Improving Cooling Performance of Gas Conditioning Towers/Downcomers to Reduce Plant Emissions

A project was initiated at a midwestern cement plant that needed to improve their cooling capacity of their existing Gas Conditioning Tower (GCT) to reduce the tower outlet temperature and to improve Mercury (Hg) removal downstream in the process. In achieving a lower outlet temperature of the cooling tower, a plant can increase the adsorption of the Activated Carbon, thereby decreasing the amount required to meet emission requirements. The plant was hoping to avoid investing in a new cooling tower or other high capital cost equipment. The challenge was to increase cooling without experiencing wetting or buildup in the tower or ductwork. The upgraded tower has been running successfully for approximately 2 years. Before and after results will be presented.