Spray Tower
Environmental Equipment
Spray Tower (Scrubber)
Professional Environmental Equipment Supplier
1. Product Overview
The spray tower (scrubber) is a highly efficient wet scrubbing device for exhaust gas purification based on gas-liquid contact. Equipped with multi-stage spray systems inside the tower, it brings the absorption liquid (water or chemical solution) into full contact with the exhaust gas, removing harmful gases through absorption, dissolution, and chemical reaction of the gaseous pollutants. With its simple structure, easy operation, and high purification efficiency, it is one of the most widely used wet scrubbing devices in industrial exhaust gas treatment. A spray tower typically consists of a tower body, spray system, packing layer, demister, circulation tank, circulation pump, and fan. Depending on the composition and concentration of the exhaust gas, different absorption liquids and packing types can be selected to achieve comprehensive treatment of acid and alkaline gases, organic gases, dust, and other pollutants. The spray tower offers stable operation, low maintenance costs, and strong adaptability, readily meeting emission compliance requirements across a wide range of industries.
2. Working Principle
The working principle of the spray tower is based on the mass transfer absorption process between gas and liquid phases: exhaust gas is introduced into the bottom of the tower by a fan and flows upward; simultaneously, the absorption liquid is delivered by the circulation pump to the top spray system, atomized through nozzles, and sprayed downward, forming counter-current contact with the rising exhaust gas. During gas-liquid contact, pollutant molecules in the gas phase diffuse through the gas-liquid interface into the liquid phase, undergoing physical dissolution or chemical reactions (such as acid-base neutralization, oxidation-reduction), thereby being absorbed and removed. The packing layer inside the tower serves to increase the gas-liquid contact area and extend contact time, improving mass transfer efficiency; the demisting layer captures liquid droplets carried out by the gas flow, preventing flooding and liquid entrainment. The purified gas exits through the top exhaust port, while the absorption liquid flows back to the circulation tank, where fresh absorption liquid is replenished and waste liquid is discharged based on pH and concentration changes. The entire process is monitored in real-time by a PLC control system to ensure stable and reliable purification performance.
3. System Classification
3.1 Classification by Gas Type
| Type | Applicable Gas | Absorption Liquid | Purification Efficiency |
|---|---|---|---|
| Acid Gas Scrubber | HCl, HF, H2SO4 mist | NaOH alkaline solution | 95~99% |
| Alkaline Gas Scrubber | NH3, amines | H2SO4/citric acid | 90~98% |
| Mixed Gas Scrubber | Acid-base mixed gas | Multi-stage absorption | 95~99% |
3.2 Classification by Structure
| Type | Structural Features | Air Volume | Application Scenario |
|---|---|---|---|
| Single-Stage Scrubber | Single spray layer + packing | ≤30000m³/h | Low concentration single gas |
| Multi-Stage Scrubber | 2~4 spray layers + multi-section packing | 3000~100000m³/h | High concentration complex gas |
| Swirl Plate Tower | Swirl plates replace packing | 1000~50000m³/h | Dust-laden acidic gas |
4. Detailed Technical Parameters
4.1 Main Component Materials
| Component | Material | Surface Treatment | Characteristics |
|---|---|---|---|
| Tower Body | PP/FRP | Hand lay-up/filament winding | Corrosion-resistant, lightweight |
| Spray Nozzle | PP | Injection molded | Acid-alkali resistant, uniform atomization |
| Packing Media | PP Pall ring/multi-face hollow ball | Injection molded | Large specific surface area, high capacity |
| Circulation Pump | SS304/316L | Mechanical seal | Corrosion-resistant, stable operation |
| Fan | FRP | Hand lay-up | Corrosion-resistant, low noise |
| Piping | PP | Heat fusion welding | Corrosion-resistant, good sealing |
4.2 Specification Parameters
| Parameter | Small Type | Medium Type | Large Type |
|---|---|---|---|
| Treatment Volume | 1000~10000m³/h | 10000~50000m³/h | 50000~100000m³/h |
| Filtration Velocity | 1.0~2.0m/s | 1.0~2.0m/s | 1.0~2.0m/s |
| Spray Layers | 2~3 layers | 3~4 layers | 4~6 layers |
| Pressure Drop | 200~500Pa | 300~600Pa | 400~800Pa |
| Pump Power | 1.5~5.5kW | 5.5~22kW | 22~75kW |
| Fan Power | 2.2~11kW | 11~55kW | 55~200kW |
| Tower Diameter | 0.6~1.5m | 1.5~3.0m | 3.0~5.0m |
| Tower Height | 3~6m | 5~10m | 8~15m |
4.3 Performance Indicators
| Indicator | Parameter Value | Test Conditions |
|---|---|---|
| Treatment Efficiency | 95~99% | Under design conditions |
| System Pressure Drop | 200~800Pa | Rated air volume operation |
| Noise Level | ≤85dB(A) | Measured at 1m from equipment |
| Liquid-Gas Ratio | 1~5L/m³ | Normal operating conditions |
| MTBF | ≥6000 hours | Normal operating conditions |
| Equipment Availability | ≥95% | Annual statistics |
4.4 Electrical Parameters
| Item | Parameter |
|---|---|
| Power Supply | 3P AC380V±10%, 50Hz |
| Control System | PLC automatic control |
| VFD | VFD for fan and pump |
| pH Online Monitor | Online pH meter real-time monitoring |
| Level Sensor | Circulation tank level detection |
| Dosing System | Auto dosing pump quantitative feeding |
| Safety Protection | E-stop, leakage protection, overload protection |
| Communication | Ethernet, RS485, Modbus optional |
Note: Electrical component brands can be substituted with equivalent alternatives upon request.
