is Europe’s No. 1 nozzle manufacturer. A key
factor for this success is our service. For even after yoursystem has been delivered, you are in good hands with
Lechler. We offer a worldwide commissioning service
provided by employees with many years of experience.
A signal and performance test ensures optimal system
operation taking all operating and safety aspects into
consideration. An important point of commissioning is
also the detailed briefing of operating and maintenancepersonnel in the operation and maintenance of the plant.
We are your competent partner who will provide you withassistance to solve your problems. Our on-site service
for preventive maintenance ensures continuous operation.
We will be more than happy to draw up a maintenancecontract tailored to your needs.

24

Our drawings are created using state-of-the-art design
engineering software.

Lechler systems are built to withstand harsh conditions
and enable reliable and long-term operation. But we too
have to lend to the extreme process conditions in the
power plant industry. Which is why it is all the more important to us to have a guaranteed long-term supply of
spare parts for wearing parts – worldwide. With our global
network of repre­sentatives, we offer a worldwide platform
for contact and advice. You will find your competent­contacts on the Lechler website.

CFD Analysis
Flow optimization with computational fluid dynamics

Fluid Dynamics simulation as a process optimization tool
For us, perfection is not just a promise, but is based on calculation of computational fluid dynamics (CFD).
No matter what the spray application, the goal is always to achieve the maximum effect with the minimum possible useof ­material, spray media and energy. It is therefore essential to have a detailed understanding of how spray mist is formed
and propagated. This is made possible by computer-aided simulation of the flow processes (CFD – computational fluid­dynamics) of one or more substances in static or dynamic environments taking into account heat and mass transfer.
These simulations incorporate our many decades of know-how from the field of nozzle development. Initially, CFD was only ani­nternal tool which helped us to develop a desired nozzle more quickly and precisely. The completion of our high-performancecluster with a processing power of around 8,500 GFlops means that we can now offer our know-how as a service. We simulate
nozzle applications and processes individually for your environment and your requirements. So that your processes also run­perfectly in real life.

Our services:Your advantages:


Calculation of the flow field including ­pressure losses with one or more flowing
media in pipes and fittings
Maximum efficiency as regards:– the use of expensive consumable media
 eometric dimensions of the overall spray–g
process


Spray propagation including heat and masstransfer with the surrounding gases underpractically all conceivable ambient conditions

Calculation of internal nozzle flows and­prediction of the spray pattern, water­distribution and spray characteristics down
to droplet sizes in the near-nozzle range
Through targeted optimization of:– nozzle selection– nozzle operating point (taking into accountyour pumps, compressors and blowers)– liquid distribution– droplet sizes– inflow and outflow of your process gases
in relation to the spray process (with theaim of achieving uniformity and reducing
pressure losses)

You can’t just guess at perfection,
it must be precisely calculated

Optimization of SNCR process –best possible selection and placement of nozzles

The flow behavior of gases is significantly determined by
the geometry of the environment. By applying computer
simulation using computational fluid dynamics (CFD),
our specialists can detect unequal gas distributions aswell as turbulence. Depending on the specific conditions,these issues can be resolved in different ways. Installing
baffles, perforated plates or even repositioning nozzles canbe simulated to achieve the desired flow chara­cteristics.
The result of optimized gas flow via CFD can significantly
reduce energy and/or material requirements.

Benefits:
Reactive ammonia vapor
is present where the gas
containing nitrogen (NOx)
flows


Avoidance of unnecessary NH3 slip, meaning
efficient use of the­ammonia solution
Best possible reduction
rates of nitrogen oxides

Optimization of the gas flow in thegas cooling tower
Benefits:
Efficient cooler operation
thanks to lower atomizing
air consumption and/or
lower connection pressures at the nozzle lances
Wet ground avoided aswell as possible caking
on the inner wall of thecooler
Stable process in various
load cases

BeforeDesign and continuous optimizationof our products
Benefits:

Optimal atomization
effect
Efficient use of the­connected atomization
media


Reduction of therequired nozzle
connection pressures
Individual nozzle development in the shortest
time

After

27

NOZZLES FOR FLUE-GAS DESULFURIZATION

Flue-gas desulfurization in power plants requires nozzles
that guarantee precise long-term operation and are also
to withstand extremely aggressive ambient con­ditions.
Lechler has developed atomizing nozzles made of ceramicmaterials, e.g. from SIC, SISIC or ReSIC, for these applications.
Lechler TwinAbsorb® nozzles ensure efficient flue gas cleaning
and reliable SO2 separation. Their improved efficiency, reduced
operating costs as well as low maintenance costs make
TwinAbsorb® nozzles the first choice for power plant operatorsfor both process and economic reasons.

