Venturi Scrubber Systems: Applications, Real-World Implementations, Cost Factors, and Troubleshooting

Author: Anna Frank, Equipment Selection Expert

This type of absorption tower is essential for the wet purification of gases from smoke, chemicals, aerosols, and industrial dust. It also be used for the absorption of gaseous pollutants. In this case, special solutions must be applied instead of the fluid normally supplied to the unit.

Venturi scrubber applications include the removal of:

• Organic compounds
• Sulfur-containing compounds
• Inorganic dust
• Phenol and formaldehyde
• Aerosols, vapors, and acid mixtures
• Industrial dust

In a wet Venturi scrubber, contaminants ranging from 1-2 microns are efficiently removed. In classical wet air purification systems, pollutants are captured starting from 3-5 microns. Smaller contaminants are poorly collected due to two main reasons. First, fine matter moves with the air flow and bypasses the wet surface without making contact. Second, there is a boundary air layer near the wetted area, which these tiny impurities are not always able to penetrate.

In a Venturi dust scrubber, where gas moves at high velocity, the inertial forces generated by vortex breakdown help contaminants overcome the boundary layer of laminar current. Consequently, they can trap fine solids down to 1–2 microns and mist   as small as 0.2 microns.

Contraction of the tube:
When the contaminated airstream passes through the narrowing part of the tube, its velocity increases sharply. In the high-speed current zone, intense turbulence is created, which promotes the collision of microparticles with the solution injected into the airstream. As a result, small airborne solids coalesce into bigger agglomerates, facilitating their capture from the airflow.

Droplet Capture of Particles:
Venturi particulate scrubber involves the spraying of solution (usually water) into the airstream. Fine mist interact with particulate matter, capturing it through adhesion. This process is called "wet capture". It is important that the fluid droplets have sufficient surface area and size to effectively trap microparticles.

Gravitational Settling:
As the contaminants increase in size due to agglomeration, they become heavier and begin to settle under the influence of gravity or centrifugal forces (depending on the design). This allows the contaminated droplets to be separated from the purified stream.

According to industrial trials and operational performance data, two venturi scrubber systems have proven to be the most effective for removing particulate and gaseous pollutants. These systems are engineered to meet strict EPA standards and are ideal for facilities seeking to minimize emissions while ensuring superior purification performance.

The contaminated airstream is accelerated through the throat, where it mixes intensively with the atomized cleaning solution. The gas-liquid mixture then enters a cyclonic separator, where centrifugal forces separate the contaminated aerosols from the cleaned stream.

Two stages of droplet removal: first, centrifugal separation, followed by an optional additional labyrinth filtration stage. Three tube options available: low, medium, and high-pressure.

Key Benefits:

• Two-stage purification: mechanical and chemical.
• Stable performance under varying flow rates and contaminant loads.
• Low pressure drop and exceptional energy performance.
• Ideal for airstreams containing organics, acids, and VOCs.

📌 Both systems can be fully customized to meet specific process requirements — based on air flow volume, pollutant type, and regulatory compliance needs. If you're planning to buy a Venturi scrubber, consider models with corrosion-resistant materials for longer service life.

The cost of a Venturi scrubber in the United States can vary significantly — from $10,000 to $200,000+, depending on specific requirements, air flow volume, and technical specifications of the equipment.
Key Factors That Influence the Price:

• Capacity and Size
• The greater the gas volume to be treated, the more powerful and expensive the equipment will be.
• Materials
• Units made of stainless steel or resistant to corrosion and aggressive chemicals are typically more expensive.
• Type of Pollutants
• Complex mixtures (e.g., organics, acids, aerosols) often require customized configurations, which affects the cost.
• Custom Engineering
• Adapting a unit to specific industrial processes increases the final price.
• Installation and Delivery
• Setup, commissioning, and transportation costs within the USA are also included in the total budget.
• Warranty and Technical Support
• Extended warranties, maintenance services, and spare parts availability are long-term investments in reliability and performance.

When considering these factors, it’s essential to work with an experienced Venturi scrubber manufacturer who can tailor the system to your specific application. A reliable partner will not only help optimize initial investment but also ensure long-term operational efficiency and compliance with environmental standards.

Average Price Ranges:

• Request a custom quote from the venturi scrubber supplier based on your parameters.
• Check for EPA compliance and relevant certifications.
• Compare not only the price but also operating costs (energy, maintenance, water, reagents).

📞 Ready to Select the Right Venturi for Your Needs?
Contact us for a free consultation and cost estimate tailored to your project. Our experts will help you choose the most efficient solution based on gas volume, type of contaminants, and your budget.

We offer certified equipment, professional installation, and technical support.
Submit your request today info@torch-air.com and get a personalized quote within 1 business day.
Sales Office in Oklahoma: +1 (918) 406-5684, California: +1 (213) 403-6530

The specifications of a Venturi scrubber can vary based on application, but typical parameters include:

💡 Custom specs are always available based on the type of contaminants (dust, VOCs, acids, fumes), required performance, and environmental regulations.

Selecting a Venturi scrubber for particulate removal requires careful consideration of various technical and operational factors. First, define the airstream characteristics—volume, velocity, temperature, and contaminant type and concentration. These determine the appropriate throat geometry and diffuser length, directly affecting purification performance. The type of pollutant—solid, liquid, vapor, or a combination—is also critical. For fine particulate removal, high air velocity and effective fluid atomization are essential.

Material selection matters: in corrosive environments (e.g., acidic or alkaline gases), corrosion-resistant materials like stainless steel, plastics, or coated metals are recommended. To minimize operational costs, consider liquid pressure, water consumption, and fan energy requirements. If absorption is needed (e.g., SO₂ or ammonia), a neutralizing solution should be applied.

Equipment configuration is another key factor. Some models include cyclone or mist eliminator modules for improved performance. Automated monitoring—pressure, flow, and fluid level sensors—can ensure stable, low-maintenance operation.

For industrial applications, opt for a scalable design adaptable to changing demands. Finally, ensure compliance with regional emission standards and environmental regulations.

Gas Velocity and Turbulence:
The high velocity of air in the throat promotes the formation of turbulent current, which increases the likelihood of collisions between particles and fluid droplets. However, if the velocity is too intense, the contact time between airborne solids and the solution may decrease, which could also reduce removal efficiency.
Particulate emission control by a wet Venturi scrubber requires even distribution of the fluid throughout the airstream, which ensures effective capture of solid contaminants and provides optimal conditions for purification.

Size of Liquid Droplets:
The efficiency of particle removal depends on the size of the sprayed fluid droplets. Fine mist has a larger surface area for particle adsorption, but it may have less inertia, which makes its settling more difficult. Therefore, it is important that the droplet size is optimized for the specific process.

Size and Type of Particles:
Fine contaminants (e.g., smaller than 1 µm) are more difficult to remove, and their effective removal may require specific conditions, such as increased turbulence or the use of specialized liquids. Although coarse matter tends to settle more easily, it still requires controlled velocity and turbulence levels for effective separation.

Temperature and Composition of the Liquid:
The solution used for spraying may influence its viscosity and, therefore, the effectiveness of atomization. Water is typically applied, but chemical mixtures (for example, to absorb sulfur compounds) may be used to capture certain types of pollutants.

Pressure and Liquid Supply:
The pressure of the fluid supply affects the degree of its atomization and the ability to capture contaminants. At low pressure, the solution may not be atomized finely enough, while at high pressure, there may be issues with excessive resistance to movement.

Venturi scrubber troubleshooting involves identifying and addressing common issues that may affect the performance of the system.