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Author:
Nikulin V, Head of Engineering
Nikulin V, Head of Engineering
The definition scrubber system refers to equipment used in manufacturing applications to remove contaminants from air streams.
Industrial application of wet scrubber covers a wide range of processes where emissions need to be cleaned from pollutants such as particulates, acid gases, or chemical vapors. Common industries using it include:
Industrial application of wet scrubber covers a wide range of processes where emissions need to be cleaned from pollutants such as particulates, acid gases, or chemical vapors. Common industries using it include:
- Power plants – for desulfurization of flue fumes (removal of SO₂).
- Chemical manufacturing – to capture corrosive fumes like HCl, Cl₂, or NH₃.
- Metal smelting and refining – to remove heavy metals and acid mists.
- Waste incineration – to reduce hazardous emissions.
- Pulp and paper industry – to control odorous sulfur compounds.
Venturi TORNADO Fluidized Bed Scrubber
Types of Industrial Cleaning Equipment
Although devices are, by the industrial scrubber definition, typically wet systems, experts distinguish semi-dry or dry scrubbers as a separate category. This term refers to equipment in which the liquid almost completely evaporates after interacting with contaminants, or is initially supplied in the form of vapor.
Dry, semi-dry, and industrial wet air scrubber units differ significantly in their design. The following sections will examine the various types of equipment, with explanations of their operating features.
The main types of industrial scrubber systems include:
Packed-bed configurations are equipped with either stationary or moving packing material, which serves as the internal filler. Both large structured bodies with specific geometries and loose fill materials made of small elements are employed. Popular choices include small balls, rings, spirals, and metal shavings.
Dry, semi-dry, and industrial wet air scrubber units differ significantly in their design. The following sections will examine the various types of equipment, with explanations of their operating features.
The main types of industrial scrubber systems include:
- Packed-bed – with the interior of the vessel filled with packing material;
- Spray Tower (also known as nozzle installations) – designed for unrestricted interaction between phases.
- Tray Tower – featuring movable trays inside.
Packed-bed configurations are equipped with either stationary or moving packing material, which serves as the internal filler. Both large structured bodies with specific geometries and loose fill materials made of small elements are employed. Popular choices include small balls, rings, spirals, and metal shavings.
A spray-type industrial wet scrubber contains only nozzles inside the chamber and effectively removes coarse and medium-sized dust particles through short contact with water droplets. Inside the empty chamber, water is sprayed from nozzles in such a way that it forms a dense liquid curtain across the path of the air stream. In some cases, devices with a horizontal chamber orientation are used, which can simplify sludge removal.
An industrial scrubber with a Venturi tube features a narrow throat section where gas velocity increases, creating intense turbulence. This turbulence causes the washing medium to atomize into fine droplets, maximizing contact with pollutants. As a result, it’s especially effective for capturing fine particulate matter, mists, and acidic vapors. Venturi devices are commonly employed in metal processing, chemical plants, and waste incineration.
The tray tower is equipped with nearly flat circular trays that rotate within the body of the unit. These trays, perforated with small holes, are irrigated with liquid. As air passes through the holes, it comes into intense contact with the water. This process is known as bubbling (barbotage), during which mixing creates bubbles, and when surfactants are added to the fluid, the entire chamber fills with foam.
The foam-type industrial water scrubber used for dust removal is highly efficient, but it requires regular shutdowns to remove accumulated contaminants. It is nearly impossible to fully automate the cleaning process and perform it while the equipment is operating. Nevertheless, the trays are relatively easy to clean, both manually and with automatic methods such as high-pressure washing. Unlike packed-bed units, there is no need to completely replace the internal filling.
Dry units are employed when the use of liquid for purification is technologically undesirable or economically unjustified. Essentially, they function as adsorbers, where pollutants are captured on solid sorbent surfaces.
Dry systems are typically used for the preliminary neutralization or partial removal of pollutants such as SO₂, HCl, and HF, particularly in applications where high purification efficiency is not required or where further treatment is feasible. Reagents such as calcium hydroxide or sodium bicarbonate are employed as sorbents. The resulting reaction products are then captured using filters.
The tray tower is equipped with nearly flat circular trays that rotate within the body of the unit. These trays, perforated with small holes, are irrigated with liquid. As air passes through the holes, it comes into intense contact with the water. This process is known as bubbling (barbotage), during which mixing creates bubbles, and when surfactants are added to the fluid, the entire chamber fills with foam.
The foam-type industrial water scrubber used for dust removal is highly efficient, but it requires regular shutdowns to remove accumulated contaminants. It is nearly impossible to fully automate the cleaning process and perform it while the equipment is operating. Nevertheless, the trays are relatively easy to clean, both manually and with automatic methods such as high-pressure washing. Unlike packed-bed units, there is no need to completely replace the internal filling.
