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Author: Michael Klepik, Chief Executive Officer
Investing in a high-capacity fume scrubber treatment plant can help industrial sites handle corrosive exhaust streams while reducing operational risks. This reduces the risk of equipment corrosion and protects personnel health.
In addition, such a system ensures compliance with environmental regulations and stable operation under variable loads.
In the long term, it lowers operating costs and prevents fines for emission limit violations.
Industries such as metal finishing, chemical processing, and pharmaceuticals rely on wet fume scrubber factories for reliable air pollution control.
Torch-Air is an American manufacturing company specializing in the design and production of industrial air purification systems. Our equipment is successfully operating at over 400 facilities across the United States, Canada, and Mexico, delivering high air cleaning efficiency and compliance with environmental standards.
In addition, such a system ensures compliance with environmental regulations and stable operation under variable loads.
In the long term, it lowers operating costs and prevents fines for emission limit violations.
Industries such as metal finishing, chemical processing, and pharmaceuticals rely on wet fume scrubber factories for reliable air pollution control.
Torch-Air is an American manufacturing company specializing in the design and production of industrial air purification systems. Our equipment is successfully operating at over 400 facilities across the United States, Canada, and Mexico, delivering high air cleaning efficiency and compliance with environmental standards.
Typical Applications
Fume scrubber equipment is commonly used to capture emissions from:
- Acid emissions releases (e.g., HCl, HF, SO₂)
- Ammonia and amine vapors
- Metal plating processes
- Chemical storage tank vents
- Lab exhaust units
- Combustion off-gases containing soluble components
Key Components
The structural components of the equipment depend on the type of unit. Here are the basic elements:
- Inlet duct – Brings in fume-laden gas
- Chamber – Where gas contacts water (can be packed bed, spray tower, or venturi)
- Solution distribution system – Nozzles, sprays, or distributor trays
- Mist eliminator (demister) – Removes entrained moisture from the airstream prior to discharge.
- Recirculation pump – Keeps solution in motion
- Makeup water line – Replaces evaporated or overflowed water
- Drain or blowdown system – Discharges spent solution to wastewater treatment
Device Diagram
Optional Additions
- pH adjustment module
- Level sensors and automatic blowdown
- Chemical dosing (if neutralization is needed)
Design Calculation Steps
Performing an accurate fume scrubber design calculation requires the expertise of qualified and experienced engineers. The process involves complex chemical, thermodynamic, and fluid dynamic principles, and any miscalculation can lead to inefficient pollutant removal, excessive pressure drops, or even equipment failure. Proper understanding of reaction kinetics, gas-liquid contact mechanics, and materials compatibility is essential for ensuring system safety and compliance.
An experienced engineer can accurately interpret process requirements, select appropriate design parameters, and account for real-world variables such as fouling, corrosion, and fluctuating operating conditions. In addition, professional judgment is required to balance performance, cost, and maintenance considerations. For this reason, all design work must be reviewed and validated by personnel with relevant technical expertise and practical field experience.
1. Identify Pollutant Characteristics
An experienced engineer can accurately interpret process requirements, select appropriate design parameters, and account for real-world variables such as fouling, corrosion, and fluctuating operating conditions. In addition, professional judgment is required to balance performance, cost, and maintenance considerations. For this reason, all design work must be reviewed and validated by personnel with relevant technical expertise and practical field experience.
1. Identify Pollutant Characteristics
- Type of pollutant (e.g., HCl, SO₂, ammonia, particulates)
- Concentration of pollutant in inlet air (mg/m³ or ppm)
- Required removal efficiency (e.g., 95%)
- Flow rate of gas (m³/h or CFM)
- Temperature and pressure of process stream
- Use system specifications or process requirements:
The volumetric air flow rate is one of the most critical input parameters in the design of a water scrubber for fume collection. It is typically provided based on the process conditions and is measured in cubic meters per hour (m³/h) or standard cubic feet per minute (SCFM). The flow rate should reflect the actual operating conditions, taking into account temperature and pressure corrections if needed.
This value directly influences the sizing of the unit vessel, packing material, and fan or blower selection.
3. Select Liquid
Type of solution (e.g., water, NaOH solution, acid). Choosing the right fume scrubber liquid can significantly reduce chemical consumption and improve system longevity.
This value directly influences the sizing of the unit vessel, packing material, and fan or blower selection.
3. Select Liquid
Type of solution (e.g., water, NaOH solution, acid). Choosing the right fume scrubber liquid can significantly reduce chemical consumption and improve system longevity.
