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Home / Case Studies / Custom Scrubbing System for HCl and Titanium Tetrachloride Gas and Dust Removal
Custom Scrubbing System for HCl and Titanium Tetrachloride Gas and Dust Removal
Client
One of the largest weapons manufacturers in the United States.
Production Process
Loading Titanium tetrachloride into glass ampules. The is a possibility to spill. If it does spill, HCL and Titanium dioxide will be created and will need to be removed.
Problem
The client requires a dust and gas scrubbing system capable of handling highly corrosive chemicals (HCl and titanium tetrachloride) combined with particulate matter. The system must efficiently remove both dust and chemical components while being corrosion-resistant and adaptable to intermittent use. Existing solutions often specialize in either dust or chemical treatment, but integrating both into a single efficient system presents a challenge.
Task
To design a custom scrubbing solution that:
- Removes particulate matter and harmful gases with at least 90% efficiency.
- Uses corrosion-resistant materials like polypropylene or stainless steel.
- Balances cost-effectiveness and high performance.
- Meets operational needs, including intermittent use, water cleaning, and outdoor placement with insulation.
- Ensures material and electrical compatibility for seamless integration.
Initial Data
Technical Specifications and Operational Requirements for Gas and Dust Treatment System
Client Communication
Client:
Please provide a quote for Venturi Tornado-FB Fluidized Bed Scrubber With a Venturi Tube that can handle at least 1000 CFM.
Engineer Torch-Air:
Good day, below are the comments from our technical manager:
Without knowledge of the particle size distribution, the use of a Venturi tube may not be effective.
We suggest using a two-stage system, which consists of a sieve tray scrubber stage and a packed bed scrubber stage.
A stage with a sieve tray, in turn, containing two stages of trays has less pressure drop than a medium-pressure Venturi tube and will have high efficiency for both particles and HCl gas removal. The subsequent packed bed stage utilizes highly effective packing which, in turn, causes high efficiency for HCl removal.
The whole scrubbing system will have around 15 inches of water pressure drop.
The scrubber material is polypropylene. The scrubber should be designed to provide required efficiency, because the inlet concentrations are relatively high.
Due to the periodic use of the scrubber, we suggest replacing the scrubber solution in batches.
What is your estimate of how long the scrubber will operate before the spill is removed?
Even your rough estimate will help us evaluate the volume of recirculating tank.
In the attachment the drawing of a two-stage system. That is a rough, approximate presentation, just to give you an idea. The tanks are going to be combined, the pumps might be semi-submersible etc.
You specified that you are going to place the new system outside. Therefore, we need to provide insulation and heating for the whole system. But if you can consider to place the circulation tank, pumps, valves etc. inside, then we can split the system and put outside only the columns, which still require insulation, but won’t require continuous heating.
If you are interested in our solution, I am ready to prepare a commercial proposal.
For greater visualization and understanding how its work.
Without knowledge of the particle size distribution, the use of a Venturi tube may not be effective.
We suggest using a two-stage system, which consists of a sieve tray scrubber stage and a packed bed scrubber stage.
A stage with a sieve tray, in turn, containing two stages of trays has less pressure drop than a medium-pressure Venturi tube and will have high efficiency for both particles and HCl gas removal. The subsequent packed bed stage utilizes highly effective packing which, in turn, causes high efficiency for HCl removal.
The whole scrubbing system will have around 15 inches of water pressure drop.
The scrubber material is polypropylene. The scrubber should be designed to provide required efficiency, because the inlet concentrations are relatively high.
Due to the periodic use of the scrubber, we suggest replacing the scrubber solution in batches.
What is your estimate of how long the scrubber will operate before the spill is removed?
Even your rough estimate will help us evaluate the volume of recirculating tank.
In the attachment the drawing of a two-stage system. That is a rough, approximate presentation, just to give you an idea. The tanks are going to be combined, the pumps might be semi-submersible etc.
You specified that you are going to place the new system outside. Therefore, we need to provide insulation and heating for the whole system. But if you can consider to place the circulation tank, pumps, valves etc. inside, then we can split the system and put outside only the columns, which still require insulation, but won’t require continuous heating.
If you are interested in our solution, I am ready to prepare a commercial proposal.
For greater visualization and understanding how its work.
First scrubber stage.
Second scrubber stage.
Wet Scrubber
Client:
Good Morning,
I do not believe we will need this large of a unit. I was conservative in my estimate.
