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Tray-Scrubber (Bodenkolonnen-Wäscher)

Tray-Scrubber (Bodenkolonnen-Wäscher)

Der Tray-Scrubber sorgt mit mehrstufigem Bodenaufbau für intensiven Gas-Flüssigkeits-Kontakt und effiziente Wäsche korrosiver und saurer Gasströme.

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Tray-Scrubber (Bodenkolonnen-Wäscher)

Wet Collection

DUCON

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Tray-Scrubber (Bodenkolonnen-Wäscher)

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Tray-Scrubber (Bodenkolonnen-Wäscher)
Tray-Scrubber (Bodenkolonnen-Wäscher)
Tray-Scrubber (Bodenkolonnen-Wäscher)
Tray-Scrubber (Bodenkolonnen-Wäscher)
Tray-Scrubber (Bodenkolonnen-Wäscher)

Tray-Scrubber (Bodenkolonnen-Wäscher)

Der MDSJ-Bodenwäscher (Reinluft-Technologie) ist ein vielseitiger Niederdruckwäscher mit äußerst effizienter Staubabscheideleistung, der in einem breiten Anwendungsspektrum eingesetzt werden kann. Der MDSJ-Bodenwäscher eignet sich zudem zur Abscheidung von Gasen und Dämpfen wie SO2, HF, HCl, NH3 und Cl2 sowie zur SO2-Entfernung.

Der Wäscher kann mit einem perforierten Turbulenz-Kontaktboden oder einem gesteuerten Boden ausgestattet werden. Der perforierte Boden enthält eine Vielzahl von Öffnungen. Der gesteuerte Boden ähnelt einem herkömmlichen Bodenwäscher, verfügt jedoch über spezielle, oberhalb jeder Öffnung angeordnete Leitbleche. Diese Leitbleche lenken den Staub direkt auf ein darunter eingetauchtes Prallziel und erhöhen so die Staubabscheideleistung; anschließend wird der Staub vom Flüssigkeitsstrom ausgewaschen und abgeführt.

Je nach Anwendungsanforderungen können in den MDSJ-Boden mehrere Bodentypen sowie eine oder mehrere Stufen integriert werden. Der Wäscher kann mit rückgeführten Flüssigkeiten mit einem Feststoffanteil von 2 % betrieben werden. Während des Prozesses tritt das Rohgas im unteren Teil des Wäschers ein und strömt durch die Öffnungen des Bodens. Die Waschflüssigkeit gelangt in die obere Kontaktstufe und fließt über den Boden. Das Gas absorbiert die Flüssigkeit, wodurch die Staubbindung und ein spezielles Gas-/Flüssigkeitsgemisch entstehen. Das gereinigte Gas durchströmt anschließend den Tropfenabscheider und wird im oberen Teil der Einheit an die Atmosphäre abgegeben.

MDSJ Turbulenz-Kontaktboden-Wäscher können aus Kohlenstoffstahl, Edelstahl, Speziallegierungen und Kunststoffen gefertigt werden. Die Einheiten verfügen über Kapazitäten von 1.000 bis 400.000 m³. Der Wäscher kann rückgeführte Flüssigkeiten mit einem Feststoffanteil von 2 % verarbeiten. Während des Prozesses tritt das Rohgas im unteren Teil des Wäschers ein und strömt durch die Öffnungen des Bodens.

Das gereinigte Gas durchströmt anschließend den Tropfenabscheider und wird im oberen Teil der Einheit an die Atmosphäre abgegeben.

Konstruktive Merkmale

MDSJ Turbulenz-Kontaktboden-Wäscher können aus Kohlenstoffstahl, Edelstahl, Speziallegierungen und Kunststoffen gefertigt werden. Die Einheiten verfügen über Kapazitäten von 1.000 bis 400.000 m³. Die vielseitigen Anwendungen des MDSJ Process Engineering TS-Füllkörperwäschers eignen sich für ein breites Anwendungsspektrum, darunter die Chemie-, Zellstoff-, Stahl- und Metallbeschichtungs-, Dünger- und Pharmaindustrie.

Der MDSJ Process Engineering TS-Bodenwäscher entfernt korrosive und/oder schädliche Rauch- und Nebelbestandteile (6–8 Mikron und größer) wirksam aus dem Gasstrom.

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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