Where:
Ql= the liquid flow rate (L/m³ or m³/h)
L/G = selected liquid-to-gas ratio (L/m³), typically 5–20 L/m³ depending on the pollutant
4. Mass Balance Calculation
Ql= the liquid flow rate (L/m³ or m³/h)
L/G = selected liquid-to-gas ratio (L/m³), typically 5–20 L/m³ depending on the pollutant
4. Mass Balance Calculation
- Determine mass of pollutant entering and leaving:
Where:
Cin = inlet concentration (mg/m³)
η = removal efficiency (as decimal)
5. Tower Sizing
Cin = inlet concentration (mg/m³)
η = removal efficiency (as decimal)
5. Tower Sizing
- Column diameter based on gas velocity:
where:
νg = superficial gas velocity (1–3 m/s)
A = cross-sectional area (m²)
D = diameter (m)
6. Pump and Nozzle Sizing
νg = superficial gas velocity (1–3 m/s)
A = cross-sectional area (m²)
D = diameter (m)
- Bed height:
6. Pump and Nozzle Sizing
- Calculate pressure drop and head required to size pump
- Select nozzles by evaluating spray angle and dosing capacity
- Included at the top to capture entrained droplets
- Must handle the expected liquid loading
- Corrosion-resistant materials (e.g., FRP, stainless steel, PVC) are chosen according to the chemical characteristics of the involved media.
- Include provisions for:
- pH control
- Overflows
- Blowdown/makeup equipment
- Access for cleaning and inspection
Design Risks and Recommendations
Category | Problem | Solution |
Input Data | Exact chemical content of the emission is uncertain | Perform laboratory analysis of emissions; use analyzers under actual operating conditions |
Lack of data on solubility and reactivity of substances | Refer to engineering handbooks (e.g., Perry’s, DDB, NIST); conduct solubility testing | |
Chemical Reactions | Unaccounted side reactions (formation of salts, foam, precipitates) | Run pilot-scale tests; use defoaming agents if necessary |
Ignoring corrosion processes (affecting material choice and equipment lifespan) | Material selection should account for the pH, thermal conditions, and nature of the process stream—consult a process chemist. | |
Mass Transfer | Incorrect determination of bed height | Use standard HETP calculation methods; apply CFD simulations |
Hydraulics | Errors in pressure drop and flow velocity calculations | Conduct detailed hydraulic calculations considering packing and mist eliminator pressure losses |
Difficulty selecting a pump with the right head and flow rate | Refer to pump performance curves; include losses in piping and spray system | |
Incorrect selection of nozzles or sprays | Use nozzles with known spray characteristics; verify spray coverage area | |
Water Circuit | Excess or insufficient water | Add level sensors and dosing meters; automate fresh water and blowdown control |
Errors in recirculation, pH control, or blowdown calculations | Integrate pH sensors and fluid regulation devices; use SCADA/PLC for automation | |
Practical Experience | Some parameters are difficult to determine without field experience | Involve engineers with practical expertise; use data from similar projects to guide development |
Modeling requires high-level expertise | Delegate modeling to specialized engineering teams; use reliable software (e.g., Aspen Plus, Ansys) |
Professional assistance in fume scrubber calculation helps avoid costly design revisions and ensures regulatory compliance.
Selection
Absorption towers for treating gaseous emissions are applied when pollutants are readily soluble in water or chemical solutions. This is the most effective solution for removing a wide range of contaminants, including acidic compounds like SO₂, HCl, and HF, as well as ammonia, VOCs, and particulate matter.
When selecting a water scrubber for fumes, it's essential to determine pollutant concentration and composition, gas flow rate, temperature, humidity, and the required efficiency of purification. Common types used include packed-bed, bubble (barbotage), and venturi scrubbers.
Additionally, selecting an appropriate scrubbing reagent (water, alkaline or acidic solutions, or other substances) is crucial, along with calculating the required contact time and contact surface area between the phases. It is also important to plan for subsequent wastewater treatment to handle reaction byproducts and removed pollutants.
When selecting a water scrubber for fumes, it's essential to determine pollutant concentration and composition, gas flow rate, temperature, humidity, and the required efficiency of purification. Common types used include packed-bed, bubble (barbotage), and venturi scrubbers.
