Fume Scrubbers: Functions, Installation, Maintenance, and Cost Estimation

Author: Nikulin V, Head of Engineering

The primary function of a fume scrubber is to control and eliminate airborne pollutants from manufacturing exhaust streams by using physical and chemical methods. It serves as an emission management equipment that ensures the safe release of air into the environment by reducing concentrations of hazardous substances to acceptable regulatory levels.
Key functional objectives include:

1. Gas-phase contaminant removal – Targeting harmful vapors such as acidic compounds (e.g., HCl, SO₂), ammonia, and volatile organic compounds (VOCs), through absorption or chemical neutralization.
2. Particulate filtration – Capturing fine solid particles, mist, and aerosols suspended in the gas stream.
3. Corrosion prevention – Preventing damage to downstream equipment and infrastructure by removing corrosive substances from exhaust streams.
4. Regulatory compliance – Ensuring emissions meet environmental and occupational safety standards.
5. Worker and environmental protection – Reducing the release of toxic vapors to protect both personnel inside the facility and surrounding ecosystems.
6. Depending on the application, devices may also contribute to odor control and the recovery of valuable materials from process gases.

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The fume scrubber install process typically includes setup positioning, mechanical assembly, utility hookup, and unit testing and calibration. It must be performed according to safety regulations and tailored to the specific application and emission profile.

Key steps in the industrial fume scrubber installation process:
Site Preparation

• Evaluate the layout for space, ventilation, and structural support.
• Ensure access to utilities: water supply, drainage, electricity, and process exhaust ducts.
• Install concrete foundations or steel frames if required for large units.

Positioning

• The unit is lifted and mounted (often vertically) using cranes or hoists.
• It is securely anchored to prevent vibration and shifting during operation.
• Isolation pads or flexible supports may be used to reduce mechanical stress.

Ductwork and Piping Connection

• Inlet and outlet ducts are connected to the process setup and exhaust stack.
• Supply lines for cleaning liquid, neutralizing agents, and compressed air (if needed) are installed.
• Drainage networks for spent liquid and overflow are routed to treatment or disposal units.

Installation of Peripheral Equipment

• Pumps, control valves, level sensors, pH meters, and demisters are mounted and connected.
• Electrical wiring and monitoring panels are configured for integration into the facility’s automation system (PLC/SCADA).

Testing and Commissioning

• Leak tests and pressure checks are conducted.
• Flow rates, pH levels, and substance dosing are calibrated.
• A trial run ensures stable operation and compliance with emission requirements.

Documentation and Safety Checks

• Operating manuals and safety instructions are provided.
• Personnel receive training on operation and emergency procedures.
• Final inspection is performed by engineering and environmental compliance teams.

Proper fume scrubber maintenance is essential to ensure consistent performance, prevent equipment failure, and maintain compliance with air quality standards. Maintenance involves both routine inspections and periodic servicing of mechanical, hydraulic, and reactive components.
The frequency of the fume scrubber cleaning depends on the level of contamination, operating conditions (such as elevated concentrations of substances or high temperatures), the type of device used, and its configuration.
🔧 Key Maintenance Procedures:
1. Visual Inspections (Daily to Weekly)

• Check for leaks in piping, nozzles, tanks, and ductwork.
• Inspect the structural integrity of the unit (corrosion, cracks, loosened bolts).
• Ensure spray nozzles and demisters are unobstructed and properly aligned.

2. Liquid Monitoring

• Test and adjust pH, conductivity, or solution concentration in the sump or recirculation tank.
• Refill neutralizing agents (e.g., caustic or acidic solutions) as needed.
• Check liquid levels, flow rates, and pump function.

3. Mechanical Component Checks

• Inspect and lubricate pumps, fans, and motors according to the manufacturer's schedule.
• Replace worn gaskets, seals, and filters.
• Verify the performance of level sensors, flow meters, and control valves.

4. Demister and Packing Media Cleaning (Monthly or as needed)

• Remove and clean mist eliminators to avoid pressure drops.
• Backflush or manually wash packing materials to remove scaling and particulate buildup.

5. Drainage and Waste Handling

• Clean out sludge and sediment from the sump or reservoir.
• Ensure drain lines are free-flowing and connected to approved treatment/disposal facilities.

