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Author: Anna Frank, Equipment Selection Expert
Wet fume scrubber are devices of various designs used for washing gases with liquids for the purpose of cleaning or cooling them. Their main function is to capture and neutralize harmful components present in air streams that are generated during industrial processes or laboratory research.
Harmful compounds released during different technological processes may contain substances hazardous to human health and the environment, such as acids, alkalis, heavy metals, organic compounds, suspended particles, and even volatile toxic wastes. The release of these substances into the atmosphere leads to air pollution, occupational diseases, equipment damage, and increases the risk of accidents.
They are used in almost all industries where harmful substances are generated, including science labs, metallurgy, electroplating, chemical production, pharmaceuticals, and so on.
Harmful compounds released during different technological processes may contain substances hazardous to human health and the environment, such as acids, alkalis, heavy metals, organic compounds, suspended particles, and even volatile toxic wastes. The release of these substances into the atmosphere leads to air pollution, occupational diseases, equipment damage, and increases the risk of accidents.
They are used in almost all industries where harmful substances are generated, including science labs, metallurgy, electroplating, chemical production, pharmaceuticals, and so on.
Classification
Modern purification systems differ not only in their operating principle, but also in their design. There are several main types of towers by construction, each optimal for specific tasks.
Vertical fume scrubber is the most common design of equipment for removing harmful airborne contaminants. Its configuration involves the upward movement of the air stream through a system of packings or nozzles, where it contacts the solution. This ensures optimal contaminant removal.
Advantages:
Vertical fume scrubber is the most common design of equipment for removing harmful airborne contaminants. Its configuration involves the upward movement of the air stream through a system of packings or nozzles, where it contacts the solution. This ensures optimal contaminant removal.
Advantages:
- Compact design and minimal footprint.
- Easy maintenance and repair.
- Ability to handle large air volumes.
- Superior capability for dust and vapor capture.
Vertical Orientation of the Column
Our company is a leading vertical fume scrubber factory, ensuring the highest quality of purification systems. Contact us — we will help you design a custom fume scrubber that fully meets your requirements and technical specifications. Customization allows the system to be tailored to the specifics of the production process and purification efficiency requirements.
Unlike vertical constructions, a horizontal fume scrubber channels the contaminated stream sideways rather than upward. This configuration is optimal for facilities with limited ceiling height or where the system needs to be arranged in line with other machinery.
When is a Horizontal Configuration Optimal?
Horizontal models generally require more floor space in length, but less in height. They may be less efficient when treating heavily contaminated streams, but are easier to integrate into existing production lines.
When is a Horizontal Configuration Optimal?
- When there is insufficient ceiling height.
- For cleaning large air volumes with a moderate level of contamination.
- If the equipment needs to be installed in a straight line.
Horizontal models generally require more floor space in length, but less in height. They may be less efficient when treating heavily contaminated streams, but are easier to integrate into existing production lines.
Horizontal Arrangement of the Tower
By scale and project volume, types can be distinguished
⚙ Portable fume scrubber — mobile units for local air purification. They are compact, lightweight, and easy to move.
Advantages:
Portable models are in demand for handling small volumes of harmful pollutants, in mobile labs, at repair sites, or during temporary technological operations.
🏭 Industrial fume scrubber — optimized for extensive air volumes and considerable contaminant concentrations. These units have powerful pumps, complex filtration systems, automation, and can be integrated into large-scale production lines.
Industrial units may include other types of air purification, such as cyclones, demisters, and so on. We manufacture modular filters so that our customers can easily increase capacity at any time.
💠Simple fume scrubber — budget solutions for tasks with a low level of contamination. They usually have a simplified configuration, require minimal maintenance, and are suitable for small workshops, laboratories, and classrooms. When available space is at a premium, specialized compact unit can ensure reliable air purification at the source. Due to their straightforward construction, a mini fume scrubber can be installed quickly and operated without specialized training, making them a practical choice for facilities with limited technical staff or resources.
🌀 Vent fume scrubber — installed directly into general or local ventilation systems to remove harmful gases and dust from the air. This is an ideal solution for laboratories, educational institutions, and small-scale production.
Advantages:
- Can be employed in different production zones.
- Quick installation and start-up.
- Ideal for temporary operations, emergency service, and local laboratory processes.
Portable models are in demand for handling small volumes of harmful pollutants, in mobile labs, at repair sites, or during temporary technological operations.
🏭 Industrial fume scrubber — optimized for extensive air volumes and considerable contaminant concentrations. These units have powerful pumps, complex filtration systems, automation, and can be integrated into large-scale production lines.
Industrial units may include other types of air purification, such as cyclones, demisters, and so on. We manufacture modular filters so that our customers can easily increase capacity at any time.
💠Simple fume scrubber — budget solutions for tasks with a low level of contamination. They usually have a simplified configuration, require minimal maintenance, and are suitable for small workshops, laboratories, and classrooms. When available space is at a premium, specialized compact unit can ensure reliable air purification at the source. Due to their straightforward construction, a mini fume scrubber can be installed quickly and operated without specialized training, making them a practical choice for facilities with limited technical staff or resources.
