- Spray tower
Spray towers or spray chambers are a form of
pollution control technology. They consist of empty cylindrical vessels made ofsteel orplastic and nozzles that spray liquid into the vessels. The inlet gas stream usually enters the bottom of the tower and moves upward, while liquid is sprayed downward from one or more levels. This flow of inlet gas and liquid in the opposite direction is calledcountercurrent flow. Figure 1 shows a typicalcountercurrent -flow spray tower. This type of technology is a part of the group ofair pollution controls collectively referred to aswet scrubber s.Countercurrent flow exposes the outlet gas with the lowestpollutant concentration to the freshest scrubbing liquid.Many nozzles are placed across the tower at different heights to spray all of the gas as it moves up through the tower. The reasons for using many nozzles is to maximize the number of fine droplets impacting the pollutant particles and to provide a large surface area for absorbing gas.Theoretically, the smaller the droplets formed, the higher the collection efficiency achieved for both gaseous and particulate
pollutant s. However, the liquid droplets must be large enough to not be carried out of thescrubber by the scrubbed outlet gas stream. Therefore, spray towers use nozzles to produce droplets that are usually 500 to 1,000 µm in diameter. Although small in size, these droplets are large compared to those created in theventuri scrubber s that are 10 to 50 µm in size. The gas velocity is kept low, from 0.3 to 1.2 m/s (1 to 4 ft/s) to prevent excess droplets from being carried out of the tower.In order to maintain low gas velocities, spray towers must be larger than other
scrubber s that handle similar gas stream flow rates. Another problem occurring in spray towers is that after the droplets fall short distances, they tend to agglomerate or hit the walls of the tower. Consequently, the total liquid surface area for contact is reduced, reducing the collection efficiency of the scrubber.in configuration. In
cocurrent -flow spray towers, the inlet gas and liquid flow in the same direction. Because the gas stream does not "push" against the liquid sprays, the gas velocities through the vessels are higher than incountercurrent flow spray towers. Consequently,cocurrent -flow spray towers are smaller thancountercurrent -flow spray towers treating the same amount of exhaust flow. Incrosscurrent -flow spray towers, also called horizontal-spray scrubbers, the gas and liquid flow in directions perpendicular to each other (Figure 2).In this vessel, the gas flows horizontally through a number of spray sections. The amount and quality of liquid sprayed in each section can be varied, usually with the cleanest liquid (if recycled liquid is used) sprayed in the last set of sprays.
Particle collection
Spray towers are low energy
scrubber s. Contacting power is much lower than inventuri scrubber s, and thepressure drop s across such systems are generally less than 2.5 cm (1 in) of water. The collection efficiency for small particles is correspondingly lower than in more energy-intensive devices. They are adequate for the collection of coarse particles larger than 10 to 25 µm in diameter, although with increased liquid inlet nozzle pressures, particles with diameters of 2.0 µm can be collected.Smaller droplets can be formed by higher liquid pressures at the nozzle. The highest collection efficiencies are achieved when small droplets are produced and the difference between the velocity of the droplet and the velocity of the upward-moving particles is high. Small droplets, however, have small settling velocities, so there is an optimum range of droplet sizes for scrubbers that work by this mechanism.
This range of droplet sizes is between 500 to 1,000 µm for gravity-spray (counter current) towers ("Stairmand 1956"). The injection of water at very high pressures – 2,070 to 3,100 kPa (300 to 450 psi) - creates a fog of very fine droplets. Higher particle-collection efficiencies can be achieved in such cases since collection mechanisms other than
inertial impaction occur ("Bethea 1978"). However, these spray nozzles may use more power to form droplets than would a venturi operating at the same collection efficiency.Gas collection
Spray towers can be used for gas
absorption , but they are not as effective as packed or plate towers. Spray towers can be very effective in removingpollutant s if the pollutants are highly soluble or if a chemical reagent is added to the liquid.For example, spray towers are used to remove
HCl gas from the tail-gas exhaust in manufacturinghydrochloric acid . In the production ofsuperphosphate used in manufacturingfertilizer , SiF4 and HF gases are vented from various points in the processes. Spray towers have been used to remove these highly soluble compounds. Spray towers are also used for odor removal inbone meal andtallow manufacturing industries by scrubbing the exhaust gases with a solution of KMnO4.Because of their ability to handle large gas volumes in corrosive atmospheres, spray towers are also used in a number of
flue gas desulfurization systems as the first or second stage in thepollutant removal process.In a spray tower,
absorption can be increased by decreasing the size of the liquid droplets and/or increasing theliquid-to-gas ratio (L/G). However, to accomplish either of these, an increase in both power consumed and operating cost is required. In addition, the physical size of the spray tower will limit the amount of liquid and the size of droplets that can be used.Maintenance problems
The main advantage of spray towers over other
scrubber s is their completely open design; they have no internal parts except for thespray nozzles . This feature eliminates many of the scale buildup and plugging problems associated with other scrubbers.
The primary maintenance problems are spray-nozzle plugging or eroding, especially when using recycled scrubber liquid. To reduce these problems, a settling or filtration system is used to remove abrasive particles from the recycled scrubbing liquid before pumping it back into the nozzles.ummary
Spray towers are inexpensive control devices primarily used for gas conditioning (cooling or humidifying) or for first-stage particle or gas removal. They are also being used in many
flue gas desulfurization systems to reduce plugging and scale buildup bypollutant s.Many scrubbing systems use sprays either prior to or in the bottom of the primary scrubber to remove large particles that could plug it.
Spray towers have been used effectively to remove large particles and highly soluble gases. The
pressure drop s across the towers are very low - usually less than 2.5 cm (1.0 in) of water; thus, the scrubber operating costs are relatively low. However, the liquid pumping costs can be very high.Spray towers are constructed in various sizes - small ones to handle small gas flows of 0.05 m³/s (106 ft³/min) or less, and large ones to handle large exhaust flows of 50 m³/s (106,000 m³/min) or greater. Because of the low gas velocity required, units handling large gas flow rates tend to be large in size. Operating characteristics of spray towers are presented in Table 1. [* [http://www.epa.gov/apti/ US EPA Air Pollution Training Institute] developed in collaboration with North Carolina State University, College of Engineering (NCSU)]
Bibliography
*Bethea, R. M. 1978. Air Pollution Control Technology. New York: Van Nostrand Reinhold.
*Gilbert, J. W. 1977. Jet venturi fume scrubbing. In P. N. Cheremisinoff and R. A. Young (Eds.), Air Pollution Control and Design Handbook. Part 2. New York: Marcel Dekker.
*McIlvaine Company. 1974. The Wet Scrubber Handbook. Northbrook, IL: McIlvaine Company.
*Richards, J. R. 1995. Control of Particulate Emissions (APTI Course 413). U.S. Environmental Protection Agency.
*Richards, J. R. 1995. Control of Gaseous Emissions. (APTI Course 415). U.S. Environmental Protection Agency.ee also
Spray Nozzle References
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