Author: Nikulin V, Head of Engineering
In operating within an industrial environment, the quality of sanitation and the use of industry-leading technology to eliminate harmful and hazardous phenomena is absolutely crucial. There have been too many cases of workplace accidents, fires, respiratory illnesses, and it is an all-too-often reality that exhaust and waste generated by factories lead to perilous consequences for the environment. Now let’s dig into how this can be turned into a non-issue.
How it Works
What is an acid gas scrubber? When it comes to a variety of undesirable debris and gases floating about on a factory floor or other similar facility, the most effective option for ridding the premises of these elements is an acid alkaline scrubber. There are different parts added to the system to use for different purposes and concentrations of debris and gases.
The way it generally works is that the air or gas is fed into the machine where it then is forced to collide with cleaning liquids. When it comes to a wet acid scrubber, a special acid-treating reagent is used to break down these chemicals. There are different options for applying this reagent, but the reagent is set on a collision course with these gases to a maximum extent so as to ensure that the chemicals cannot make it through the end of the filter. This is because the reagent is denser than the gases.
Once the coagulated gas-liquid phase makes it to the other side of the acid vapor scrubber, it enters a droplets eliminator which separates the freshly cleaned air from the liquid solution, which then enters a circulation cavity before being reused again or removed. Meanwhile, the cleaned air is ejected back into the industrial premises or released outside.
The way it generally works is that the air or gas is fed into the machine where it then is forced to collide with cleaning liquids. When it comes to a wet acid scrubber, a special acid-treating reagent is used to break down these chemicals. There are different options for applying this reagent, but the reagent is set on a collision course with these gases to a maximum extent so as to ensure that the chemicals cannot make it through the end of the filter. This is because the reagent is denser than the gases.
Once the coagulated gas-liquid phase makes it to the other side of the acid vapor scrubber, it enters a droplets eliminator which separates the freshly cleaned air from the liquid solution, which then enters a circulation cavity before being reused again or removed. Meanwhile, the cleaned air is ejected back into the industrial premises or released outside.
Scheme
Varieties of Acid Scrubbers and the Gases They Treat
How does an acid scrubber work? When it comes to floating compounds with a high pH level, a liquid reagent needs to be utilized with an opposite pH level to neutralize this before it can do harm or pose a hazard. Here are the different types of machines that exist and the intent behind their design.
The main factors that will drive this selection are
The main factors that will drive this selection are
- The specific type of acid: along with its corresponding reactivity and physical properties
- The concentration: the greater the high pH content in the air, the more robust of a design that the filter will require to fully cleanse the gases sufficiently
- Exhaust volume: high volumes of exhaust are best processed in spray towers, while Venturi tubes are more suitable for smaller denser streams
- Corrosion resistance: for this, stainless steel or plastic linings are the optimal choice
TORNADO-FB
Packed Bed Scrubbers
These are ceramic or plastic acid scrubber media used to create a large surface area for gases and liquids to come in contact with each other after the gas enters the inlet at the top of the tower. In this case, gas streams are accelerated into a venturi tube which narrows and then widens. At this narrow junction, gas and dust are irrigated with moisture particles of scrubbing liquid. They coagulate and the denser dust falls into the inertia-type droplets eliminator. TORNADO SP Packed Bed Scrubber with Structured Packing
Spray Tower
These spray a liquid solution onto incoming gases out of nozzles which may face in or against the direction that the gas is flowing in, capturing the hazardous molecules. In the case of the TORNADO-ST, there can be multiple irrigation layers – as many as three. The gas while rotating takes the accumulated liquid and sends it into rotary movement. Then the liquid case flows into the circulation cavity. It’s useful for ammonia and hydrogen chloride when large volumes of exhaust are involved.
Tray-Type
These types use perforated trays in a tower to ramp up the amount of contact taking place between gases and a liquid. Gases flow through the trays. This is good for treating hydrogen fluoride and sulfur dioxide.
Venturi
These remove particulates and gases using high-velocity liquid injection. A constricted venturi throat increases the gas stream’s velocity, causing intense mixing with the scrubbing liquid. The turbulence promotes efficient contact between pollutants and the liquid, removing it well. Such filters are good for high-temperature or corrosive gases.
Fixed Bed
This type of acid vapor scrubber features stationary packings like activated carbon or structured ceramic media. The stream passes through without much of a risk for damage and thus little maintenance is required.
Floating Bed
In this case, machines use media that freely move or float within the scrubbing liquid to enhance mass transfer and prevent clogging. There is dynamic movement creating turbulence that increases the surface area for absorption. This is especially good for particulate-laden exhaust streams. The system has to be robust enough to not be damaged though.
Spark and explosion-resistant
These are designed to handle flammable and reactive gases, often featuring non-sparking and anti-static coatings to dissipate electrical charges along with high-level durability and corrosion-resistance. This is a big issue with perchloric acids for instance. Gases are abundantly irrigated too against the current.
Random Packing
This type is used to increase the surface area of the packings. These feature irregular shapes and are loosely poured into a column, making for a chaotic arrangement. These commonly feature Raschig rings, Pall rings, etc. These are light-weight and corrosion-resistant and their open structure minimizes resistance to flow and energy consumption.
Tank Vent
Acid tank vent scrubbers are designed to purify air released from containers holding chemicals, removing pollutants such as volatile organic compounds (VOCs), acids, and other water-soluble contaminants. The operating principle is as follows: dirty gas is passed through a liquid that absorbs the pollutants. The purified air is discharged, while the contaminated liquid is collected for disposal.
