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The Definitive Guide To Wet Scrubbers: Understanding How They Work And Their Benefits

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In today’s industrial landscape, environmental regulations and air quality concerns are paramount. Wet scrubbers have emerged as a crucial solution for industries seeking to control air pollution and reduce harmful emissions. This comprehensive guide will delve into the world of wet scrubbers, exploring their inner workings and highlighting the reasons why your facility should consider implementing one.

What is a Wet Scrubber?

A wet scrubber is an air pollution control device that efficiently removes pollutants from industrial exhaust gases. It operates on the principle of using a liquid (usually water or a chemical solution) to trap and neutralize harmful pollutants before they are released into the atmosphere. Wet scrubbers are highly effective in capturing various pollutants, including particulate matter, sulfur dioxide (SO2), nitrogen oxides (NOx), and volatile organic compounds (VOCs). Learn more about “what is a wet scrubber”.

How Do Wet Scrubbers Work?

Particle Capture

The first stage of a wet scrubber’s operation involves capturing and removing particulate matter from the exhaust gas. As the contaminated gas enters the scrubber, it passes through a series of water droplets or a wetted surface. The particles in the gas collide with the liquid, causing them to adhere to the droplets’ surface. Gravity then pulls these laden droplets down into a collection area, effectively removing the particles from the gas stream.

Gas-Absorption

In the gas-absorption stage, wet scrubbers target gaseous pollutants such as SO2 and NOx. The contaminated gas is brought into contact with the scrubbing liquid, which chemically reacts with the pollutants to neutralize them. This reaction converts harmful gases into harmless compounds, making them safe for release into the environment. Learn more about gas wet scrubbers.

Types of Wet Scrubbers

Venturi Scrubbers

Venturi scrubbers utilize a converging-diverging section to create a high-velocity throat that generates turbulence and increases contact between the gas and the scrubbing liquid. This design maximizes particle capture efficiency and is particularly effective for fine particulate matter.

Packed Bed Scrubbers

Packed bed scrubbers consist of layers of packing material (such as plastic or metal) that provide a large surface area for gas-liquid contact. Pollutants are absorbed as they pass through the packed bed, ensuring efficient removal of gaseous contaminants.

Spray Tower Scrubbers

Spray tower scrubbers work by spraying the scrubbing liquid from the top of a tower, while the contaminated gas enters from the bottom and flows upwards. This counter-current flow enhances gas-liquid contact, resulting in effective pollutant removal.

The Importance of Wet Scrubbers in Industrial Settings

Regulatory Compliance

One of the primary reasons to invest in a wet scrubber is to ensure compliance with environmental regulations. Governments impose strict emissions standards, and non-compliance can lead to hefty fines and legal issues. A well-maintained wet scrubber helps industries meet these standards, avoiding potential penalties.

Protecting Public Health

Harmful pollutants emitted from industrial processes can have severe health consequences for nearby communities. Wet scrubbers play a vital role in minimizing these emissions, protecting public health, and contributing to cleaner air for everyone.

Preserving the Environment

Air pollution not only affects human health but also leads to environmental degradation. Wet scrubbers aid in preserving ecosystems, reducing acid rain formation, and mitigating the adverse effects of pollution on vegetation and wildlife.

Implementing a wet scrubber in your industrial facility is a wise and responsible decision. Not only does it enhance regulatory compliance, but it also demonstrates a commitment to environmental stewardship and public health. Choose the right type of wet scrubber based on your specific needs and enjoy the benefits of cleaner air and a greener future.

What Is A Filter Separator?

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In industrial processes where the separation of liquids, solids, and gases is critical, filter separators play a vital role. These highly effective devices are designed to remove impurities and contaminants from the process stream, ensuring optimal performance and safeguarding equipment integrity. In this article, we will delve into the concept of a filter separator, explore its functionality, and highlight its significance in achieving efficient industrial filtration.