The operational time would be roughly 1 to 2 hours at a time roughly 4 times a day.
If you can please quote both units, and I can work with our chemist on which machine would fit our needs the best as they know more about the chemical’s size and properties.
Thanks
I do not believe we will need this large of a unit. I was conservative in my estimate.
The operational time would be roughly 1 to 2 hours at a time roughly 4 times a day.
If you can please quote both units, and I can work with our chemist on which machine would fit our needs the best as they know more about the chemical’s size and properties.
Thanks
Engineer Torch-Air:
Good day, below are the comments from our technical manager:
1000 CFM, particulate 1000grams/hour, HCl 35%
Which equals:
Volume 1700 m³/hr
Particulate 0.6 g/m³
HCl 570 g/m³
The first stage is a sieve tray scrubber PVPR-2. This type of scrubber removes particles as small as 5 microns with an efficiency of 99%. This scrubber would remove HCl gas as well with an efficiency up to 98%, but exact number is unpredictable. It can handle particulate flow rates up to 15 g/m3, but has relatively high Pressure drop of 11 in.w.
The second stage is a packed bed scrubber T-RP-2-1. This type of scrubber can’t handle that much of particulate rates as the first one. It can only process particulate flow rates up to 0.05 g/m3. Otherwise, the packed bed would be clogged. On the other hand, this type of scrubber has high and predictable efficiency for gases. And it also has lower pressure drop. For the standard model (in attachment T-PR-2-1) with an efficiency of 97% at a HCl flow rate of 1 g/m3 the pressure drop would be 2 in.w.
For your specific application, the packed bed scrubber must be designed to meet the required efficiency. After this, the size of the scrubber will certainly change.
Please tell me what interested you in our technical proposal and I will make a final offer?
1. Two column system?
2. Packed bed column only system?
3. Sieve tray column only system?
4. See drawings in the attached file
1000 CFM, particulate 1000grams/hour, HCl 35%
Which equals:
Volume 1700 m³/hr
Particulate 0.6 g/m³
HCl 570 g/m³
The first stage is a sieve tray scrubber PVPR-2. This type of scrubber removes particles as small as 5 microns with an efficiency of 99%. This scrubber would remove HCl gas as well with an efficiency up to 98%, but exact number is unpredictable. It can handle particulate flow rates up to 15 g/m3, but has relatively high Pressure drop of 11 in.w.
The second stage is a packed bed scrubber T-RP-2-1. This type of scrubber can’t handle that much of particulate rates as the first one. It can only process particulate flow rates up to 0.05 g/m3. Otherwise, the packed bed would be clogged. On the other hand, this type of scrubber has high and predictable efficiency for gases. And it also has lower pressure drop. For the standard model (in attachment T-PR-2-1) with an efficiency of 97% at a HCl flow rate of 1 g/m3 the pressure drop would be 2 in.w.
For your specific application, the packed bed scrubber must be designed to meet the required efficiency. After this, the size of the scrubber will certainly change.
Please tell me what interested you in our technical proposal and I will make a final offer?
1. Two column system?
2. Packed bed column only system?
3. Sieve tray column only system?
4. See drawings in the attached file
Scrubber Diagram
Client:
Good day,
I believe the first stage sieve tray scrubber PVPR-2 column-only system would meet our requirements.
However, I am reaching out to the Director of Production here at Spectra for guidance on which he would recommend.
Thanks
I believe the first stage sieve tray scrubber PVPR-2 column-only system would meet our requirements.
However, I am reaching out to the Director of Production here at Spectra for guidance on which he would recommend.
Thanks
Engineer Torch-Air:
We can also make a scrubber from PVC. The cost of such a scrubber should be approximately the same as polypropylene.
We are open to negotiations.
We are open to negotiations.
Client:
Good Morning,
After evaluating the quote, I believe we would want to go with the polypropylene Typhoon Tray Scrubber.
Equipment name: TYPHOON TRAY SCRUBBER 1700
Material of execution: polypropylene.
I have two questions,
After evaluating the quote, I believe we would want to go with the polypropylene Typhoon Tray Scrubber.
Equipment name: TYPHOON TRAY SCRUBBER 1700
Material of execution: polypropylene.
I have two questions,
- Can you please provide information on the polypropylene used? We just want to verify it will not be affected by the titanium tetrachloride.
- What stainless steel would you be using if we decided to go that route?