TwinAbsorb®-EV
Equilateral Double Full Cone Nozzle

TwinAbsorb®-EH
Equilateral Double Hollow Cone Nozzle

The proven equilateral double full cone nozzle­TwinAbsorb®-EV generates two full cones by using
one single supply.

The proven equilateral double hollow cone nozzle
TwinAbsorb®-EH generates two hollow cones by using
one single supply.

Advantages
Provides smaller Sauter diameter (SMD d32) causedby dual cones.
Particularly advantageous not only for high flow rates
per nozzle.

Improved mass transfer caused by increased specificsurface area.
Supports an even gas distribution over the scrubber
cross-section.
Rotation impact onto the gas flow is compensatedwithin the nozzle.

Better coverage of scrubber wall section.

Reduced slurry loss at the scrubber wall in comparison
to hollow cone nozzles.
Reduced stress at scrubber wall in comparison to­hollow cone nozzles.
Reduced torque onto the pipe branches.
Keeps the advantages of Lechler tangential flow fullcone nozzles– completely self draining– large free passages– non-clogging designed

Advantages
Provides smaller Sauter diameter (SMD d32) causedby dual cones.
Particularly advantageous not only for high flow rates
per nozzle.
Extra overlapping area for highly intensive secondary
atomization.
High efficient generation of new stimulated reaction
surface without additional energy input.
Increased turbulence within the drop achieves re­activity of reaction surface.
Improved mass transfer caused by increased specificsurface area.

Rotation impact onto the gas flow is compensatedwithin the nozzle.

Better coverage of scrubber cross-section.

Reduced torque onto the pipe branches.
Keeps the advantages of Lechler tangential flow­hollow cone nozzles– completely self draining– large free passages– non-clogging designed

29

NOZZLES FOR FLUE-GAS DESULFURIZATIONTwinAbsorb®-V
Double Full Cone Nozzle

TwinAbsorb®-H
Double Hollow Cone Nozzle

The proven double full cone nozzle TwinAbsorb®-V
generates two counter rotating full cones by using one
single supply.

The proven double hollow cone nozzle TwinAbsorb®-H
generates two counter rotating hollow cones by using
one single supply.

Advantages

Improved mass transfer caused by higher relative­velocity of liquid to flue gas.
Rotation impact onto the gas flow is compensatedwithin the nozzle.
Increased turbulence within the drop for highly active
reaction surface.
Increased residual time of drops during the process.
Duplication of hydraulic spray level in comparison to
single spray nozzles.
Reduced pressure loss in case of counter current
gas flow.

Reduced slurry loss at the scrubber wall in comparison
to hollow cone nozzles.

Better coverage of scrubber wall section.
Provides smaller Sauter diameter (SMD d32) causedby dual cones.

Reduced stress at scrubber wall in comparison to­hollow cone nozzles.
Reduced torque onto the pipe branches.
Keeps the advantages of Lechler tangential flow fullcone nozzles– completely self draining– large free passages– non-clogging designed

Advantages

Improved mass transfer caused by higher relative­velocity of liquid to flue gas.
Rotation impact onto the gas flow is compensatedwithin the nozzle.
Intensive secondary atomization results in an­increased surface for faster mass transfer.

Increased turbulence within the drop for highly active
reaction surface.
Increased residual time of drops during the process.
Supports an even gas distribution over the scrubber
cross-section.
Duplication of hydraulic spray levels in comparison
to single spray nozzles.
Reduced pressure loss in case of counter current
gas flow.
Provides smaller Sauter diameter (SMD d32) causedby dual cones.

Reduced torque onto the pipe branches.
Keeps the advantages of Lechler tangential flow­hollow cone nozzles– completely self draining– large free passages– non-clogging designed30

Process-oriented nozzle
configuration
Supports bettergas distributionHighly efficientsecondary atomization
Improved mass transfer
Swirl compensation

TwinAbsorb®-EH 120°
Equilateral Double Hollow Cone Nozzle
TwinAbsorb®-EV 90°
Equilateral Double Full Cone Nozzle
TwinAbsorb®-H 120°
Double Hollow Cone Nozzle
TwinAbsorb®-V 90°
Double Full Cone Nozzle
Secondary atomization(droplet collision areas)
Flue gas

In addition to the TwinAbsorb® series, Lechler also offers a comprehensive range of nozzles for flue gas desulfurization
in a wide range of designs and materials that are exactly tailored to your specific application.