5. Core Component Selection
| Component | Recommended Brand | Model | Function |
|---|---|---|---|
| PP/FRP Tower Body | Zhongchuang/Custom | Custom-made | Main exhaust gas treatment structure |
| PP Spray Nozzle | BETE/Custom | Spiral/hollow cone | Absorption liquid atomization |
| Packing Media | PP Pall ring/hollow ball | DN50/DN76 | Increase gas-liquid contact area |
| Circulation Pump | Southern Pump/CNP | IH/FS series | Circulating absorption liquid |
| FRP Fan | Shangfeng/Nanfeng | F4-72 series | Exhaust gas induced draft |
| pH Controller | Yokogawa/E+H | FYA20/CPS11 | Online pH monitoring of circulation liquid |
| Dosing Pump | SEKO/ProMinent | AKS/BT4 series | Auto replenishment of absorption chemicals |
Note: Core component brands can be configured per customer specification with prior confirmation.
6. Typical Application Fields
Chemical Industry: Treatment of sulfuric acid, hydrochloric acid, hydrofluoric acid and other acidic exhaust gases using NaOH alkaline solution absorption, with purification efficiency above 99% to ensure compliance with GB 16297 emission standards.
Pharmaceutical Industry: Treatment of acidic, alkaline, and solvent-containing exhaust gases from reaction vessels and drying processes, where multi-stage spraying with mist elimination ensures compliant emissions.
Electroplating Industry: Treatment of toxic gases such as chromic acid mist, hydrogen cyanide, and nitrogen oxides, using multi-stage segmented absorption for high-efficiency purification.
Electronics Industry: Treatment of HF, HCl and other exhaust gases from etching processes; corrosion-resistant PP construction and an automatic dosing system ensure stable operation.
Metallurgy Industry: Treatment of acid mist from pickling processes, large-volume spray tower with swirl plate demisting, low operating cost.
7 Design Standards & Certification
7. Design Standards and Certifications
| Standard Category | Standard No. | Standard Name |
|---|---|---|
| China | GB 16297-1996 | Comprehensive Emission Standard for Air Pollutants |
| China | GB 37822-2019 | Emission Standard for VOCs Fugitive Emission |
| China | GB 31571-2015 | Emission Standard for Petrochemical Industry |
| China | GB 14554-93 | Emission Standard for Odor Pollutants |
| International | ISO 9001:2015 | Quality Management System Requirements |
| International | ISO 14001:2015 | Environmental Management System Requirements |
8. Customization Options
| Option | Description | Application Scenario |
|---|---|---|
| Multi-Stage Series Scrubber | 2~4 scrubbers in series operation | High concentration difficult gas |
| Auto Dosing System | Online pH monitoring + auto dosing pump | Continuous unattended operation |
| Swirl Plate Demister | High-efficiency swirl plate replaces wire mesh | Dust-laden liquid-containing gas |
| Online Monitoring System | VOCs/pH/flow online monitoring | Environmental online supervision |
| Waste Liquid Treatment Integration | Scrubber waste liquid to wastewater system | Comprehensive environmental treatment |
| Remote Monitoring Platform | IoT remote O&M platform | Multi-plant/remote management |
| Explosion-Proof Configuration | ExdIIBT4 explosion-proof rating | Flammable/explosive gas environment |
| Insulation & Anti-Freeze Type | Tower insulation + electric tracing | Outdoor installation in cold regions |
9. Warranty Terms
| Warranty Item | Warranty Content |
|---|---|
| Machine Warranty Period | 12 months from acceptance date |
| Core Component Warranty | Pump/fan/PLC: 24 months |
| Wearable Parts Warranty | Nozzles/packing/seals: 6 months |
| Software Upgrade | Free upgrade during warranty period |
| Technical Training | Free training for 2~3 operators during installation |
| After-Sales Response | Phone response within 2 hours, on-site within 24~48 hours |
| Spare Parts Supply | Guaranteed for 5 years after production discontinuation |
Note: Free repair and replacement during warranty for quality-related failures; damage caused by human factors or force majeure is excluded.
10. Packaging & Delivery
| Item | Description |
|---|---|
| Packaging Method | Machine wrapped in moisture-proof film + wooden crate |
| Crate Specification | Export-grade plywood crate (fumigation-free) |
| Moisture Protection | Desiccant + vacuum aluminum foil bag |
| Shock Protection | EPE foam + bubble wrap cushioning |
| Lifting Method | 4-point top lifting |
| Transport Method | Truck/railway/ocean shipping |
Lead time: 30~45 working days after contract signing and deposit received. Installation & commissioning: Seller dispatches technicians for on-site installation, approximately 3~5 working days.
11. Inquiry Information Required
To receive an accurate quotation, please provide the following information:
Exhaust gas composition and concentration (mg/m³)
Exhaust gas treatment volume (m³/h)
Exhaust gas temperature (°C)
Emission standard requirements (national/local)
Existing ductwork and fan conditions
Site space constraints (L×W×H)
Absorption liquid source and disposal method
Power supply and compressed air specifications
Whether online monitoring system is required
Other special customization requirements