6. Equipment Calibration and Functional Testing

• Periodically calibrate instrumentation (pH sensors, flow monitors).
• Test emission levels downstream to confirm removal efficiency.

🧰 Recommended Maintenance Schedule:

Note: Maintenance intervals may vary depending on the type of fume and gas wet scrubber, process conditions, and contamination level.

In the United States, prices for fume scrubber installations vary widely depending on the type of device, its size, capacity, construction materials, design complexity, manufacturer, and specific application requirements. Below are approximate pricing categories for different types of units:
1. Small to Medium Units (for laboratories or small-scale operations)

• Price range: $5,000 to $50,000
• These devices are built to handle low air volumes, commonly found in laboratory settings or small production areas.

2. Medium-Scale Industrial Units

• Price range: $50,000 to $200,000
• Suitable for mid-sized production sites such as metal finishing plants, chemical processing operations, or petrochemical industries. These installations handle more complex contaminants and offer higher airflow capacity.

3. Large-Scale Manufacturing Units

• Price range: $200,000 to $1,000,000+
• Designed for heavy-duty applications in large manufacturing plants, chemical facilities, smelters, incineration sites, and similar operational environments. This equipment is built to handle elevated temperatures, large gas flow rates, and aggressive toxic pollutants.

4. Custom or Specialized Units

• Price range: Can exceed $1,000,000
• For applications requiring tailor-made configurations—such as processing hazardous substances, extreme temperature conditions, or stringent regulatory standards—expenses can rise significantly due to advanced engineering and materials.

Operating and Additional Costs
1. Energy Consumption
Larger installations may incur substantial energy expenses for operating pumps, blowers, and circulation fans.
2. Maintenance
Routine maintenance expenses can range from $1,000 to $20,000 per year depending on setup complexity, operational hours, and service frequency.
3. Solution
Depending on the type of cleaning media used (e.g., water, alkaline or acid solutions), annual expenses for replenishing the liquid can range from $1,000 to $10,000.
4. Engineering and Installation Services
Custom engineering, design, and installation may between $10,000 and $100,000 or more, based on project scale and requirements.
5. Auxiliary Components
Additional components such as monitoring installations, pumps, filters, pH sensors, dosing devices, and control panels may also contribute significantly to the overall project cost.

In total, the final cost of equipment includes both the base unit and associated infrastructure, utilities, and ongoing operational expenses.

Request a fume scrubber pricelist for detailed pricing based on unit type and specifications.

2. Specific Application Requirements

• The expense depends on the specific pollutants being removed (e.g., acidic vapors, ammonia, organic compounds). The more complex the treatment task, the higher the price, especially if special neutralizing agents are required.
• If extremely high purification standards or strict environmental regulations must be met, more advanced and therefore costlier devices are needed.
• Operating in environments with elevated temperatures, humidity, or corrosive activity will increase equipment expenses due to the need for enhanced protection and structural adaptations.

3. Installation and Engineering

• Engineering services such as system sizing, needs assessment, device selection, and the development of custom solutions for complex facilities all contribute to the total expense.
• Installation expenses include connection to water supply, power, ventilation, and commissioning, including adjustments and test runs.
• Integration with existing pollution control systems or waste treatment infrastructure adds to the project’s complexity and overall expenses.

4. Operating Costs

• Some chemical gas treatment systems require high amounts of electricity to power pumps, fans, and dosing apparatus. Large-scale units tend to have greater energy demands.
• If the setup uses reactive cleaning solutions, these must be replenished or replaced regularly, contributing to annual operating expenses.
• Components such as pumps, filters, spray nozzles, and demisters wear out over time and need regular replacement or servicing, increasing operating expenses.

5. Pollution Load and Service Frequency

• The higher the pollution level, the more frequently the equipment requires maintenance. For example, environments with dust, aggressive substances, or high temperatures lead to more frequent filter replacements and device checks.
• If the equipment handles aggressive substances like acids, components such as packing media or pipework may degrade faster, requiring more frequent replacement and increased service costs.

Taking all these factors into account allows for selecting the most suitable and cost-effective air purification unit tailored to the specific operational and environmental needs of an industrial facility.