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Author: Michael Klepik, Chief Executive Officer
The wet scrubber tower is widely used for removing various pollutants from the air. What is a scrubber tower used for in industrial processes?
- Dust and Particulate Matter: The technology involved can effectively capture and remove dust and fine particulate matter from the air stream by utilizing liquid to trap and settle the particles.
- Gaseous Pollutants: They are suitable for removing water-soluble contaminants such as sulfur dioxide (SO₂), hydrogen chloride (HCl), ammonia (NH₃), and nitrogen oxides (NOₓ).
- Acidic Vapors: They are often used to neutralize acidic vapors, such as sulfur dioxide (SO₂), by adding alkaline substances (e.g., lime or sodium hydroxide), which create a chemical reaction.
- Organic Compounds: In some cases, these systems can be used to remove volatile organic compounds (VOCs), especially if they are easily soluble.
- Odors and Biological Contaminants: This equipment is effective in removing unpleasant odors and biological particulate matter such as mold spores and bacteria due to its ability to capture and neutralize these substances.
- Smoke: A flue gas scrubber tower is specifically engineered to treat exhaust emissions from industrial processes, particularly those involving combustion. This equipment efficiently removes a range of pollutants, including sulfur dioxide (SO₂), nitrogen oxides (NOₓ), particulate matter, and other harmful substances from the flue stream before they are emitted into the atmosphere.
Operational Principle
Scrubber tower working involves injecting a liquid into the contaminated air stream to remove pollutants effectively. As the air flows through the unit, droplets capture and absorb contaminants, including dust and particulate matter. The sludge is then collected and treated, while the cleaned air exits the device. This process relies on mass transfer between the phases, effectively removing airborne particles from the atmosphere.
Overview TORNADO-RP
Components
A packed tower scrubber consists of several key components intended to facilitate efficient air-liquid contact for impurity removal. Here is a description of its construction:
1. Cylindrical Column: The main body of the equipment is a vertical cylindrical structure, typically made of materials resistant to corrosion, such as stainless steel or fiberglass-reinforced plastic.
2. Media: The unit is filled with beds, which can come in various shapes. Common types include Raschig rings, Pall rings, and structured packings. The purpose is to provide a large surface area for interaction between the stream and the fluid.
3. Liquid Distributor: Located at the top of the unit, the liquid distributor evenly sprays the scrubbing solution (usually water or a chemical reagent) over the structured medium. This ensures uniform wetting of the surface provided by the internals.
4. Inlet and Distributor: The contaminated air enters the structure through a inlet, usually located at the bottom.
5. Air Control Scrubber Tower Blower: It is essential for maintaining optimal air movement through the system.
1. Cylindrical Column: The main body of the equipment is a vertical cylindrical structure, typically made of materials resistant to corrosion, such as stainless steel or fiberglass-reinforced plastic.
2. Media: The unit is filled with beds, which can come in various shapes. Common types include Raschig rings, Pall rings, and structured packings. The purpose is to provide a large surface area for interaction between the stream and the fluid.
3. Liquid Distributor: Located at the top of the unit, the liquid distributor evenly sprays the scrubbing solution (usually water or a chemical reagent) over the structured medium. This ensures uniform wetting of the surface provided by the internals.
4. Inlet and Distributor: The contaminated air enters the structure through a inlet, usually located at the bottom.
5. Air Control Scrubber Tower Blower: It is essential for maintaining optimal air movement through the system.
Scheme
6. Mist Eliminator: Positioned at the top of the structure, the mist eliminator captures any entrained droplets from the cleaned stream before it exits the equipment, preventing fluid carryover.
7. Sump and Recirculation System: The bottom of the structure includes a sump where the contaminated effluent collects. This fluid is either drained or recirculated back to the top of the unit using a pump, depending on the layout and operational requirements.
8. Clean Stream Outlet: The cleaned air exits the unit through an outlet at the top after passing through the mist eliminator.
The packed tower wet scrubber operates by promoting intimate contact between the phases as the gas flows upwards and the wash solution flows downwards over the structured elements. This interaction facilitates the transfer of contaminants from the stream to the liquid, resulting in purified air.
7. Sump and Recirculation System: The bottom of the structure includes a sump where the contaminated effluent collects. This fluid is either drained or recirculated back to the top of the unit using a pump, depending on the layout and operational requirements.
8. Clean Stream Outlet: The cleaned air exits the unit through an outlet at the top after passing through the mist eliminator.
The packed tower wet scrubber operates by promoting intimate contact between the phases as the gas flows upwards and the wash solution flows downwards over the structured elements. This interaction facilitates the transfer of contaminants from the stream to the liquid, resulting in purified air.
Types
A tray tower scrubber consists of multiple perforated plates arranged horizontally within a vertical cylindrical structure. The scrubbing solution flows down from level to level, forming a thin film on each surface. Contaminated stream enters from the bottom and passes through the solution on each tray as it flows upward. This scrubber tower design provides effective gas-liquid interaction and is suitable for high throughput rates.