Dry units are employed when the use of liquid for purification is technologically undesirable or economically unjustified. Essentially, they function as adsorbers, where pollutants are captured on solid sorbent surfaces.
Dry systems are typically used for the preliminary neutralization or partial removal of pollutants such as SO₂, HCl, and HF, particularly in applications where high purification efficiency is not required or where further treatment is feasible. Reagents such as calcium hydroxide or sodium bicarbonate are employed as sorbents. The resulting reaction products are then captured using filters.
A chemical industrial scrubber system made of polypropylene is well-suited for use in the chemical, metallurgical, food, and pharmaceutical industries, as well as in mechanical engineering and laboratory settings. These devices are highly resistant to aggressive environments.
They purify air from pollutants such as:
They purify air from pollutants such as:
- Acidic substances: inorganic acids, acidic oxides, organic acids, hydrogen cyanide, chlorine, bromine;
- Basic substances: alkalis, ammonia, amines, soluble salts, alcohols, ethers, phenols;
- Other pollutants: hydrogen sulfide, odors, aldehydes, ozone, and more.
- The air cleaning process generates virtually no waste;
- Resistant to clogging by various substances;
- High resistance to fluctuating loads;
- Tolerant to temperature variations;
- Easy to operate.
Step-by-step Design Overview
Step 1. Defining the objectives and requirements will help prepare the Terms of Reference (ToR) for the equipment.
Wet-type units are suitable for soluble or reactive compounds. Dry setups are intended for low volumes and simple pollutants. A Venturi is effective for removing fine particles. Packed towers with packing or nozzles offer a versatile option, effective against most contaminants. Sometimes hybrid configurations are required, such as wet plus dry arrangements.
Step 4. Design of the Contact Zone
The contact zone must provide a maximum interface area (or sorbent surface) to enhance the intensity of mass transfer and chemical reactions that remove pollutants.
This calculation in industrial wet scrubber design is a balance between pollutant removal efficiency, energy consumption, and operational reliability. Accurate calculations enable the design of equipment that operates reliably and cost-effectively under specified operating conditions.
When choosing materials, it is essential to consider the chemical aggressiveness of the pollutants. The body of an industrial gas scrubber can be manufactured from stainless steel, FRP (fiber-reinforced plastic), PVC, or carbon steel with a protective coating. Valves and piping should also be made from chemically resistant materials. It is also important to take the temperature of the stream into account.
Packings are made from ceramics, plastic, or metal. Each case is unique, so for industrial scrubber design, it is always recommended to consult with specialists.
Step 7. Integration of auxiliary components that ensure the stable and safe operation of the industrial air scrubber system, enhance purification efficiency, and improve ease of operation.
This step also includes scrubber control definition, covering the setup of monitoring, automation, and regulation solutions for optimal performance.
At this stage of design, it is important to properly select and integrate such components. For example:
At this stage, equipment features are developed to facilitate future maintenance. For example, installation of safety relief valves, design of inspection hatches and platforms, automatic cleaning and monitoring setups, electrical safety measures, and so on.
- Which pollutants need to be removed? (e.g., SO₂, HCl, dust, ammonia, etc.)
- What is the required removal efficiency (in %)?
- What are the emission standards (environmental regulations, norms)?
- Is the operation continuous or periodic?
- Gas volume (m³/h)
- Temperature and pressure
- Concentration of pollutants
- Presence of dust, droplets, or aggressive compounds
- Corrosiveness and viscosity
Wet-type units are suitable for soluble or reactive compounds. Dry setups are intended for low volumes and simple pollutants. A Venturi is effective for removing fine particles. Packed towers with packing or nozzles offer a versatile option, effective against most contaminants. Sometimes hybrid configurations are required, such as wet plus dry arrangements.
Step 4. Design of the Contact Zone
The contact zone must provide a maximum interface area (or sorbent surface) to enhance the intensity of mass transfer and chemical reactions that remove pollutants.
- The method of wetting/reaction is determined: nozzles, packing, foam layers, etc.
- Calculation of residence time and column height.
- Selection of packing (e.g., Raschig rings, Pall rings, structured packing).
- Ensuring uniform distribution of air and fluid flow.
This calculation in industrial wet scrubber design is a balance between pollutant removal efficiency, energy consumption, and operational reliability. Accurate calculations enable the design of equipment that operates reliably and cost-effectively under specified operating conditions.
- Gas velocity (m/s)
- Liquid flow rate (L/h)
- Column diameter
- Pressure drop
- Mass transfer coefficient
- Calculation of pH, chemical reactions, and stoichiometry
When choosing materials, it is essential to consider the chemical aggressiveness of the pollutants. The body of an industrial gas scrubber can be manufactured from stainless steel, FRP (fiber-reinforced plastic), PVC, or carbon steel with a protective coating. Valves and piping should also be made from chemically resistant materials. It is also important to take the temperature of the stream into account.