Additionally, selecting an appropriate scrubbing reagent (water, alkaline or acidic solutions, or other substances) is crucial, along with calculating the required contact time and contact surface area between the phases. It is also important to plan for subsequent wastewater treatment to handle reaction byproducts and removed pollutants.
TORNADO-RP
The TORNADO-RP unit is engineered specifically for chemical industry applications, incorporating an integrated spray system combined with a multi-stage droplet separator. This enables efficient removal of acidic, alkaline, and other harmful emissions.
A vertical column with integrated packing support and distribution structures is a key part of the configuration. During operation, these elements are continuously irrigated, creating an extensive phase-contact surface.
A vertical column with integrated packing support and distribution structures is a key part of the configuration. During operation, these elements are continuously irrigated, creating an extensive phase-contact surface.
BOREAS-P2
The BOREAS-P2 equipment features a horizontally arranged housing with spray nozzles designed to irrigate the incoming stream. To achieve greater coverage, the nozzles can be arranged in multiple rows if necessary. The polluted air then moves through a dense packing layer, effectively trapping most acidic contaminants.
Subsequently, the air flow passes through a multi-stage droplet separation system, where contaminated liquid is removed and directed into a circulation tank. After thorough cleaning, the purified air is discharged into the atmosphere.
Subsequently, the air flow passes through a multi-stage droplet separation system, where contaminated liquid is removed and directed into a circulation tank. After thorough cleaning, the purified air is discharged into the atmosphere.
BOREAS-P3
This horizontal system ensures detailed, multi-stage filtration of aggressive compounds. Its substantial dimensions and multi-level droplet separation mechanism are essential for thorough and extended purification of contaminated gas streams.
The BOREAS-P3 operates similarly to the previously described model, differing primarily in its ability to handle larger volumes and higher concentrations of acidic components in the polluted gas. Typically, the BOREAS-P3 is chosen by major industrial and manufacturing enterprises.
The BOREAS-P3 operates similarly to the previously described model, differing primarily in its ability to handle larger volumes and higher concentrations of acidic components in the polluted gas. Typically, the BOREAS-P3 is chosen by major industrial and manufacturing enterprises.
Case Studies
Types of Packing
The packing in a fume scrubber is one of the most important components for promoting phase contact, which enables effective mass transfer and pollutant removal.
Packing refers to the structured or random material that fills the scrubbing tower. Its purpose is to provide a large surface area for the liquid to interact with the contaminated gas, enhancing absorption or neutralization of pollutants.
1. Random Packing
Randomly dumped loose shapes that create surface area for interaction. Common types include:
🟩 Advantages: Low cost, easy to install
🟥 Disadvantages: Higher pressure drop at high gas velocities
2. Structured Packing
Carefully arranged materials (corrugated sheets or meshes) that provide uniform flow channels and high surface area. Engineers frequently select structured fume scrubber media to maximize surface area while minimizing pressure loss.
🟩 Advantages: Lower pressure drop, better efficiency, compact design
🟥 Disadvantages: Higher cost, more complex installation
Packing refers to the structured or random material that fills the scrubbing tower. Its purpose is to provide a large surface area for the liquid to interact with the contaminated gas, enhancing absorption or neutralization of pollutants.
1. Random Packing
Randomly dumped loose shapes that create surface area for interaction. Common types include:
- Raschig rings
- Pall rings
- Berl saddles
- Intalox saddles
🟩 Advantages: Low cost, easy to install
🟥 Disadvantages: Higher pressure drop at high gas velocities
2. Structured Packing
Carefully arranged materials (corrugated sheets or meshes) that provide uniform flow channels and high surface area. Engineers frequently select structured fume scrubber media to maximize surface area while minimizing pressure loss.
🟩 Advantages: Lower pressure drop, better efficiency, compact design
🟥 Disadvantages: Higher cost, more complex installation
Packing Choices
Common Materials:
Environmental regulations are driving fume scrubber manufacturers to develop more energy-efficient and compact designs.
If you're looking for a reliable partner in advanced air treatment solutions — contact us to discuss your project.
- Polypropylene (PP) — good chemical resistance, lightweight
- Polyvinyl chloride (PVC) — cost-effective for mild conditions
- PTFE (Teflon) — resistant to extreme chemical corrosion
- Ceramics — high-temperature applications
- Stainless steel — rare; used only in special high-strength cases
Environmental regulations are driving fume scrubber manufacturers to develop more energy-efficient and compact designs.
If you're looking for a reliable partner in advanced air treatment solutions — contact us to discuss your project.
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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
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