Understanding the Filter Separator

A filter separator is a specialized piece of equipment utilized in industrial settings to remove solid and liquid contaminants from gases or liquids. It operates on the principle of filtration, employing various filter media to capture and separate particles, solids, and liquids of different sizes. The filter separator typically consists of a vessel housing the filter elements, an inlet for the contaminated stream, and separate outlets for the clean gas or liquid and the collected contaminants.

Key Functionality of Filter Separators

The primary function of a filter separator is to efficiently remove impurities and contaminants from process streams. It achieves this through several key processes:

Filtration: The filter separator employs a range of filter media, such as mesh screens, porous membranes, or pleated cartridges, to physically trap and retain particles and solids of varying sizes.

Separation: The filter separator allows for the separation of liquids and solids from gases or liquids, preventing them from entering downstream equipment and causing damage or operational issues.

Contaminant Collection: As the process stream flows through the filter separator, the captured contaminants accumulate within the vessel. Periodic maintenance and cleaning of the separator are necessary to remove the collected impurities.

Significance in Industrial Filtration

Filter separators are crucial components in numerous industrial applications where the presence of contaminants can compromise product quality, equipment functionality, and overall process efficiency. They find extensive use in oil and gas production, petrochemical refineries, pharmaceutical manufacturing, power generation, and wastewater treatment, among others. By removing harmful particulates, liquids, and solids, filter separators ensure the integrity of downstream equipment, enhance operational safety, and minimize the risk of process disruptions and costly repairs.

Types of Filter Separators

Filter separators are available in various configurations to suit different application requirements. Some common types include:

Gas Filter Separators: Specifically designed for gas filtration, these separators are utilized in gas processing plants, natural gas pipelines, and compression stations.

Liquid Filter Separators: Primarily used in liquid processing industries such as chemical manufacturing and wastewater treatment, these separators effectively remove contaminants from liquids.

Coalescing Filter Separators: These separators focus on removing liquid droplets and aerosols from gas streams by employing coalescing filter media.

Filter separators are indispensable in industrial filtration systems, ensuring the efficient removal of impurities and contaminants from process streams. By employing various filter media and separation mechanisms, these devices safeguard equipment integrity, enhance operational efficiency, and uphold product quality. Whether it’s in the oil and gas industry or pharmaceutical manufacturing, filter separators play a crucial role in maintaining clean and reliable process streams. To benefit from the advantages of a filter separator tailored to your specific needs, consult with filtration experts like CECO Environmental, who offer a wide range of innovative filtration solutions.

Wet Vs. Dry Scrubbers: Choosing The Right Solution For Your Environmental Needs

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When it comes to controlling air pollution, industrial facilities and power plants often rely on scrubber systems. These systems help remove harmful pollutants from exhaust gases before they are released into the atmosphere. Two commonly used types of scrubbers are wet scrubbers and dry scrubbers. In this article, we will explore the key differences between wet and dry scrubbers, their advantages and disadvantages, and how to choose the right solution for your specific environmental needs.

Understanding Wet Scrubbers

Wet scrubbers, also known as wet air scrubbers or wet gas scrubbers, are pollution control devices that use liquid to capture and remove pollutants from industrial emissions. These scrubbers work by directing the gas stream through a liquid spray or a wetted surface, which traps the pollutants and cleans the exhaust gas. The liquid used in wet scrubbers can be water, water mixed with chemicals, or other suitable liquids.

Learn more about “What is a Wet Scrubber?”

Wet Packed Bed Scrubber System, Horizontal

Wet Packed Bed Scrubber System, Vertical

Fume and Gas Wet Scrubbers

Advantages of Wet Scrubbers

One of the primary advantages of wet scrubbers is their ability to efficiently remove both particulate matter and gas-phase pollutants. They are highly effective at capturing fine particles, acidic gases, and even some heavy metals. Wet scrubbers can handle high-temperature and high-humidity environments and are particularly suitable for applications where the pollutants are soluble in water. They are also well-suited for removing odorous compounds, making them an excellent choice for industries dealing with strong odors.