Twin4Absorb
Twin4Absorb nozzles are a further development of the TwinAbsorb® nozzle series.
Four overlapping spray cones generate additional jet collisions and thus a more active
reaction surface. Thanks to the enhance spatial distribution, the Twin4Absorb nozzles
are ideal for optimizing existing scrubbers.

Nozzles made of SIC

Nozzles made of SISIC

Helix nozzles made of SISIC/ReSIC

Helix nozzles made of Stellite... !
Talk to us
Are you not sure which configuration best meets your­requirements? We will gladly advise you. Just give usa call.

31

LECHLER DROPLET SEPARATORS
Keep it dry and eliminate mist

The introduction of wet flue-gas desulfurization in Germany is inconceivable without Lechler. As a partner to plantbuilders, we have made a crucial contribution to success in this area with our development work. The result is nozzles
made of highly wear-resistant and corrosion-resistant silicon carbide and droplet separator systems that meet thehighest process engineering demands.
Lechler droplet separators are optimally designed for the droplets produced during scrubbing and thus achieve
maximum separation levels.

Task:

Removal of sulfur compoundsProtection off downstream installation components
Reduction of operating costs

Advantages:
Modular system designHighest degrees of separation for large liquid quantities

Separation of small dropletsCompact design even for high gas speeds
Low pressure lossesMore uniform flow distributionUse also with high solid particle quantities

Cleaning during ongoing operation

Delivery of an overall concept– Nozzles for desulfurization of flue gases– Droplet separator systems– Integrated cleaning systems for droplet separators... !
Talk to us
Do you know your process but are not sure which droplet
separator is best suited for your purposes? No problem.
Based on your individual requirements, we will choose
from a finely graded range of vane profiles with single ormultiple deflection.

32

In order to design and plan
droplet separators, it is necessary to be familiar with theoperating and performancedata of the separation systems. An in-depth technicalunderstanding of the processes in each applicationis also required. Know-how
about droplet formation anddroplet movement in a gas
flow is essential to ensure
fault-free operation of a droplet separator. For more than
100 years now, we haveworked on detection, measurement and definition ofdroplets. It is therefore not bychance that Lechler nozzles
and Lechler droplet sepa­
rators are now considered­integral elements in processengineering.
Corresponding to the flow
­direction, Lechler high-­
performance separators
are ­differentiated based onhorizontal and vertical gas
flow. Sepa­rators are also
­realized for oblique gas flow
under certain conditions.
The choice of flow direction
depends on the individual
process or plant design.
Lechler offers a suit­able­solution for all installations­ ituations.

LTV 120 C

33

LECHLER DROPLET SEPARATORS
Keep it dry and eliminate mist

The LTV 120 droplet separator for vertical gas flows is available in different designs and also with multiple stages.
Integrated cleaning systems with highly efficient Lechler cleaning nozzles permit continuous operation and reduce therisk of clogging. The angled installation position allows reliable removal of the separated liquid even at high gas speeds.

LTV 120 AA

LTV 120 C

2-stage droplet separator system with integrated
cleaning system for installation on two levels.

2-stage droplet separator system with integrated
cleaning system for installation on one level. This systemis optimized for restricted installation spaces.

LTV 120 CR

LTV 120 A + LTV 400

3-stage droplet separator system with integrated
cleaning system for installation on two levels. The first
separator stage consists of horizontally arranged
pipes for pre-separation and flow optimization.

2-stage droplet separator system with integrated
cleaning system for installation on two levels. The firstsep­arator stage consists of the LTV 400 as a flat
separator level.

34

The different droplet separator systems can be combined with each other, depending on individual requirements inrelation to efficiency and space.

LTV 400

LTV 271

The LTV 400 is a universal separator system. Thanks tointensive optimization of the profile contour, the LTV 400
achieves high separation values even without additional
drainage aids for the separated liquid. The resultant smoothprofile surface has a very low fouling tendency and can
be cleaned very easily. The LTV 400 can be realized with
one or multiple stages and is available with or withoutcleaning system.

The LTV 271 is a proven, widely used separator system.
It also impresses with its straightforward handling andeasy adaptation to the existing installation space. The useof our optional “Fix-Clip” connectors prevents packages
from slipping.

LTV 300

LTH 100

The LTV 300 is characterized by high separation performance – also for very fine droplets – and an exceptionallyhigh hydraulic load capacity. The special profile geometry
and angled installation position permit reliable draining of
the separated liquid.

The LTH 100 for horizontal gas flows is characterized byextremely flexible application and combination possibilities.
Low pressure loss, high hydraulic load capacity as well
as a low fouling tendency make the LTH 100 a universal
droplet separator system that has proven itself over thecourse of many decades.

