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Author:
Anna Frank, Equipment Selection Expert
Anna Frank, Equipment Selection Expert
Most often, scrubber malfunctions occur due to improper operation or, in some cases, incorrect data provided during the design stage.
We would like to remind you that it is extremely important for the manufacturer to receive the most complete information from the client — type of dust, production volumes, workshop area, etc. It is precisely during the production stage that accurate calculations must be made so that the wet scrubber operates as efficiently as possible and does not fail. The system should work continuously, reliably, and with high quality, meeting the performance specifications calculated by the manufacturer. However, even precise calculations, correct installation, and assembly do not always guarantee uninterrupted operation. It is always essential to remember proper wet scrubber maintenance.
We would like to remind you that it is extremely important for the manufacturer to receive the most complete information from the client — type of dust, production volumes, workshop area, etc. It is precisely during the production stage that accurate calculations must be made so that the wet scrubber operates as efficiently as possible and does not fail. The system should work continuously, reliably, and with high quality, meeting the performance specifications calculated by the manufacturer. However, even precise calculations, correct installation, and assembly do not always guarantee uninterrupted operation. It is always essential to remember proper wet scrubber maintenance.
TORNADO — Torch-Air
From Practical Experience
We are often contacted with questions about various malfunctions and breakdowns. The most common problem is clogging caused by debris carried with the gas, or from the drainage or circulation systems.
To prevent this, our company Torch-Air implements a number of measures:
To prevent this, our company Torch-Air implements a number of measures:
- Installation of special tanks for easy cleaning with sludge discharge.
- Drainage lines that are designed not to clog.
- Gas scrubbing equipment with nozzles that do not clog, or without nozzles at all, depending on the specific configuration.
Real Situations We Have Encountered
Errors in Equipment Selection
A client approached a company that selected equipment without a thorough analysis. The manufacturer did not accurately assess the specifics of the production process, which led to operational difficulties. Specifically, fluctuations in temperature and dust volume were not taken into account. A scrubber was installed, and a large dust flow was fed directly into it, although it would have been more efficient to first reduce the dust flow using a cyclone and/or bag filter. As a result, the system began to “choke” on the dust and rising temperature, and overall performance dropped. Dust collection did not meet the planned specifications, making it difficult to operate in the workshop. Our specialists had to redesign the aspiration apparatus entirely — from selection and project planning to manufacturing and delivery.
Errors in Choosing the Type of Scrubber
An incorrect choice of design type that could not handle the contaminant properly. The client needed a unit with floatig-bed, but a fixed-packing scrubber was installed instead. It clogged with dust (or sludge) more quickly and did not clean properly. Ultimately, the entire system failed and required replacement, resulting in additional costs. We performed calculations and selected a design that would perfectly handle the required level of purification.
Wet scrubber problems are widespread; some are due to manufacturer oversights, while others result from inaccurate data provided by the client or irregular maintenance.
How can additional costs be avoided and efficiency maintained? It is enough to monitor the absorption tower, perform technical service, and carry out periodic upkeep to keep it fully operational.
A client approached a company that selected equipment without a thorough analysis. The manufacturer did not accurately assess the specifics of the production process, which led to operational difficulties. Specifically, fluctuations in temperature and dust volume were not taken into account. A scrubber was installed, and a large dust flow was fed directly into it, although it would have been more efficient to first reduce the dust flow using a cyclone and/or bag filter. As a result, the system began to “choke” on the dust and rising temperature, and overall performance dropped. Dust collection did not meet the planned specifications, making it difficult to operate in the workshop. Our specialists had to redesign the aspiration apparatus entirely — from selection and project planning to manufacturing and delivery.
Errors in Choosing the Type of Scrubber
An incorrect choice of design type that could not handle the contaminant properly. The client needed a unit with floatig-bed, but a fixed-packing scrubber was installed instead. It clogged with dust (or sludge) more quickly and did not clean properly. Ultimately, the entire system failed and required replacement, resulting in additional costs. We performed calculations and selected a design that would perfectly handle the required level of purification.
Wet scrubber problems are widespread; some are due to manufacturer oversights, while others result from inaccurate data provided by the client or irregular maintenance.
How can additional costs be avoided and efficiency maintained? It is enough to monitor the absorption tower, perform technical service, and carry out periodic upkeep to keep it fully operational.