Dry
In cases with high initial concentrations of pollutants and no dust, we recommend installing a dry scrubber (mist eliminator). Its operating principle is based on inertial separation: the gas flow passes through a system of curved plates or meshes where droplets collide with the surfaces, merge into larger ones, and flow downward, separating from the cleaned gas.
For a clearer understanding of how these devices work and their applications in wet and dry scrubbers, we recommend watching the video:
For a clearer understanding of how these devices work and their applications in wet and dry scrubbers, we recommend watching the video:
Mist Eliminators
Request your acid scrubber design pricelist from our specialists +1 (918) 406-5684
Applications for Specific Acids
One of the primary determinants for the acid scrubber material and components used in wet cleansing machines is the specific types of acids prevalent on the premises being cleaned. This is because hazardous streams feature their own unique chemical properties.
Acetic
This is a weak organic variant with a pungent smell and is volatile in vapor form, as they can easily escape. These are corrosive but not as much as mineral compounds. An acetic acid scrubber should ideally be constructed with polypropylene materials or stainless steel.
Hydrofluoric
This is a highly reactive, toxic, volatile material capable of dissolving glass and silica. It is extremely corrosive and hazardous to human health, generating fumes that can damage filter components if improperly handled. Essential components of a hydrofluoric acid scrubber are fluoropolymer-based or ceramic packings, which stand up to these threats nicely.
Sulfuric
This is a strong, corrosive mineral variant with a high boiling point, often released as a mist or a vapor. Fine-particulate capture methods are necessary when it forms a mist and it is highly hygroscopic, which poses a challenge in high-humidity environments. Thus, a caustic scrubber for sulfuric acid, usually going against the incoming current, is a good solution with fiberglass-reinforced plastic or rubber-lined steel. Incorporating droplet eliminators is also important to avoid mist carryover.
Perchloric
This is a strong oxidizing agent and mineral compound. It’s highly reactive, corrosive as a vapor, and potentially explosive under certain conditions. A perchloric acid scrubber can form explosive perchlorate salts if not thoroughly rinsed. All components must be spark-resistant to avoid triggering explosions.
Phosphoric
This is a moderately strong one, less volatile but viscous and often released as fumes or mist. A phosphoric acid scrubber tends to form deposits requiring robust designs to prevent fouling. It also has a tendency to create clogging since it forms particulates. Thus, fiberglass or lined steel components are optimal, and periodic cleaning is necessary to manage residue.
Acetic
This is a weak organic variant with a pungent smell and is volatile in vapor form, as they can easily escape. These are corrosive but not as much as mineral compounds. An acetic acid scrubber should ideally be constructed with polypropylene materials or stainless steel.
Hydrofluoric
This is a highly reactive, toxic, volatile material capable of dissolving glass and silica. It is extremely corrosive and hazardous to human health, generating fumes that can damage filter components if improperly handled. Essential components of a hydrofluoric acid scrubber are fluoropolymer-based or ceramic packings, which stand up to these threats nicely.
Sulfuric
This is a strong, corrosive mineral variant with a high boiling point, often released as a mist or a vapor. Fine-particulate capture methods are necessary when it forms a mist and it is highly hygroscopic, which poses a challenge in high-humidity environments. Thus, a caustic scrubber for sulfuric acid, usually going against the incoming current, is a good solution with fiberglass-reinforced plastic or rubber-lined steel. Incorporating droplet eliminators is also important to avoid mist carryover.
Perchloric
This is a strong oxidizing agent and mineral compound. It’s highly reactive, corrosive as a vapor, and potentially explosive under certain conditions. A perchloric acid scrubber can form explosive perchlorate salts if not thoroughly rinsed. All components must be spark-resistant to avoid triggering explosions.
Phosphoric
This is a moderately strong one, less volatile but viscous and often released as fumes or mist. A phosphoric acid scrubber tends to form deposits requiring robust designs to prevent fouling. It also has a tendency to create clogging since it forms particulates. Thus, fiberglass or lined steel components are optimal, and periodic cleaning is necessary to manage residue.
Maintenance and Support
The way that acid scrubber maintenance and support is done on a wet cleansers varies based on the design. For the most part there are floors and stairs that allow people to access hatches to remove and clean filters. There is also filter frame insulation installed and heating of the water feeding system. Each individual part also has insulation to prevent undesirable effects like condensation.
Each part is tracked well using a smooth launch device and special control board. The latter allows a technician to manage a module, connection, and controls. These inform specifically the performance indicators for each component. If there are irregularities they can be promptly inspected. These include such things as:
Each part is tracked well using a smooth launch device and special control board. The latter allows a technician to manage a module, connection, and controls. These inform specifically the performance indicators for each component. If there are irregularities they can be promptly inspected. These include such things as:
- data collection from the dust
- pressure variation
- equipment condition transmitters, such as the fan, worm, or feeder
- emergency stop action
- device deactivation in the event that the fire alarm sounds off
- differential manometer variation between the clean and dirty areas.
Materials and Filtration Media
Different scrubbers can be made of steel or plastic. These use different types of fans, some have to be sturdier if they are dealing with greater volumes and diameters of debris or particular corrosive substances. Here are the top types of materials used in such an acid exhaust scrubber.
If you are dealing with hazardous acid compounds in your factory premises, don’t hesitate to get in touch with Torch Air and we will deliver the perfect acid removal complex designed specially for your industrial site.
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We always perform precise calculations and offer expert assistance in selecting the optimal dust collection or gas cleaning systems, typically completing this process within 1 to 2 days
Head of Engineering,
Vladimir Nikulin
Vladimir Nikulin
CALCULATION AND SELECTION
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