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Home / Case Studies / Sulfuric Acid Scrubber Solution with Enhanced Components for Advanced Pharmaceutical Operations
Sulfuric Acid Scrubber Solution with Enhanced Components for Advanced Pharmaceutical Operations
Client
One of the largest and most advanced pharmaceutical compound manufacturers in the Western United States, actively attracting investments, securing contracts, and expanding. Currently, the client is restructuring their facility and introducing new production capacities.
Production Process
The client required a wet scrubber system to manage emissions, specifically for a process utilizing 70% sulfuric acid as the scrubbing solution. Additional chemical processes involve non-corrosive organic scrubbing solutions.
Problem
The client faced challenges in designing a robust and efficient scrubbing system tailored to handle highly corrosive 70% sulfuric acid, while ensuring safety, reliability, and ease of maintenance. Constraints included:
- Integration with existing infrastructure.
- Resistance to seismic activity due to frequent earthquakes in the area.
- Mitigating concentrated gas emissions near the scrubber.
Task
Torch-Air designed a custom wet scrubber system to handle 70% sulfuric acid, ensuring corrosion resistance, safety, and compatibility with existing infrastructure. Key features included:
- A polypropylene scrubber.
- Additional equipment: fan, mist eliminator, and custom valves.
- Modifications for seismic stability and safe operation.
System components
Initially, the client intended to use only a scrubber. However, as the project was further developed and improved, a fan and a specialized mist eliminator were added to the scrubber. Additionally, changes were made to components such as the recirculation tank, and new valves and faucets were incorporated.
Initial Data
Client Communication
Client:
Hello,
I am looking for Wet Scrubbers for 3 Different Chemical Processes.
One process is using a corrosive scrubbing solution 70% Sulfuric Acid. The other two processes have the organic scrabbing solutions are not corrosive.
Do you sell and build the wet scrubbers from different construction materials? If you do, please response by e-mail or phone.
I am looking for Wet Scrubbers for 3 Different Chemical Processes.
One process is using a corrosive scrubbing solution 70% Sulfuric Acid. The other two processes have the organic scrabbing solutions are not corrosive.
Do you sell and build the wet scrubbers from different construction materials? If you do, please response by e-mail or phone.
Engineer Torch-Air:
Hello, yes we do
We need the following data:
We need the following data:
- Air Volume
- Temperature
- Composition of pollution
Client:
Attached you will find the questionnaire for scrubber.
This is the finish part of the process we need to scrub the gas. The flow is 100 cfm and only 15 % is flammable gas. I described it in the questionnaire.
The scrubber should stay along unit. Preferably in vertical position.
We have already built the concreate pad right near the pilot plant.
It has conduit for electrical wiring and drainage for atm. Condensate or rain water.
I am also thinking about pre scrubber nock off vessel or drum before the flow will entrance the scrubber.
But if you have any ideas for it please let me know and if you have any questions call on my mobile.
This is the finish part of the process we need to scrub the gas. The flow is 100 cfm and only 15 % is flammable gas. I described it in the questionnaire.
The scrubber should stay along unit. Preferably in vertical position.
We have already built the concreate pad right near the pilot plant.
It has conduit for electrical wiring and drainage for atm. Condensate or rain water.
I am also thinking about pre scrubber nock off vessel or drum before the flow will entrance the scrubber.
But if you have any ideas for it please let me know and if you have any questions call on my mobile.
Engineer Torch-Air:
My engineers are proposing this scrubber drawing. Which material do you prefer? Polypropylene?
Tank Ventilation Scrubber
Client:
It Looks fantastic!
I need have a discussion with my engineering team about this design.
Some more information with electrical load on pump. In our plant we use 460V 3 Phases on regular basis.
We do not have limitation on the electric power. This is just for your reference.
The Polypropylene is a good material. I will response with all information and questions you provided after discussion with the team.
From the drawing I understood that scrubber solution will be always inside of the scrubber. The pump and sprinkle line will be inside.
I kind of like it. It means no circulation line outside of the scrubber.
So, let me do the negotiation and discussion on my side and I will be contacting you soon.
Please let me know if you have any other designs in mind. Because I might use for other processes on plant.
I am still reviewing the drawings and if you can help to figure out some items in design of the scrubber.
The type of the scrubber is acceptable. Some parts of the scrubber I would like to change if it does not make a lot of trouble.
11. Could you please send a quotation for scrubber with proposed changes?
12. I will be adding small changes during the construction time if necessary if you will have some issues.
Please let me know if I miss anything.
I need have a discussion with my engineering team about this design.
Some more information with electrical load on pump. In our plant we use 460V 3 Phases on regular basis.
We do not have limitation on the electric power. This is just for your reference.
The Polypropylene is a good material. I will response with all information and questions you provided after discussion with the team.
From the drawing I understood that scrubber solution will be always inside of the scrubber. The pump and sprinkle line will be inside.
I kind of like it. It means no circulation line outside of the scrubber.
So, let me do the negotiation and discussion on my side and I will be contacting you soon.
