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Wet Scrubber Guide: Advantages, Disadvantages, Operation Manual, and Case Study

Wet scrubbers are the most effective at removing high concentrations of exhaust gases from the air. They are used in metallurgical production, energy, petrochemical, chemical, mining, processing and pulp and paper industries, in the production of building materials and agriculture, as they provide the necessary efficiency and are relatively safe to use. Let's consider wet scrubber advantages and disadvantages.

Principle of Operation of a Wet Scrubber

Regardless of the type of product, all designs use the following operating principle.

The operating principle is based on the interaction of gas particles with the device's liquid. Water is typically used. Solid particles are removed by physical impact and diffusion, while gaseous particles are removed by adsorption. The same purification system can be used for both types of contamination. As a result, clean air comes out of the device, and the liquid with captured particles and dissolved impurities is drained for further cleaning or disposal. The device also lowers the air temperature and humidifies it.

Tornado ST | Spray Tower Scrubber

TORNADO FB Scrubber by Torch-Air GIF

Advantages of the Scrubber

Advantages of wet scrubber are:

small dimensions and the ability to move the structure to the required location;
low cost and lack of consumables;
fire safety and explosion protection;
purification of nitrogen, sulfur, and carbon oxides, ammonia, hydrogen sulfide, and other hazardous substances, as well as organic compounds;
low maintenance design;
rarely fails;
purification efficiency reaches 99.9%;
can be used to purify hot gases with temperatures up to 450°C (in comparison, dry scrubbers are limited to 300°C), as well as to reduce their temperature;
have a beneficial effect on the environment, as the collected waste is not subject to leakage.

TORNADO ST Spray Tower Wet Scrubber

Performance:
600 — 30 000 cfm

TORNADO RP Vertical Wet Scrubber

Performance:
600 — 24 000 cfm

TYPHOON Tray Tower Scrubber

Performance:
100 — 175 000 cfm

BOREAS Compact Ion-Exchange Fiber-Bed Scrubber

Performance:
30 000 cfm

Tank Vent Scrubber

Performance:
0 — 3 000 cfm

TORCH-AIR Profi New

Performance:
600 — 12 000 cfm

Disadvantages

The main drawback is the large amount of sludge formed from solid particles trapped in the water. Therefore, when used in a large complex, there is a need to purify wastewater, for which treatment facilities and settling tanks are used. This increases the wet scrubber operating cost. Moreover, the resulting waste is useless for further use.

Additionally, there are the following wet scrubber disadvantages:

corrosion on the working mechanisms of the housing (this can be prevented by lining or purchasing a plastic version);
a high-quality, stable power supply is required, as high pressure drops in the structure consume increased amounts of electricity;
the equipment is not used outdoors in cold weather, as the water in the sludge may freeze;
there is a risk of clogging of the nozzles.

If we consider all wet scrubber pros and cons, the advantages of the method far outweigh the disadvantages, and problematic issues can be addressed by using additional equipment.

Operating Parameters

Key operating parameters include: performance, i.e., the volume of air processed, the degree of purification, the air flow rate, the hydraulic resistance, and the flow rate of the spraying fluid. Performance is the key characteristic. It is determined at the design stage of the cleaning system, and the overall dimensions of the wet dust collector depend on it. Additional parameters considered when selecting a product include wet scrubber operating temperature and the size of the particles captured.

Wet Scrubber Dust Collector

Case Study: Venturi Scrubber for Pyrite Dust Control at a Copper-Zinc Mine

In one of the largest copper-zinc mines, Torch-Air implemented a Venturi scrubber to control fine pyrite dust generated during ore crushing and conveying. The system provides at least 98% air-cleaning efficiency through intensive gas–liquid contact and the return of the resulting slurry back into the process. The solution was engineered for harsh conditions — operating temperatures from –20 °C to +20 °C — and integrated into the existing Profibus DP control system. Learn More

Operation Manual

To avoid the disadvantages of a wet scrubber, it's important to remember how to use it properly. To do this, let's review a brief wet scrubber operation manual.

Before starting the scrubber, ensure all hoses are securely fastened with clamps, drain hoses are sloped and do not obstruct free drainage, fan rotation is correct, and the water supply line has adequate pressure. Nozzles, attachments and drip collectors must be clean. If the Venturi tube is used, it must be free of any unnecessary components, and there should be no exposed welds or protruding parts near the spray points. The solenoid valve must be positioned strictly horizontally and in an accessible location. The coupling valve must be free of contamination. Additionally, check the functionality of the pressure gauges and water meters.

Under normal operating conditions, scrubber maintenance consists of periodic weekly and quarterly inspections.

A Clear and Simple Guide to Annual Wet Scrubber Inspections

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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

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