🌀 Vent fume scrubber — installed directly into general or local ventilation systems to remove harmful gases and dust from the air. This is an ideal solution for laboratories, educational institutions, and small-scale production.
Materials
The choice of material for a chemical fume scrubber directly affects the service life of the equipment, its resistance to aggressive environments, and operating costs. Below are the most common options.
PVC fume scrubber is among the most popular on the market due to its properties. They offer excellent chemical resistance, are not subject to corrosion, and can withstand exposure to most acids, alkalis, and salts. This material ensures lightweight construction, making it easier to transport and install the unit. They are also more affordable compared to metal counterparts, require minimal maintenance, and have a long service life. PVC unit is particularly relevant for the chemical, electroplating, and pharmaceutical industries, where continuous operation in aggressive environments is essential.
An acrylic fume scrubber is used where it is important to visually monitor the purification process. They are suitable for labs and educational institutions—transparent walls allow observation of the process. Best for situations with moderate concentrations of aggressive substances and for lightweight, compact installations. These constructions have an aesthetic appearance, good resistance to most inorganic compounds, low weight, and are easy to install.
Polypropylene (PP) is widely used for the production of chemically resistant towers. It has high resistance to acids and alkalis and can withstand temperatures up to +90°C. PP unit is a popular choice for many industrial applications.
Stainless steel is used in elevated-temperature environments, for purifying extremely aggressive or abrasive gases, and wherever maximum structural strength is required. Advantages include superior mechanical strength, corrosion resistance, and durability, though these units are more expensive.
Fiber-reinforced composites and fiberglass (FRP — fiberglass reinforced plastic) offer both strength and durability in contact with corrosive agents, making them suitable for acidic and alkaline emissions. They are lightweight, strong, and can be manufactured in complex shapes.
PVC fume scrubber is among the most popular on the market due to its properties. They offer excellent chemical resistance, are not subject to corrosion, and can withstand exposure to most acids, alkalis, and salts. This material ensures lightweight construction, making it easier to transport and install the unit. They are also more affordable compared to metal counterparts, require minimal maintenance, and have a long service life. PVC unit is particularly relevant for the chemical, electroplating, and pharmaceutical industries, where continuous operation in aggressive environments is essential.
An acrylic fume scrubber is used where it is important to visually monitor the purification process. They are suitable for labs and educational institutions—transparent walls allow observation of the process. Best for situations with moderate concentrations of aggressive substances and for lightweight, compact installations. These constructions have an aesthetic appearance, good resistance to most inorganic compounds, low weight, and are easy to install.
Polypropylene (PP) is widely used for the production of chemically resistant towers. It has high resistance to acids and alkalis and can withstand temperatures up to +90°C. PP unit is a popular choice for many industrial applications.
Stainless steel is used in elevated-temperature environments, for purifying extremely aggressive or abrasive gases, and wherever maximum structural strength is required. Advantages include superior mechanical strength, corrosion resistance, and durability, though these units are more expensive.
Fiber-reinforced composites and fiberglass (FRP — fiberglass reinforced plastic) offer both strength and durability in contact with corrosive agents, making them suitable for acidic and alkaline emissions. They are lightweight, strong, and can be manufactured in complex shapes.
Top Materials for Chemical Wet Use: Durability and Performance
Application-Specific Varieties
The choice of construction material depends on the chemical composition of the gases to be treated, temperature conditions, requirements for process visualization, and budget. For most standard applications, PVC and polypropylene are optimal; for complex and high-temperature processes, stainless steel or composites are preferable.
Type | Description and Features | Main Application Areas | Design |
HF fume scrubber | Removes hydrogen fluoride (HF) vapors. Resistant to aggressive HF exposure. | Aluminum, glass, semiconductor production, laboratories working with HF | Packed bed, spray |
Chrome fume scrubber | Cleans emissions containing hexavalent chromium vapors. Reduces environmental and sanitary impact. | Electroplating, anodizing, metal processing, auto parts, electronics, labs | Foam, spray |
Zinc fume wet scrubber | Removes zinc vapors and aerosols. Especially in demand in metallurgy, galvanizing, and metal recycling. | Metallurgy, galvanizing, metal recycling | Venturi, spray |
Toxic/hazardous waste fume scrubber | Captures especially hazardous compounds: organics, inorganics, carcinogens, toxic vapors. Often custom-made. | Petrochemical, pharmaceutical, medical industries, waste disposal | Foam, packed bed |
Chemical waste fume scrubber | Removes chemical waste, including acids and alkalis. Reduces equipment corrosion and protects the environment. | Industries with elevated emissions of aggressive compounds | Packed bed, foam |
Fume scrubber for flammable gasses | Designed to safely capture and neutralize vapors associated with flammable and explosive gases, minimizing fire risk. | Chemical processing, refineries, paint and solvent manufacturing, laboratories | Packed bed, spray, explosion-proof materials |
Explanations
Spray Tower — efficient for trapping particles and soluble gases at medium and low concentrations. It is effective for mixed flows containing dust and other solid particles.