35

MEASURING TECHNOLOGYHOW OUR RESOURCES HELP US ACHIEVE PRECISION

The basis for precision
nozzle development
At Lechler, exact measurements have long been thebasis for clearly defined spraycharacteristics. The data
­obtained in our laboratories
form the foundation for any
development and make iteasier for our customers tochoose nozzles for specificapplications. This saves time,
lowers costs and provides
planning security.

Advanced technology
We have further expanded
our research capacities by
opening our own Development
and Technology Center.
A highlight here is a laser-­assisted phase doppler anemo­
meter. As one of the mostmodern optical measuring
procedures, it measures thevelocity and the diameter ofspherical droplets simulta­
neously and without contact.
Using the data obtained,
spectra can be reliably derived
for particle size distributionsand velo­cities.

International cooperation
Measurements range fromtiny water droplets in the­micrometer region to verylarge droplets of around 8 millimeters. These are performed
with a high temporal and­spatial resolution.
Individual positions in thespray can be automati­callyapproached and measured
with extremely high accuracy –in x, y and z directions.

We at Lechler value theimportance of international
cooperation. For this is often
what opens up new perspectives on a problem. In addition,
cooperation offers us thepossibility of testing nozzles invery special test environments
and of discovering new use
scenarios in this way.

Our unique selling proposition: Practice-based knowledge
Since it was founded, Lechler has stood out for its development of new technologies. In more than a century we havesuccessfully filed a large number of patents. Starting with the “Centrifugal Sprayer” from 1893 and going up to state-of-the-art
technologies of the 21st Century. We will continue this proud tradition into the future, and our new technical center will be
key to doing so. After seven years of construction, the Lechler Development and Technology Center was opened in thesummer of 2016. Since then it has offered everything nozzle developers dream of on a surface of over 600 m². In addition
to extensive measuring facilities, state-of-the-art test benches with a wide range of pump performances are available tomeasure and investigate sprays, from microfine mist to fuller sprays with varying jetting characteristics.

37

MEASURING TECHNOLOGY
THE LECHLER DEVELOPMENT AND TECHNOLOGY CENTER

Our measurement range:Precise and reproducible measurement of droplet
sizes and speeds in sprays

Measurement of complete sprays or of local
positions in a spray
Documentation of the spectra for particle size
distribution and velocities

Determination of the Sauter mean diameter and ofmany other variables relevant for process engineeringMeasurement of very dense sprays using state-ofthe-art laser technology

Measurement validation of our calculation models
taking the example of a gas cooling tower
Key figures of our ex­
perimental cooler withindustry partners:
Approx. two megawattsof thermal performanceUse of single-fluid andtwin-fluid nozzles underthe most realistic con­ditions possibleFlexible variation of inlet
and outlet temperaturesMeasurement of tiniest droplets in the µm region
and measurement of very large drops of up to 8 mm
Measurement of droplet velocities up to 200 m/sMonitoring of droplet
sizes and numbers inseveral levels

Detection of the evaporation rates of injected
sprays
Use of more than
50 sensors of different
kinds for the precise
detection of all operating
parameters

High temporal and spatial resolution
Positions in the spray can be automaticallyapproached and measured with extremely highaccuracy – in a 3-dimensional space in x, y andz directions
Very large measuring range allows measurementof very wide particle spectra
The size and velocity of each individual droplet isdetected
Error-free results in accordance with ISO 9001

Spray characteristics over area mapped in 3D
Detection of positive and negative velocity
components

QUALITY WITH A SYSTEM
Lechler products are used in a wide variety of sectors
and applications.
Which is why the products’ requirements are often very
specific to certain applications. We define the term “quality”
as the extent to which our products fulfill our customers’
individual requirements.
We are certified according to internationallyrecognized standards. Conscientious working
and constant quality controls have always
been carried out at Lechler, from materials
receiving, development and production rightthrough to shipping. So that our products
keep what we promise in their daily use.

38

... !
Talk to us
Your requirements are the first step towards a solution.
We are more than happy to help you solve your individualtasks. Tell us your objectives and we will take care of
the solution. If the solution is not yet available, we will
tailor-make one for you. That is our promise.

FOR YOUR QUESTIONS

Data collection sheet
for calculatinga gas cooling system

QUESTIONNAIRE

Dear customer,
to comment on your gas conditioning problem, we would require all data known to you and indispensable for computing.

Company:

Date:

Address:

Contact person:
Phone/Fax:
E-Mail:Nobody knows yourprocess and requirements
better than you. Yourknowledge is critical to us
in order to find the optimal
nozzle for your application.