Please let me know if you have any other designs in mind. Because I might use for other processes on plant.
I am still reviewing the drawings and if you can help to figure out some items in design of the scrubber.
The type of the scrubber is acceptable. Some parts of the scrubber I would like to change if it does not make a lot of trouble.
- Motor for pump: 460 V 3 phase is desirable. Also, the motor needs to be TEFC (Totally Enclosed, Fan-Cooled).
- The pump will be ok to bring the scavenger solution to this height. Could you please describe the type of the pump?
- I do not see on the drawing the diameter of the column. I assumed it is I.D. = 12” not less.
- Length of the pipe above the mesh eliminator should be 3-4 feet longer.
- Additional valve on the upper pipe of the over flow. This if practical to isolate the scrubbing solution when needed. Maybe this upper overflow pipe is not necessary? I don’t have a strong opinion.
- Do you provide (install) the electrical panel for electrical motor/pump?
- What is the voltage of the electrical motor you will be installing?
- Can you increase the height of the main tank? For instance, to 50” internal measurements.
- The same with I.D. diameter increasing to 30” or close to 35”. The construction material of the tank is LLDPE. Is this only option available? It would be more reliable to have better temperature handling if PP will be used or Perfluoro plastics. The LLDPE could be good as a sleeve around of tank for mechanical/weather protection.
- The additional item if possible. Before the fumes will be entering the scrubber could you design the cyclone vessel (aprox. 150-200 liters of volume) with the same flanges as on entrance of the scrubber? Made out of any compatible plastic including LLDPE partially or all construction. This is the optional item but very desirable. (Additional Element).
11. Could you please send a quotation for scrubber with proposed changes?
12. I will be adding small changes during the construction time if necessary if you will have some issues.
Please let me know if I miss anything.
Engineer Torch-Air:
1. Confirm, the voltage will be 208-230/460v 3ph
2. The pump will be one of these
Material — polypropylene
The model, for example, is P-3HP-3 3/4 HP, 208-230/460v 3ph
The exact model will be chosen after we agree on the design of the scrubber.
3. The diameter of the column on the drawings is ID
Superficial velocity @ 100 CFM will be 0.96 m/s which is very low already, there is no need of increasing the diameter to ".
4. Do you mean the pipe of the column or the stack pipe?
Please specify and we will make changes.
5. The overflow pipe is necessary for the scrubber tank. It's a common part of our scrubbers. Having it prevents overflowing. We can get rid of this feature, but you'll need to monitor the liquid level
6. Ok.
7. 208-230/460v 3ph
8. Yes, we can, see below
9. We can design the tank with 35" diameter and 50" height made of polypropylene. The LLDPE sleeve in that case won't be possible.
10. I would not recommend using a cyclone. It would be more practical to use a dedicated mist eliminator. (Photo)
A cyclone is less effective for particles smaller than 10 microns and has significantly higher resistance. Under ideal conditions, the efficiency of a cyclone for liquid particles of 10 microns with a specific gravity of 1.0 will, at best, reach 70%, with a pressure drop of 1000 Pa. Meanwhile, a mist eliminator’s efficiency will be 99% for particles of 10 microns, with an initial pressure drop of only 100 Pa.
In terms of dimensions, a mist eliminator would be less than 8" in diameter. It can be installed inline in the ductwork or at the inlet of the scrubber.
Optional: The mist eliminator can be equipped with a wash system for cleaning, but it can also be installed without it.
Approximate dimensions:
11. Yes, if you are satisfied with using a mist eliminator instead of a cyclone, I will prepare a proposal for you.
Hello!
Alright, just let me know if you need anything from me or when the payment is planned.
2. The pump will be one of these
Material — polypropylene
The model, for example, is P-3HP-3 3/4 HP, 208-230/460v 3ph
The exact model will be chosen after we agree on the design of the scrubber.
3. The diameter of the column on the drawings is ID
Superficial velocity @ 100 CFM will be 0.96 m/s which is very low already, there is no need of increasing the diameter to ".
4. Do you mean the pipe of the column or the stack pipe?
Please specify and we will make changes.
5. The overflow pipe is necessary for the scrubber tank. It's a common part of our scrubbers. Having it prevents overflowing. We can get rid of this feature, but you'll need to monitor the liquid level
6. Ok.
7. 208-230/460v 3ph
8. Yes, we can, see below
9. We can design the tank with 35" diameter and 50" height made of polypropylene. The LLDPE sleeve in that case won't be possible.
10. I would not recommend using a cyclone. It would be more practical to use a dedicated mist eliminator. (Photo)
A cyclone is less effective for particles smaller than 10 microns and has significantly higher resistance. Under ideal conditions, the efficiency of a cyclone for liquid particles of 10 microns with a specific gravity of 1.0 will, at best, reach 70%, with a pressure drop of 1000 Pa. Meanwhile, a mist eliminator’s efficiency will be 99% for particles of 10 microns, with an initial pressure drop of only 100 Pa.