Tray Tower — well-suited for capturing aerosols, providing a large contact surface between the phases. The configuration includes special grids and sieve trays, which create a fluidized packed bed effect.
Packed Bed Tower — a universal solution, highly effective for most acidic and alkaline vapors. Inside the tower, there are special elements of various shapes that enhance mass transfer efficiency.
Venturi — designed for removing dust and fine aerosols when maximum efficiency is required. The operation of the Venturi unit is based on accelerating the gas flow in the Venturi throat, where liquid droplets collide with pollutant particles, capturing them. These droplets then settle in the expanding section and are removed from the system.
Tray Tower — well-suited for capturing aerosols, providing a large contact surface between the phases. The configuration includes special grids and sieve trays, which create a fluidized packed bed effect.
Packed Bed Tower — a universal solution, highly effective for most acidic and alkaline vapors. Inside the tower, there are special elements of various shapes that enhance mass transfer efficiency.
Venturi — designed for removing dust and fine aerosols when maximum efficiency is required. The operation of the Venturi unit is based on accelerating the gas flow in the Venturi throat, where liquid droplets collide with pollutant particles, capturing them. These droplets then settle in the expanding section and are removed from the system.
Specialized Liquids
Cleaning solutions are applied in every type of wet scrubber. They play a crucial role in the filtration process. For effective operation, many setups use a special fume scrubber solution concentrate, which enhances pollutant capture, accelerates neutralization, and extends the service life of the equipment.
The composition of the concentrate is selected based on:
The composition of the concentrate is selected based on:
- The exact composition of the emissions.
- The concentration of the pollutant.
- The temperature and humidity of the stream.
- The material and configuration of the equipment.
- Accelerate the chemical reaction with pollutants (acids, alkalis, gases, heavy metals).
- Improve the efficiency of capturing dust, aerosols, and vapors.
- Protect the inner surfaces of the toxic waste fume scrubber from aggressive environments.
- Reduce maintenance and cleaning costs.
- For acidic vapors (e.g., hydrogen chloride, hydrofluoric acid):
- Effective neutralization is typically achieved with mildly alkaline solutions such as sodium hydroxide or sodium carbonate.
- For alkaline and ammonia emissions: Mildly acidic solutions are applied (acetic or citric acid, phosphoric acid).
- For organic compounds and volatile solvents: Solutions may contain oxidizers (sodium hypochlorite, potassium permanganate) or special absorbents.
- For heavy metal removal: Solutions with precipitants or complexing agents are applied.
Mass Transfer Packings
A packed bed (or column) unit is one of the most popular constructions of air purification system. The main factor determining the efficiency of such a unit is the packing, which ensures maximum mass transfer. The choice of packing elements affects the unit’s performance, hydraulic resistance, and even its size.
Type | Description | Advantages |
Raschig rings | Cylindrical rings made of ceramic, plastic, or metal with a large surface area. | Simplicity, availability, versatility |
Pall rings | Cylinders with slots and internal struts, increasing the contact area. | Excellent efficiency, less prone to clogging, better mass transfer |
Berl and Intalox saddles | Saddle-shaped packings with a wavy surface, improving phase mixing. | Low resistance, effective wetting, and increased throughput |
Cascade mini ring | Modified packing with open walls and petals, resistant to clogging. | Suitable for dirty flows and high gas velocities |
Ball packing, Hollow balls | Plastic or ceramic balls with holes. | Easy installation, durability |
Structured packing | Metal or plastic strips arranged in a special way (mesh, corrugated, etc.). | Superior purification efficiency, compactness |
Overview of Packings
Which Kind to Choose?
- For standard applications: Pall rings, Berl saddles, or Raschig rings are most commonly used.
- For treating contaminated flows and under high loads: Cascade mini rings, Intalox saddles, or structured packings are recommended.
- For chemically aggressive environments: Packings made of plastic or ceramic are employed.
Types of Spray Nozzles
Spray nozzles differ primarily in their spray pattern, droplet size, and flow rate. The main kinds include:
If you need assistance with selection or consultation, feel free to contact us—we’re here to help!
- Full cone constructions produce a uniform distribution of droplets in a conical pattern, providing excellent coverage.
- Hollow cone types generate a ring-shaped spray with smaller droplets, which increases the contact area and is effective for removing fine particles and cooling gases.
- Flat fan models create a thin, wide spray, making them suitable for applications where a broad, even coverage is needed, such as surface washing inside the waste fume scrubber.
- Atomizing options deliver very fine droplets, which enhances mass transfer efficiency. However, they may be more prone to clogging and are best applied where extremely maximum scrubbing performance is required.
If you need assistance with selection or consultation, feel free to contact us—we’re here to help!
Overview of Nozzles Used
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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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