Simply send us thecompleted questionnaire
or enter your information
online.

1. Gas dataClinker production (in case of cement plant)t/dGas flowt inlet [°C]

max.:

min.:

nominal:

min.:

min.:

min.:

max.:

standard:

max.:

max.:

H2O

Gas composition [Vol. %]t outlet [°C]

max.:

CO2

O2

N2


Other components of gas (HCI, HF, CaCl2 etc.)[mg/Nm3*, humid]Dust content in gas
System pressure (in the reaction area)
Altitude of the plant

meters above sea level

2. Conditions on SiteAre gas cooling tower dimensions fixed?
(Please attach Sketch/drawing of GCT or Duct!)

 Yes
 No

Ø
Favorite -Ø[mm] dimensions[mm] dimensions

Available reaction distancem Reaction distance to be determined
Direction of gas

 ⇓

 ⇑


Nozzle type: Single fluid TwinfluidComplete evaporation required?

[mm x mm]
[mm x mm] ⇒
 Both types possible

 Yes  No
Is water injection system always in operation?  Yes  No

In case the operation is interrupted, running time%

* T0 = 273 K (0°C), P0 = 1 bar

Lechler GmbH · Precision Nozzles · Droplet Separators
P. O. Box 1323 · 72544 Metzingen, Germany · Phone +49 7123 962-0 · Fax +49 7123 962-405 · info@lechler.de · www.lechler.com

Data collection sheet for design of a gas cooling systemwww.lechler.de/environmental/questionnaire_gascooling

Data collection sheet for design of a DeNOx systemwww.lechler.de/environmental/questionnaire_denox

FULL INFORMATION IS JUST A CLICK AWAY:
THE LECHLER WEBSITE

Our website contains
further information on
our products as wellas useful resources.

www.lechler.com

39

World Headquarters
Lechler Companies
Sales Offices

Lechler GmbH · Precision Nozzles · Nozzle Systems
P.O. Box 13 23 · 72544 Metzingen, Germany · Phone: +49 7123 962-0 · Fax: +49 7123 962-301 · info@lechler.de · www.lechler.com
ASEAN: Lechler Spray Technology Sdn. Bhd. · No. 23, Jalan Teknologi 3/3A · Taman Sains Selangor 1 · Kota Damansara, PJU 5 · 47810 Petaling Jaya · Malaysia · info@lechler.com.my
Belgium: Lechler S.A./N.V. · Avenue Mercator 6 · 1300 Wavre · Phone: +32 10 225022 · Fax: +32 10 243901 · info@lechler.be
China: Lechler Intl. Trad. Co. Ltd. · Beijing · Rm. 418 Landmark Tower · No. 8 Dong San Huan Bei Lu · Phone: +86 10 84537968, Fax: +86 10 84537458 · info@lechler.com.cn
Finland: Lechler Oy · Jäspilänkatu 18 · 04250 Kerava · Phone: +358 207 856880 · Fax: +358 207 856881 · info@lechler.fi
France: Lechler France, SAS · Bât. CAP2 · 66-72, Rue Marceau · 93558 Montreuil · Phone: +33 1 49882600 · Fax: +33 1 49882609 · info@lechler.fr
Great Britain: Lechler Ltd. · 1 Fell Street, Newhall · Sheffield, S9 2TP · Phone: +44 114 2492020 · Fax: +44 114 2493600 · info@lechler.com
India: Lechler (India) Pvt. Ltd. · Plot B-2 · Main Road · Wagle Industrial Estate · Thane (W) - 400604 · Phone: +91 22 40634444 · Fax: +91 22 40634497 · lechler@lechlerindia.com
Italy: Lechler Spray Technology S.r.l. · Via Don Dossetti 2 · 20080 Carpiano (Mi) · Phone: +39 02 98859027 · Fax: +39 02 9815647 · info@lechleritalia.com
Spain: Lechler S.A. · Avda. Pirineos 7 · Oficina B7, Edificio Inbisa I · 28700 San Sebastián de los Reyes, Madrid · Phone: +34 91 6586346 · Fax: +34 91 6586347 · info@lechler.es
Sweden: Lechler AB · Kungsängsvägen 31 B · 753 23 Uppsala · Phone: +46 18 167030 · Fax: +46 18 167031 · info@lechler.se
USA: Lechler Inc. · 445 Kautz Road · St. Charles, IL. 60174 · Phone: +1 630 3776611 · Fax: +1 630 3776657 · info@lechlerUSA.com

Edition 08/19 · EN · 500 · S-2019-8400-063 · www.dgm-kommunikation.de · Subject to technical modification.

LECHLER WORLDWIDE