In terms of dimensions, a mist eliminator would be less than 8" in diameter. It can be installed inline in the ductwork or at the inlet of the scrubber.
Optional: The mist eliminator can be equipped with a wash system for cleaning, but it can also be installed without it.
Approximate dimensions:
- A: 4"
- B: 12"
- C: 25"
- D: 8"
- E: 14"
11. Yes, if you are satisfied with using a mist eliminator instead of a cyclone, I will prepare a proposal for you.
Hello!
Alright, just let me know if you need anything from me or when the payment is planned.
Client:
Hi,
One question for the end of the top part of the vent pipe.
Could you install on top the exhaust pipe small fan to force the gas phase to spread better to the atmosphere.
My boss does not like the idea of concentrated gas around the scrubber.
Just could you suggest an unexpansive fan on top?
One question for the end of the top part of the vent pipe.
Could you install on top the exhaust pipe small fan to force the gas phase to spread better to the atmosphere.
My boss does not like the idea of concentrated gas around the scrubber.
Just could you suggest an unexpansive fan on top?
Engineer Torch-Air:
Okay,
I will select the model tomorrow morning and send a new invoice
I will select the model tomorrow morning and send a new invoice
Client:
This drawing slightly different from original one. I would like to make some changes.
1. The upper valve on overflow can not face down with the space above it
Could you please place this valve horizontally as bottom valve. I don’t want any absorbent liquid in the pipe.
This is the operation with H2SO4 and it is very corrosive.. The drainage and the vent will be closed 100% of operational time. The bottom valve will be used only
When we replace the H2SO4.. I suspect it will be ones per year.
2. The column seats on the lid. Could you please change the design and extend the column to the bottom of the tank.
On side of the column in the low part you can make random openings for liquid to flow freely. The reason for extending the column is care free and inspection free of the scrubber. I would not like to see the weight on the lid even the material PP is very strong. We have earthquakes in our area 2-3 per month. This request was made by safety committee.
Well, everything else are looking promising.
Please let me know if you have any other questions or suggestions.
1. The upper valve on overflow can not face down with the space above it
Could you please place this valve horizontally as bottom valve. I don’t want any absorbent liquid in the pipe.
This is the operation with H2SO4 and it is very corrosive.. The drainage and the vent will be closed 100% of operational time. The bottom valve will be used only
When we replace the H2SO4.. I suspect it will be ones per year.
2. The column seats on the lid. Could you please change the design and extend the column to the bottom of the tank.
On side of the column in the low part you can make random openings for liquid to flow freely. The reason for extending the column is care free and inspection free of the scrubber. I would not like to see the weight on the lid even the material PP is very strong. We have earthquakes in our area 2-3 per month. This request was made by safety committee.
Well, everything else are looking promising.
Please let me know if you have any other questions or suggestions.
Engineer Torch-Air:
- Done
- The new drawing attached. Please see the picture below. The column does extend to the bottom of the tank and even has an additional round support plate in order to distribute it's weight.
Project
Client:
I think the design of the scrubber is acceptable. Let me know what do I have sign to start this project on your site.
Proposed Solutions
The client turned out to be very demanding, meticulous, and clear about what they wanted. We selected a scrubber that fully met 100% of their requirements, provided additional equipment for the scrubber, and delivered everything on time.
1. Scrubber Design & Material Selection:
1. Scrubber Design & Material Selection:
- Constructed from polypropylene (PP) for superior corrosion resistance and durability under harsh chemical conditions.
- The column was extended to the bottom of the tank with custom openings to ensure free liquid flow, preventing undue stress on the lid, addressing seismic safety concerns, and eliminating potential maintenance needs.
- Added a high-efficiency mist eliminator to replace a cyclone, providing 99% efficiency for removing fine particles while maintaining low pressure drop and better space optimization.
- Installed an additional fan at the top of the vent pipe to disperse gas emissions safely into the atmosphere, mitigating localized concentrations.
- Custom-designed valves for overflow and drainage systems to ensure the safe handling of H2SO4.
- Equipped with a 460V, 3-phase TEFC motor for the pump, ensuring reliability and protection against external environmental factors.
- Provided detailed design to align with client-provided voltage specifications and operational conditions.
- Incorporated seismic stability enhancements to address frequent earthquakes in the region. A support plate was added beneath the extended column to distribute weight evenly and provide additional safety.
- Designed a scalable scrubber that can be adapted to future processes, with provisions for additional equipment or design adjustments as requested by the client.
- Introduced a pre-scrubber option with a 150-200-liter vessel to further optimize gas treatment before entering the main scrubber.
- Eliminated external circulation lines by integrating the pump and sprinkle line inside the scrubber, simplifying the system’s operation and reducing maintenance efforts.
Outcome
The solution delivered a state-of-the-art wet scrubber system, tailored to handle the highly corrosive nature of 70% sulfuric acid while meeting the client’s requirements for safety, efficiency, and durability. The modifications ensured compatibility with existing infrastructure, addressed seismic risks, and provided options for future adaptability.
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