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Biotrickling Scrubber

Biotrickling Scrubber

Biotrickling Scrubber is a wet-treatment system that biologically removes odor and biogas-related contaminants over biofilm-supported packing media.

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Biotrickling Scrubber

Wet Collection

DUCON

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Biotrickling Scrubber

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Biotrickling Scrubber
Biotrickling Scrubber
Biotrickling Scrubber
Biotrickling Scrubber

DUCON® Biotrickling Filter (BTF)

DUCON® Biotrickling Filter is an advanced biological air treatment technology that combines the advantages of a biofilter and a chemical scrubber for the abatement of volatile organic compounds (VOCs) and odor-causing gases in industrial emissions. The system harnesses the metabolic capabilities of specialized microorganisms to biologically degrade organic pollutants. It features a packed bed/column filled with inert plastic media that supports robust biofilm growth. The casing and internals can be fabricated from 304/316 stainless steel (SS), PP, HDPE, or FRP depending on process requirements.

How It Works

Gas Contact


Contaminated exhaust gas is passed through the packed bed where microorganisms are immobilized. These microbes utilize selected VOCs as sources of carbon and energy.

Mass Transfer


Pollutants transfer into the biofilm and into a counter-currently recirculated wash (nutrient) solution. This liquid nourishes the microorganisms and accelerates transfer from the gas phase into the biofilm.

Biodegradation & Regeneration


Within the bio‑reactive environment, microorganisms oxidize pollutants into harmless intermediate/final products. The system is routinely controlled to keep pH, nutrients, and salt balance within optimum ranges.

Blowdown & Biomass Control


Accumulated salts and excess biomass are removed via controlled blowdown; fresh water and nutrients are added to maintain equilibrium.

Mist Eliminator


The cleaned gas passes through a mist eliminator to remove residual droplets before discharge to atmosphere.

What Problem Does It Solve?

Biotrickling filters deliver high removal efficiencies particularly for water‑soluble VOCs and odorants (e.g., H₂S, NH₃, mercaptans, selected aldehydes/ketones/alcohols). Because they use naturally occurring microorganisms, they are an environmentally sustainable solution that helps protect air quality, achieve regulatory compliance, and improve workplace conditions.

System Advantages

  • High removal efficiency with low operating cost (OPEX)

  • Low chemical consumption with no hazardous by‑products

  • Modular design: single‑column or multi‑stage configurations

  • Low pressure drop and energy‑efficient fan/pump selection

  • Automation & monitoring: pH, ORP, conductivity, level, and flow control

  • Wide material options: 304/316 SS, PP, HDPE, FRP

  • Integrated mist eliminator, easy maintenance and cleaning

  • Reliable solution for compliance with odor and VOC regulations

Typical Applications

  • Wastewater treatment plants, pump stations, sludge processing

  • Food & beverage, pulp & paper, chemical & petrochemical process ventilation

  • Waste transfer/landfills, composting, rendering lines

  • Paint/coating, resins, biogas/biomethane facilities for odor control

Design & Options

  • Single/multi‑stage spray distribution and media types

  • Heating/cooling coils or weather‑protection enclosure (cold climates)

  • Pre‑scrubber or gas humidification module

  • ATEX‑compliant fan/motor selections, bypass line, and maintenance platforms

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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