Faced with high-concentration exhaust gas, can the spray tower be competent for long-term operation?
Publish Time: 2025-05-20
With the continuous development of industrial production, the types of exhaust gas generated by various enterprises in the production process are becoming increasingly complex, including high-concentration, toxic and harmful gases. In this context, the stability and durability of exhaust gas treatment equipment have become the focus of enterprise attention. As a widely used equipment in the field of exhaust gas purification, whether the spray tower has the ability to operate stably for a long time when facing high-concentration exhaust gas has become a concern for many users.
1. Functional characteristics of spray tower
The spray tower is a purification device that uses liquid to contact exhaust gas in reverse and separates pollutants from gas through gas-liquid mass transfer. Its core principle is to atomize the absorption liquid through a high-pressure nozzle to form a large number of fine droplets, thereby increasing the contact area with the exhaust gas and improving the removal efficiency of pollutants.
The spray tower has the advantages of simple structure, easy operation and low investment cost. It is especially suitable for the treatment of acid and alkali exhaust gas, dust particles and some volatile organic compounds (VOCs). However, when faced with high-concentration, highly corrosive or easily crystallized exhaust gas components, whether the spray tower can continue to operate efficiently becomes an important criterion for testing its performance.
2. Impact and challenges of high-concentration exhaust gas on spray tower
The so-called "high-concentration exhaust gas" usually refers to harmful gas components with high concentrations per unit volume, such as hydrogen sulfide, ammonia, chlorine, benzene series, etc. This type of exhaust gas not only has great harm to the environment, but also puts higher requirements on the equipment itself.
First, high-concentration exhaust gas may cause violent chemical reactions, fast absorption saturation, and large pH fluctuations inside the spray tower, affecting the purification effect; secondly, some corrosive components in the exhaust gas (such as sulfuric acid vapor and hydrochloric acid mist) may cause erosion to the tower material and shorten the life of the equipment; in addition, some solutes are easy to precipitate and crystallize during the absorption process, resulting in nozzle blockage and scaling of the packing layer, which in turn affects the stable operation of the system.
3. Technical optimization measures for spray towers to deal with high-concentration waste gas
Despite the above challenges, through reasonable process design and technical optimization, spray towers are fully capable of long-term treatment of high-concentration waste gas.
Selection of corrosion-resistant materials: To deal with highly corrosive gases, modern spray towers often use corrosion-resistant materials such as glass fiber reinforced plastics (FRP), polypropylene (PP), and stainless steel 316L to manufacture tower bodies and pipeline systems, effectively extending the service life of the equipment.
Multi-stage series treatment process: For high-concentration waste gas, it is difficult for a single spray tower to achieve efficient purification. Therefore, a multi-stage spray + filler adsorption + demisting combined process can be used to gradually reduce the concentration of pollutants and improve the overall removal rate.
Intelligent control system: By installing intelligent control devices such as pH meters, conductivity sensors, and automatic dosing systems, the absorption liquid ratio is adjusted in real time to avoid absorption failure due to excessive concentration.
Regular cleaning and maintenance mechanism: To prevent nozzle clogging and filler scaling, the spray tower should be equipped with a regular backwashing system or online cleaning module to ensure long-term stable operation of the system.
Used in combination with other purification equipment: In actual projects, spray towers are often used in combination with other waste gas treatment equipment (such as activated carbon adsorption towers, photocatalytic oxidation equipment, RTO incinerators, etc.) to achieve a more thorough purification effect.
4. Practical application cases verify its feasibility
At present, in the chemical, pharmaceutical, printing, spraying and other industries, there are a large number of successful cases showing that the spray tower system with reasonable design and optimized configuration can treat high-concentration waste gas for a long time and stably.
In summary, although high-concentration waste gas puts higher requirements on the operation of spray towers, as long as scientific planning is carried out in terms of material selection, process design, control system and maintenance management, spray towers are fully capable of this task and achieve long-term stable operation.