Pre-Startup Checks
Before starting and operating a wet scrubber, it is essential to ensure that the equipment is in proper and safe condition. Regular wet scrubber service helps prevent emergency situations, reduce wear on components, and ensure stable operation of the gas cleaning system. Below is a wet scrubber maintenance procedure, which includes the main checks of equipment condition, safety measures, and operating parameters prior to startup.
INSPECTION AND SAFE STARTUP
Operating Parameters
INSPECTION AND SAFE STARTUP
- Disconnect the equipment power supply if necessary; follow LOTO (lockout/tagout) procedures.
- Wear personal protective equipment (PPE): safety glasses, gloves, respirator/gas mask (if hazardous vapors are present), protective clothing.
- Inspect ventilation and gas sensors (if installed).
- Integrity of the housing, flanges, and seals — check for leaks.
- Condition of nozzles/sprayers — blockages, deformation.
- Condition of pipelines, pumps, filters, and valves.
- Corrosion/wear on internal surfaces.
- Electrical wiring and sensors — dry, cables undamaged.
Operating Parameters
- Pressure drop across the scrubber (manometer) — is it within the design/normal range? (High ΔP = clogging/scaling; Low ΔP = insufficient flow/bypass).
- Liquid flow rate (L/min) — matches nozzle operation requirements.
- Pressure at the nozzles — stable?
- Gas velocity/fan speed/RPM — corresponds to design specifications.
- Gas temperature at inlet/outlet.
- pH and conductivity of the absorption liquid (if applicable).
- Liquid level in receiver/tanks — within operational marks.
- Oscillogram/pump adjustment — uniform flow, no cavitation.
- Check valves and dampers for full opening/closing.
- Inspect the condition and calibration of pressure, flow, and pH sensors.
- Date/time of inspection; operator.
- Pressure drop (at or between levels).
- Liquid flow rate and nozzle pressure.
- Gas velocity/flow, fan RPM.
- pH, conductivity, liquid temperature.
- Presence of leaks/foam/corrosion.
- Condition of nozzles, pumps, valves.
- Corrective actions performed and results (before/after).
- Possible malfunctions and methods for their elimination.
Required Maintenance Tasks
Daily maintenance of a wet scrubber is generally not necessary. Weekly monitoring of system operation and recording of results is sufficient.
Weekly:
Stop the equipment and perform a visual inspection of all components for wear or potential failure: spray systems, liquid circulation loops, pumps, fans, and automation components.
Weekly:
- Visual wet scrubber inspection through the inspection hatches without stopping the equipment to check the condition of the liquid circulation and spray system.
- Visual inspection of the recirculation tank through the inspection hatches without stopping the equipment.
- Testing the condition of the liquid circulation and spray circuit under different operating modes.
- Checking the recirculation tank for sludge accumulation.
- Inspecting the automation components for proper operation.
Stop the equipment and perform a visual inspection of all components for wear or potential failure: spray systems, liquid circulation loops, pumps, fans, and automation components.
A Clear and Simple Guide to Annual Wet Scrubber Inspections
Typical Technical Malfunctions, Causes, and Actions
During operation, wet scrubber troubleshooting issues may arise that affect cleaning efficiency and equipment stability. For convenience, a table of common problems, their possible causes, and recommended corrective actions is provided. Use it when diagnosing and maintaining the system.
If a serious hazardous leak, through-thickness corrosion, or fire/explosion hazard is detected — stop the process and call an engineer. The cost of wet scrubber reactive maintenance is usually higher than preventive service due to urgent repairs.
Preventive Maintenance
To maintain stable operation of the equipment and minimize unplanned downtime, a series of wet scrubber preventive maintenance tasks must be performed. Regular maintenance helps extend equipment life, ensures cleaning efficiency, and allows timely detection of potential system deviations.
- Regular flushing of nozzles and replacement of packing.
- Scheduled inspection and calibration of sensors (quarterly or according to the schedule).
- Maintaining a log of parameters and trends (ΔP, flow rate, pH) for early detection of deviations.
- Keep spare parts in stock: nozzles, seals, pump bearings.