Plate tower scrubbers include foam wet scrubbers. Impurities are captured by a layer of foam formed on perforated trays. The perforated plates rotate rapidly, breaking up the liquid and creating foam. Generally, the efficiency of wet equipment of the tray type is superior to that of hollow ones, but the costs for operation, maintenance, and repair of the equipment are also higher.
Plate tower scrubbers include foam wet scrubbers. Impurities are captured by a layer of foam formed on perforated trays. The perforated plates rotate rapidly, breaking up the liquid and creating foam. Generally, the efficiency of wet equipment of the tray type is superior to that of hollow ones, but the costs for operation, maintenance, and repair of the equipment are also higher.
How does a TYPHOON Tray Scrubber work
A packed tower gas scrubber features a cylindrical structure filled with contact media, such as Raschig rings or Pall rings. The scrubbing solution is disseminated over the interaction surfaces and flows in a downward direction, whereas the contaminated stream ascends, optimizing the removal of pollutants. A horizontal or vertical packed tower scrubber effectively handles almost any kind of particulate matter and impurities.
A spray column scrubber is a simple vertical cylindrical structure equipped with spray nozzles that disperse the scrubbing solution into fine droplets, creating a mist within the unit. Emissions enter from the bottom and pass through the mist, where the droplets capture and remove pollutants. This straightforward configuration is suitable for handling large air volumes with relatively low pressure drops.
It is important to consider not only the water scrubber tower price but also the costs of installation, operation, and maintenance to make the right choice. Contact us in any convenient way, and we will help you!
Design Calculation
Scrubber tower design involves several essential steps to ensure optimal performance
- Determine Flow Rates: Calculate the volumetric throughputs of both the gas and liquid streams. This helps in sizing the device and selecting the appropriate components.
- Select Type and Dimensions: Choose the form of configuration (e.g., tray, packed, or spray tower) based on the specific application and contaminants. Calculate the dimensions of the equipment, including the diameter and height, to accommodate the flow rates and ensure effective interaction between phases.
- Calculate Gas-Liquid Contact
- Area: Determine the required surface area for interaction. This involves choosing the kind and amount of scrubber tower packing media or the number and type of plates.
- Pressure Drop Assessment: Estimate the pressure drop across the device, including the pressure drop through packing, plates, and spray nozzles. Ensure that the total pressure drop is within acceptable limits for the system.
- Efficiency and Performance: Calculate the expected removal efficiency for the targeted substances. This involves considering factors such as interaction time, liquid-to-gas ratio, and the physical properties of the pollutants and scrubbing fluids.
Packed Tower Scrubber Design Considerations
To avoid performance issues, it is crucial to incorporate detailed packed tower scrubber calculation into the engineering process. Here are 5 key features to consider when designing.
- Determining the optimal height of the packing bed is crucial. This involves calculating the required height based on the desired contact time between the phases, which affects the overall efficiency of the packed tower scrubber system. The height must be sufficient to allow adequate interaction without causing excessive pressure drop.
- Consider the physical and chemical properties of the filler material, such as resistance to corrosion and temperature stability. The choice of elements impacts the long-term performance and durability of the device. Ensure that it is suitable for the specific chemical environment and operating conditions.
- Evaluate the flooding point and loading limits of the material. Flooding occurs when the rate of the fluid is too high, leading to excessive accumulation in the media, which can reduce efficiency and cause operational issues. Determine the maximum throughput for both phases that the bed can handle without flooding.
- Assess factors that influence contact efficiency, such as the arrangement of the medium and its distribution. The configuration should ensure that the scrubber tower packing is not only effective in providing surface area but also in promoting optimal gas and liquid flow patterns to avoid dead zones and improve mass transfer.
- Consider the device's ability to adapt to varying operational conditions. The configuration should accommodate changes in gas and fluid throughput, contaminants, and process conditions without compromising performance. Ensure that the system can handle transient conditions or fluctuations in load.
Packing Media
The Variety of Packing Bodies for Scrubbers
Packing media are elements used to enhance interaction between phases, facilitating efficient pollutant removal. The choice of media significantly impacts performance. Here’s an overview of common types of these media:
Key Considerations
- The contact materials should be chosen to minimize pressure drop while maintaining effective mass transfer.
- Proper distribution of fluid and gaseous phase across the bed is crucial for optimal performance.
- The components should withstand the operational conditions, including temperature, pressure, and chemical exposure.
Important Measurements
Personnel servicing the absorption unit should check the following key operating parameters:
- Absorbent temperature;
- Pressure in the absorption system;
- Absorbent circulation rate;
- Gas temperature before and after purification.
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We always make extremely precise calculations and provide assistance in choosing the optimal cleaning systems, which usually takes 1 to 2 days.
Head of Engineering,
Vladimir Nikulin
Vladimir Nikulin
CALCULATION AND SELECTION
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