Stilworx designs and supplies evaporative cooling systems for high-temperature process gases, intended for critical industrial applications such as steel mills and cement plants, where temperature control, evaporation efficiency, and operational reliability are key factors.
Our solutions are based on proven spray technologies and an engineering-driven approach, with particular attention to atomisation quality and outlet temperature control, to operate reliably on hot gas streams, under variable process conditions, and in severe industrial environments.
Stilworx supplies engineered systems for the evaporative cooling of process gases, with a focus on the injection system and atomisation control, to ensure efficient evaporation and precise outlet temperature control.
When required, Stilworx can integrate the supply with the construction of the cooling tower, drawing on in-house manufacturing capabilities.
Gas cooling performance is primarily determined by spray quality and gas–liquid interaction. For this reason, Stilworx adopts different spray technology lines, selected based on process requirements and operating philosophy.
Air-assisted spray technology.
The Dual Fluid system uses compressed air to atomise the cooling water, generating very fine droplets with controlled size and distribution.
This technology is generally applied when:
Dual Fluid systems offer excellent controllability but require significant compressed air consumption, resulting in higher energy demand and operating costs.
High-efficiency spray technology without primary air.
The Spill Air system combines high-pressure water atomisation with a controlled protective air flow, ensuring high atomisation quality without the use of compressed air for atomisation.
In this configuration:
Spill Air systems offer performance comparable to Dual Fluid systems while significantly reducing energy consumption, plant complexity, and utility requirements.
From design to commissioning, we develop solutions designed to optimize system performance and adapt to actual process conditions.
Each gas cooling system is designed starting from the process, not from predefined configurations. Key design parameters include: temperature set point, flow distribution, residence time, evaporation calculation, water quality and availability, control and regulation logic.
CFD analysis is applied to optimise: injection lance positioning, gas flow uniformity, spray–gas stream interaction, tower geometry (when applicable).
This approach minimises wetting phenomena, deposit formation, and operational instabilities.
Stilworx gas cooling systems are designed to ensure stable operation over a wide operating range. Depending on the application, control strategies may include: outlet temperature control, enthalpy-based regulation, staged spray injection, independent lance activation.
The selected control philosophy ensures rapid response to load variations, while avoiding overspray phenomena.
From Dual Fluid technology to Spill Air technology.
Many existing gas cooling systems rely on dual fluid spray technology, which requires large quantities of compressed air to achieve the desired atomisation quality. While effective, these systems are often characterised by: high compressed air consumption, significant electrical energy demand, high operating costs, greater utility and maintenance complexity.
Thanks to the high efficiency of Spill Air technology, it is often possible to replace existing dual fluid systems while maintaining comparable spray performance. Replacing a dual fluid system with a Spill Air solution can offer: a substantial reduction in electrical energy consumption, lower operating costs, simplified utilities, a reduction in the CO₂ footprint associated with energy consumption.
In many applications, these advantages translate into a rapid return on investment, making retrofit projects particularly attractive in the current context of rising energy costs and growing focus on energy efficiency.
Stilworx has extensive experience in the retrofit of existing gas cooling systems, including: replacement of obsolete spray lances and nozzles, conversion from high-energy-consumption dual fluid systems, adaptation to new operating conditions, optimisation of control and regulation logic.
Retrofit solutions are developed to minimise downtime and integrate seamlessly with existing equipment.
Gas cooling systems can be supplied as: complete custom-designed packages, spray and control skids, integration into existing or client-supplied structures.
Stilworx supports fabrication activities, installation supervision, and commissioning to ensure reliable start-up and correct operation.
The Stilworx engineering team can assist with the technical evaluation of the process and the identification of the most suitable solution.