BOREAS-P2 with random packing
Disposal of the Cleaning Solution
The wet scrubber solution disposal process depends on the type of contaminants captured — acids, alkalis, dust, heavy metals, organics, etc. Below is a detailed, technically accurate step-by-step explanation.
The working absorption solution used to wash the gas may be:
1. Solution discharge and analysis
The solution from the wet scrubber tank is periodically drained into a wastewater collection tank. Before disposal, the solution is analyzed for pH, salt content, heavy metals, organics, and sometimes COD/BOD. Based on the results, it is determined whether the solution is classified as hazardous waste.
2. Neutralization (if necessary)
The working absorption solution used to wash the gas may be:
- Alkaline (NaOH, Ca(OH)₂, Na₂CO₃, etc.) — for removing acidic gases (HCl, SO₂);
- Acidic (H₂SO₄, etc.) — for removing ammonia and basic compounds;
- Aqueous — for dust and water-soluble components;
- Sometimes it contains reagents and salts formed as reaction products between the pollutants and the solution.
1. Solution discharge and analysis
The solution from the wet scrubber tank is periodically drained into a wastewater collection tank. Before disposal, the solution is analyzed for pH, salt content, heavy metals, organics, and sometimes COD/BOD. Based on the results, it is determined whether the solution is classified as hazardous waste.
2. Neutralization (if necessary)
- If the solution is alkaline, neutralize it with acid (typically HCl or H₂SO₄).
- If the solution is acidic, neutralize it with lime milk, NaOH, or soda ash. The goal is to adjust the pH to a safe range of 6–9, suitable for discharge into the wastewater network.
TORNADO Fluidized Bed Scrubber
3. Precipitation and filtration
If the solution contains suspended solids, salts, or metals, they are precipitated using lime, sodium sulfide, ferrous sulfate, or other agents. The mixture is then filtered, settled, or centrifuged.
The resulting sludge is disposed of as solid industrial waste (for example, under waste codes F006, F019 in the U.S.).
If the solution contains suspended solids, salts, or metals, they are precipitated using lime, sodium sulfide, ferrous sulfate, or other agents. The mixture is then filtered, settled, or centrifuged.
The resulting sludge is disposed of as solid industrial waste (for example, under waste codes F006, F019 in the U.S.).
Water Disposal
A common question we receive is: Where should the water go after filtration?
This is a very complex and important issue when using a unit. In some cases, the water can turn into a toxic substance that is even more dangerous than the polluted air; in others, it can be reused in the process.
It is essential to determine what happens to the water during your gas cleaning process — what compounds are formed and whether they are hazardous. You must also determine whether and how this water can be diluted before discharge — for example, whether it can be released into the storm sewer, sanitary sewer, or if a dedicated sludge treatment system is required.
This is a very complex and important issue when using a unit. In some cases, the water can turn into a toxic substance that is even more dangerous than the polluted air; in others, it can be reused in the process.
It is essential to determine what happens to the water during your gas cleaning process — what compounds are formed and whether they are hazardous. You must also determine whether and how this water can be diluted before discharge — for example, whether it can be released into the storm sewer, sanitary sewer, or if a dedicated sludge treatment system is required.
⚠️ Observe proper water disposal procedures!
There are specific and strict regulations governing the discharge of contaminated water into sewer and stormwater systems. These standards specify everything, including the concentration of substances, water temperature, and permissible discharge volumes. It is crucial to understand that without proper analysis, water must never be discharged arbitrarily! Doing so may lead to an environmental disaster and enormous fines, including requirements for soil remediation and other costly consequences.
In some cases, alkali can be added to the water, and the dried sludge can be sent to a landfill as solid waste. In others, the treated water may be discharged safely.
Each case is highly individual and requires a separate technical assessment and detailed engineering specification.
We strongly recommend always carefully reviewing the guide to wet scrubber maintenance provided by the manufacturer, appointing responsible personnel for equipment operation, and conducting regular maintenance service!
In some cases, alkali can be added to the water, and the dried sludge can be sent to a landfill as solid waste. In others, the treated water may be discharged safely.
Each case is highly individual and requires a separate technical assessment and detailed engineering specification.
We strongly recommend always carefully reviewing the guide to wet scrubber maintenance provided by the manufacturer, appointing responsible personnel for equipment operation, and conducting regular maintenance service!
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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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