Blast Furnace – Top Spray Cooling System CFD Simulation


Detailed single nozzle

Fig. 1. Detailed single nozzle

  • The chlorides present in crude oil are carried through a distillation still. Once the gases cool, the chlorides form salts that can corrode, erode, and clog pipes.
  • As part of the OCC project, T-101 system sprays water droplets to remove the chlorides by forcing the aqueous dew point.
  • CFD study had been conducted to achieve thorough understanding of the current design.


Overhead vapor wash water system

Fig. 2. Overhead vapor wash water system

The purpose of this system is to cool chloride gases to below the aqueous dew point which will help prevent corrosion in systems further down the line. The main method of lowering the temperature is to spray water droplets in the flow. The main objective of this project is to use CFD and other calculations to determine the most effective type of nozzle and analyze their effectiveness.


Three diagrams showing droplet concentration, vapor, and temperature.

  • A multi-phase 3D CFD model had been developed
  • Different nozzles had been evaluated
  • Detailed information had been provided, such as water concentration, evaporation rate, temperature, droplet surface area, etc.

Sponsor: BP

Faculty Collaborator: Dr. Chenn Q. Zhou

Click the movie below to see Spray Cooling in detail.

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CFD Simulation of Top Spray Cooling System in a Blast Furnace

Spray Cooling Project Flyer