Packings are made from ceramics, plastic, or metal. Each case is unique, so for industrial scrubber design, it is always recommended to consult with specialists.
Step 7. Integration of auxiliary components that ensure the stable and safe operation of the industrial air scrubber system, enhance purification efficiency, and improve ease of operation.
This step also includes scrubber control definition, covering the setup of monitoring, automation, and regulation solutions for optimal performance.
At this stage of design, it is important to properly select and integrate such components. For example:
- Pumps and nozzles
- Neutralization and reagent dosing unit
- Droplet separator
- Sludge collection and drainage module
- Sensors for temperature, pressure, pH, and level
At this stage, equipment features are developed to facilitate future maintenance. For example, installation of safety relief valves, design of inspection hatches and platforms, automatic cleaning and monitoring setups, electrical safety measures, and so on.
Maintenance Work
Service maintenance is a critically important process that ensures reliable, safe, and efficient equipment operation. Below is a detailed structure of industrial scrubber maintenance, including schedules, types of work, and inspection frequency.
An industrial scrubber supplier provides a technical manual with a detailed procedure guide.
Period | Key Tasks |
a) Daily (operator maintenance) | Checking liquid level and flow rate. Monitoring temperature and pressure. Visual inspection for leaks, vibrations, noise. Checking solution pH (if reagents are used). Monitoring pumps, fans, and sensors. |
b) Weekly maintenance | Nozzle flushing (to remove clogs). Inspecting droplet separators and packing. Cleaning filters, if present. Checking drainage pipes and sludge discharge. Removing deposits on internal surfaces (if observed). |
c) Monthly maintenance | Checking pumps: pressure, flow, seals. Inspecting electrical equipment: terminals, contacts, grounding. Checking and maintaining the chemical dosing system. Verifying accuracy of sensor readings and automatic valves. Measuring pressure drop (ΔP). |
d) Quarterly maintenance | Partial disassembly of equipment (if needed). Inspection and cleaning/replacement of packing material. Testing automatic control platform (SCADA/PLC). Checking tightness of connections and housing. Chemical analysis of working liquid. |
e) Annual major maintenance (overhaul) | Full operation shutdown. Disassembly of the unit (if applicable). Removing deposits, scale, corrosion. Replacing worn parts (nozzles, gaskets, filters, packing). Overhaul of fans, motors, electrical panels. Inspection or replacement of anti-corrosion coating. |
Cost Formation Procedure
We provide customized industrial scrubber quotes based on your air flow, contaminant type, and required removal efficiency.
Pre-project Survey
Definition of requirements, analysis of process streams, and selection of configuration type.
Preliminary Calculation
Determination of capacity, gas parameters, and required materials.
Budget Preparation
Includes equipment, automation, installation, transportation, reagents, and operator training. At this stage, a preliminary industrial scrubber price can be estimated.
Tender/Contract
Suppliers provide prices, service terms, and delivery timelines. Final industrial scrubber systems cost depends on selected materials, performance, and additional options.
Installation and Commissioning
Usually included in the installation price. Afterward, service plans and reagents are paid separately.
📌 Example of a Comprehensive Project
Suppose it is necessary to clean 15,000 m³/h of acidic gases:
➡️ Total capital expenditures: approximately $115,000,
➡️ Annual operating costs (OPEX): about $5,000.
If you’re interested in efficient industrial air filtration systems, leave your contact details and our specialists will get in touch with you for a consultation.
You can also write to us directly to receive a customized solution tailored to your specific needs and production conditions.
Pre-project Survey
Definition of requirements, analysis of process streams, and selection of configuration type.
Preliminary Calculation
Determination of capacity, gas parameters, and required materials.
Budget Preparation
Includes equipment, automation, installation, transportation, reagents, and operator training. At this stage, a preliminary industrial scrubber price can be estimated.
Tender/Contract
Suppliers provide prices, service terms, and delivery timelines. Final industrial scrubber systems cost depends on selected materials, performance, and additional options.
Installation and Commissioning
Usually included in the installation price. Afterward, service plans and reagents are paid separately.
📌 Example of a Comprehensive Project
Suppose it is necessary to clean 15,000 m³/h of acidic gases:
- Medium-sized unit – $70,000
- Materials (FRP + PVC) and automation – +$20,000
- Installation and commissioning – $20,000
- Reagent and sludge reserves – $5,000
➡️ Total capital expenditures: approximately $115,000,
➡️ Annual operating costs (OPEX): about $5,000.
If you’re interested in efficient industrial air filtration systems, leave your contact details and our specialists will get in touch with you for a consultation.
You can also write to us directly to receive a customized solution tailored to your specific needs and production conditions.
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Your feedback is appreciated!
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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