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Sprühwäscher

Sprühwäscher

Der Sprühwäscher verteilt Flüssigkeit über Düsen und wäscht Schadstoffe aus dem Gasstrom – ein vertikaler Nasswäscher mit geringem Wartungsaufwand.

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Sprühwäscher

Wet Collection

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Sprühwäscher

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Sprühwäscher
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Sprühwäscher

DUCON® Sprühwäscher (Spray Scrubber)

Der DUCON® Sprühwäscher ist eine Nassreinigungslösung mit niedrigem spezifischem Flüssigkeitsverbrauch (0,5–8 L je m³ gereinigten Gases), die neben der Abscheidung von Grobstaub-Partikeln ab 9–13 µm auch für die Gaskühlung und Gaskonditionierung ausgelegt ist. Sie ist wirksam bei der Abscheidung von Geruchsstoffen sowie von SO₂, Phenol, Formaldehyd und ähnlichen Schadstoffen.

Konstruktionsübersicht

Das System besteht aus einem zylindrischen Turmkörper mit Sprühdüsen für die Flüssigkeitsverteilung sowie Ein- und Austrittsanschlüssen für den Gasstrom.

  • Düsenebenen: Eine oder mehrere Sprühebenen im oberen Turmbereich erzeugen Flüssigkeitstropfen mit einer Tropfengröße von 0,07–1,0 mm.

  • Kontaktführung: Im Gas-Flüssigkeits-Gegenstromkontakt steigt das Gas mit Turmgeschwindigkeiten von ≈0,6–1,5 m/s auf. (Bei höheren Geschwindigkeiten nimmt der Feuchtigkeitsaustrag zu; in den Austrittskanälen können sich Staubablagerungen bilden.)

  • Chemikaliendosierung: Je nach Schadstoffart werden alkalische/saure oder oxidierende Chemikalien in die Lösung dosiert, um die Reaktionskinetik zu erhöhen.

  • Werkstoffe: Je nach Prozessbedingungen Gehäuse-/Ausrüstungsoptionen aus 304/316 SS, PP, HDPE oder GFK (FRP).

Hauptkomponenten

  • Zylindrischer Turmkörper

  • Gas-Eintritts- und Austrittsstutzen/-kanäle

  • Sprühdüsen in oberer/unterer Ebene

  • Umwälzpumpe und Leitungen

  • Prozessinstrumentierung: pH, ORP, Leitfähigkeit, Füllstand, Durchfluss

  • Regelventile und Bypass-Einrichtungen

  • Tropfenabscheider (Mist Eliminator)

  • MCC- und PLC-Schaltschrank

Funktionsprinzip

  1. Das Rohgas tritt in den Turm ein und kommt beim Aufsteigen im Gegenstrom mit dem aus den Düsenebenen versprühten hochenergetischen Sprühnebel in Kontakt.

  2. Die Schadstoffe gehen durch Absorption und Reaktion in die Tropfen über; Stäube werden abgeschieden.

  3. Das gereinigte Gas verlässt das System über den Tropfenabscheider.

  4. Der Flüssigkeitskreislauf arbeitet im Umlaufbetrieb; die Chemikaliendosierung wird über die pH/ORP-Regelung automatisch eingestellt.

Modelle und Strömungskonfigurationen

  • Gegenstrom, Gleichstrom oder Querstrom

  • Ein-/mehrstufige Sprühbänke

  • Optionale Quench-Stufe (Vorkühlung)

Anwendungsbereiche

Energieerzeugung, Chemie und Petrochemie, Stahlerzeugung, fest-/flüssigbefeuerte Kessel, Waste-to-Energy, Abgaskühlung und -konditionierung sowie Anwendungen zur Geruchskontrolle.

Wet Scrubber Types and Comparison

  • Venturi Scrubber — highest energy contact for fine particulate (PM2.5); high pressure drop, requires larger fan power.
  • Packed Bed Scrubber — best for acid-gas absorption (SO2, HCl, HF, NH3); low pressure drop, polypropylene or PVC packing.
  • Spray Tower Scrubber — low pressure drop, ideal for odor and large particulate; simple design, easy maintenance.
  • Dynamic Scrubber (DUCON DY 3000) — compact and high efficiency; converts mechanical energy into liquid contact.
  • Chemical Absorption (NaOH, Na2CO3) — for toxic gas neutralization; needs pH control and dosing circuit.

Technical Specifications and Capacity Range

  • Gas flow: 1,000 - 500,000 m³/h (DUCON models scaled per application).
  • Operating temperature: -20°C to +200°C (up to 400°C with refractory lining).
  • Efficiency: Venturi 99%, packed bed 95-99%, spray tower 85-92%, dynamic 96-99%.
  • Materials: St37 / 304L / 316L stainless, FRP, PP, PVDF corrosion-resistant linings.
  • Pressure drop: packed bed 15-30 mbar, venturi 40-150 mbar, spray tower 5-15 mbar.
  • Liquid/Gas ratio (L/G): 0.5 - 3.0 L/m³ typical (optimized per application).

Pollutants Removed

  • Acid gases: SO2, SO3, HCl, HF, H2S, Cl2, partial NOx.
  • Basic gases: NH3, amine derivatives.
  • Particulate: PM10, PM2.5, fly ash, dust, mist, sulfuric acid aerosol.
  • VOC and odor: H2S, mercaptans, organic amines.
  • Heavy metals: As, Hg, Pb (gas phase), Cd (application-dependent).

