{"id":9123,"date":"2026-02-20T10:10:33","date_gmt":"2026-02-20T01:10:33","guid":{"rendered":"https:\/\/www.dry-fog.com\/en\/?post_type=cases&p=9123"},"modified":"2026-03-09T11:02:52","modified_gmt":"2026-03-09T02:02:52","slug":"nozzle-cement-001","status":"publish","type":"cases","link":"https:\/\/www.dry-fog.com\/en\/projects-technology\/cases\/nozzle-cement-001\/","title":{"rendered":"Cement Plant | Optimizing Emergency Water Spray Nozzles for a Limestone Rotary Dryer"},"content":{"rendered":"
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\u25b6 Watch this case in a short video<\/a>\n<\/p>\n<\/div>\n

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Challenges Faced by the Customer<\/h3>\n<\/div>\n

A cement plant was using a rotary dryer<\/span> to dry limestone, but was experiencing performance issues with the spray nozzles used in the dryer\u2019s emergency water-spray system.<\/p>\n

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The dryer is operated with a system that recovers and reuses the heat generated during operation. In an emergency shutdown, the heat-recovery cycle stops and the internal temperature rises excessively, so water must be sprayed through the nozzles to cool the dryer.<\/p>\n

However, the originally installed nozzles caused excessive wetting inside and around the dryer<\/span> during spraying.<\/p>\n

The original nozzle supplier could no longer be identified, making it difficult to order replacements or find a suitable alternative. As a result, the customer consulted IKEUCHI, a specialist in industrial spray nozzles.<\/p>\n

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Solutions Proposed by IKEUCHI<\/h3>\n<\/div>\n

After visiting the site and confirming the nozzle type, required spray rate, and equipment specifications, IKEUCHI determined that its spillback nozzle*1<\/span>\u2014the GSPB<\/a> nozzle*2<\/span>\u2014was the most suitable option.<\/p>\n

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\n Left: Spraying image | Right: GSPB nozzles supplied with protective pipes (as delivered)
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*1<\/span>A spillback nozzle (also called a return-flow nozzle) is a spray nozzle that allows the spray capacity to be adjusted by opening or closing a return flow valve while keeping the supply pressure constant. It features minimal variation in droplet size<\/span> even when the spray rate is increased or decreased. In the standard SPB series, the largest model delivers 30 L\/min at a supply pressure of 0.2 MPa.<\/p>\n

Learn more about the SPB Series<\/span><\/u><\/a><\/p>\n

*2<\/span> The GSPB<\/span> Series is a higher-capacity version of the SPB series, with a maximum spray rate of 167 L\/min (10 t\/h)<\/span>. This enables optimal cooling inside a rotary dryer with an inner diameter of 5 m and a length of over 30 m\u2014without causing flooding in the surrounding area.<\/p>\n

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\n Spray from a GSPB nozzle
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The rotary dryer had six nozzle ports near the material chute. Because the basis for the customer\u2019s target spray rate was unclear, IKEUCHI proposed installing four nozzles first and adding more only if necessary.
\nTesting showed that four nozzles provided sufficient cooling performance, reducing cost as well as maintenance effort and expense<\/span>.<\/p>\n

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\n Spray test in progress
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Benefits Achieved<\/h3>\n<\/div>\n