Engineer Torch-Air:
Good day.
I am attaching a file with information about the types of polypropylene we use in the production of our equipment. We use AISI 304 or AISI 316. Do you have any other questions?
I am attaching a file with information about the types of polypropylene we use in the production of our equipment. We use AISI 304 or AISI 316. Do you have any other questions?
Client:
I am working with my team to determine which one we plan to go with.
What is the expected lead time?
Thanks
What is the expected lead time?
Thanks
Engineer Torch-Air:
45 working days after 50% prepayment
Client:
Good morning,
I have a query about the electrical components.
Could you please specify the voltage needed to operate the scrubber?
Thank you.
I have a query about the electrical components.
Could you please specify the voltage needed to operate the scrubber?
Thank you.
Engineer Torch-Air:
The scrubber consists the only one electric component, the pump as follows:
Penguin Series P Sealless Vertical Pumps (SKU: P-1/2BV-1)
115/230v 1ph
Best regards
Penguin Series P Sealless Vertical Pumps (SKU: P-1/2BV-1)
115/230v 1ph
Best regards
Proposed Solutions
The client faces a rather complex challenge: chemically aggressive and corrosive components are combined with dust. In this case, an effective combination of a scrubber for dust and one for chemical treatment is required. Additionally, the equipment must be protected against corrosion.
Most existing equipment is typically capable of handling either dust or chemical treatment, but it is rare to find experts who can integrate both solutions into a single system.
We presented and justified several potential solutions. As always, there was an option with a lower initial cost and another with the most efficient purification. The choice is between cost-effectiveness upfront or maximum efficiency.
SIEVE TRAY SCRUBBER (TYPHOON TRAY SCRUBBER PVPR-2)
• First Stage: Sieve tray scrubber for highly efficient removal of both dust and HCl.
• Second Stage: Packed bed scrubber for additional gas treatment, achieving an HCl removal efficiency of 97%.
• Suitable for more complex operating conditions and scenarios with higher concentrations of dust and gas.
Most existing equipment is typically capable of handling either dust or chemical treatment, but it is rare to find experts who can integrate both solutions into a single system.
We presented and justified several potential solutions. As always, there was an option with a lower initial cost and another with the most efficient purification. The choice is between cost-effectiveness upfront or maximum efficiency.
SIEVE TRAY SCRUBBER (TYPHOON TRAY SCRUBBER PVPR-2)
- Designed to remove particles as small as 5 microns with an efficiency of up to 99%.
- Also removes HCl gas with an efficiency of up to 98%.
- Features a relatively high pressure drop (11 inches of water column) but fully meets the specified parameters.
- Constructed from polypropylene, a material resistant to corrosion and chemically active substances.
• First Stage: Sieve tray scrubber for highly efficient removal of both dust and HCl.
• Second Stage: Packed bed scrubber for additional gas treatment, achieving an HCl removal efficiency of 97%.
• Suitable for more complex operating conditions and scenarios with higher concentrations of dust and gas.
Client's Decision
The client preferred the sieve tray scrubber (Typhoon Tray Scrubber) due to its high efficiency and relatively simple design.
Given the intermittent nature of its operation (1-2 hours, 4 times a day), it was recommended to periodically replace the scrubber solution to maintain its performance.
Polypropylene was chosen as the primary construction material because of its resistance to aggressive substances (including titanium tetrachloride and HCl).
Additional Parameters:
The client selected the Typhoon Tray Scrubber PVPR-2 as the optimal solution, taking into account all technical and economic factors.
Given the intermittent nature of its operation (1-2 hours, 4 times a day), it was recommended to periodically replace the scrubber solution to maintain its performance.
Polypropylene was chosen as the primary construction material because of its resistance to aggressive substances (including titanium tetrachloride and HCl).
Additional Parameters:
- The system can be manufactured from stainless steel if necessary.
- It is adapted for outdoor placement with optional thermal insulation and heating.
- Efficiency in removing dust and gases exceeds 90%, meeting the client’s requirements.
- Corrosion resistance achieved through the use of durable materials.
- Design optimized to match the client’s needs, considering the intermittent operation and outdoor placement.
- A balanced approach between the initial equipment cost and operational efficiency.
The client selected the Typhoon Tray Scrubber PVPR-2 as the optimal solution, taking into account all technical and economic factors.
The Best Air Purification Systems for Titanium Tetrachloride and HCl
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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