Industries Served

  • Cement and lime — kiln and clinker SO2 / HCl removal.
  • Iron-steel and foundry — pickling, acid wash, foundry furnace emissions.
  • Chemical industry — reactor acid-base gas neutralization, odor control.
  • Waste incineration (MSW, hazardous) — HCl/HF/SO2 and dioxin acid gas removal.
  • Hazardous waste and sulfuric acid plants — end-of-process emission control.
  • Glass and ceramic — kiln stack gas acid and particulate treatment.
  • Food and fermentation — odor and aerosol control.
  • Wastewater treatment — H2S odor control, biofilter pre-treatment.

Selection Criteria

  • Gas flow, temperature, humidity, and contaminant composition should be evaluated together.
  • Pressure drop, liquid consumption, pump load, and mist eliminator design shape the operating cost envelope.
  • Reaction chemistry, pH control, and blowdown handling should be defined early in the design phase.
  • Material selection for corrosion resistance must match the pH and temperature range.

Operation and Maintenance Notes

  • Nozzle fouling, pump-circuit stability, mist eliminator contamination, and corrosion points should be monitored routinely.
  • Liquid recirculation stability and chemical-dosing control are critical to sustained performance.
  • Installations without maintenance access planning typically increase downtime and service cost.
  • Plan for 1 major + 2-4 intermediate maintenance cycles per year.

Why DUCON, Why MDSJ Process?

  • Owner of the DUCON trademark in Europe, Asia, and Turkey — MDSJ Process is the sole manufacturer and service provider under the DUCON brand in this geography.
  • Designing, manufacturing, installing, and commissioning DUCON-brand equipment in Turkey since 1986 — 40 years of continuous industrial project experience.
  • One supplier for three core lines: wet scrubber, jet pulse filter, and pneumatic conveying — one accountable engineering team instead of three vendors.
  • End-to-end project delivery from site survey to live operation: we do not just ship equipment; we own system integration, installation, commissioning, and operator training.
  • Direct trilingual engineering support (TR / EN / DE) — technical documentation in their own language for DACH and European customers operating in Turkey.
  • Field-validated DUCON reference designs across cement, iron-steel, foundry, chemical, pharma, and power-plant projects.
  • Made in Turkey — short lead times, local service, full compliance with Turkish and EU environmental regulations.

Frequently Asked Questions

What is a wet scrubber?

A wet scrubber is an industrial emission-control system that removes particulates, acid/basic gases, and odors from flue gas using a liquid contact medium (water or chemical solution). Efficiency can reach 99%.

What is the difference between venturi and packed-bed wet scrubbers?

Venturi provides 99% efficiency on fine particulate (PM2.5) at the cost of high pressure drop; packed-bed excels at acid-gas absorption (SO2, HCl) with low pressure drop. Choice depends on pollutant type and energy budget.

Which gases does a wet scrubber remove?

Acid and basic gases like SO2, SO3, HCl, HF, H2S, Cl2, NH3, plus PM10/PM2.5 particulate, sulfuric acid aerosol, VOC, and odors.

What is the capacity range of a wet scrubber?

DUCON wet scrubber systems are designed for gas flows from 1,000 m³/h up to 500,000 m³/h. Larger capacities are achieved with parallel modules.

Is there a wet scrubber manufacturer in Turkey?

Yes, MDSJ Process designs, manufactures, installs, and commissions wet scrubbers in Turkey under the DUCON brand (MDSJ owns the DUCON trademark rights for Europe, Asia, and Turkey). Headquartered in Şişli/Istanbul, active since 1986.

When is a wet scrubber better than a dry filter?

Wet scrubbers are more suitable when gas-phase contaminants must be dissolved or neutralized, when humidity or corrosive load is high, or when cooling and scrubbing must happen together.

What is the water consumption of a wet scrubber?

Typical liquid/gas (L/G) ratio is 0.5-3.0 L/m³. Recirculation circuits minimize consumption; only evaporation and blowdown losses are compensated.

What drives wet scrubber operating cost the most?

Pressure drop (fan power), pump duty, liquid consumption, chemical dosing (NaOH/Na2CO3), and maintenance intervals are the main cost drivers.

Is ATEX required for wet scrubbers?

ATEX compliance is required in processes with explosive gases or dust (solvent vapors, alcohol, organic VOC). DUCON systems are optionally produced per ATEX zone classification.

How is a wet scrubber maintained?

Plan for 1 major service per year (internal cleaning, packing check, nozzle inspection) + 2-4 intermediate services (pump, dosing, mist eliminator). Corrosion and fouling points must be monitored continuously.

How long does wet scrubber installation take?

Standard-capacity design + manufacturing takes 8-12 weeks, site installation 2-4 weeks, commissioning 1-2 weeks. Total typical project runs 3-5 months.

Which industries use wet scrubbers?

Cement, iron-steel, chemical, waste incineration, hazardous waste, glass, ceramic, food, fermentation, and wastewater treatment are common application areas.

Quick Info

Up to 99% particulate and acid-gas removal efficiency
Gas and particulate handled in a single integrated system
Venturi, packed-bed, dynamic, and chemical-absorption layouts available

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