Disadvantages of Wet Scrubbers

While wet scrubbers offer numerous benefits, they also come with some drawbacks. Wet scrubbers tend to consume a significant amount of water, which can be a concern in regions where water scarcity is an issue. Additionally, wet scrubber systems require careful monitoring and maintenance to prevent the growth of bacteria and fungi, which can affect performance. The disposal of the captured pollutants and the wastewater generated during the scrubbing process also need to be managed properly to ensure environmental compliance.

Exploring Dry Scrubbers

Dry scrubbers, also known as dry air scrubbers or dry gas scrubbers, are pollution control devices that remove pollutants from exhaust gases without using a liquid medium. Instead, they use dry sorbent materials, such as activated carbon or hydrated lime, to chemically react with and capture the pollutants. The sorbent materials can be injected into the gas stream or placed in fixed beds through which the gas passes.

Advantages of Dry Scrubbers

Dry scrubbers offer several advantages, making them a viable alternative to wet scrubbers in certain applications. They have a smaller footprint, require less maintenance, and generally consume less energy compared to wet scrubbers. Dry scrubbers are particularly suitable for industries where water conservation is crucial. They are also effective at capturing pollutants that are not soluble in water and can handle high-temperature gas streams.

Disadvantages of Dry Scrubbers

One significant drawback of dry scrubbers is their limited efficiency in capturing fine particles. They are generally more effective at removing gas-phase pollutants than particulate matter. Dry scrubbers may also generate dust during the sorbent injection process, which needs to be properly managed to prevent fugitive emissions. The sorbent materials used in dry scrubbers may require regular replacement, adding to the operating costs.

Choosing the Right Scrubber Solution

The selection of wet or dry scrubbers depends on several factors, including the nature of pollutants, process conditions, regulatory requirements, and operational constraints. For industries dealing with water-soluble pollutants and strong odors, wet scrubbers are often the preferred choice. On the other hand, dry scrubbers are more suitable when water conservation, lower maintenance, and smaller footprint are key considerations. Consulting with experts in air pollution control systems, such as Ceco Environmental, can help determine the most appropriate scrubber solution for your specific needs.

Beyond Clean: CECO Peerless’ Refreshing Solution For Potable Water In The Oil And Gas Industry

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Access to potable water is not only a basic human necessity but also a critical factor in ensuring the well-being and productivity of workers, particularly in remote and challenging environments like the Algerian Desert. For the 12th largest oil consortium in the world, this need became a formidable challenge that demanded an innovative solution. In response, CECO Peerless, a renowned provider of water treatment solutions, stepped forward with a groundbreaking approach, designing and implementing a containerized filtration system that harnessed advanced technology explicitly tailored to the unique demands of the oil and gas industry.

In the heart of the Algerian Desert, where freshwater reserves are scarce, the oil and gas provider faced the pressing task of establishing a sustainable and reliable potable water source to meet the daily service requirements of its field workers. Ensuring compliance with global health guidelines was also paramount to safeguarding the safety and well-being of the workforce.

CECO Peerless developed a comprehensive potable water treatment package to overcome these challenges, incorporating various components to ensure water quality, safety, and availability. The package included pre-filtration and micron filtration stages to reduce turbidity and remove fine suspended solids, preparing the water for subsequent treatment processes. A chemical dosing station was integrated into the system to address specific water quality challenges. Precise dosing of chemicals optimized the treatment process, ensuring the removal of unwanted contaminants. The primary treatment method employed brackish reverse osmosis membrane technology, effectively eliminating unwanted pollutants from the water, including bacteria and viruses. Reverse osmosis simulation software aided in optimizing the system’s design and selecting appropriate membrane types, guaranteeing compliance with global health guidelines. The treatment package included a re-mineralization process to enhance the water’s taste, quality, and pH levels. This step ensured that the water met the desired standards for potability.

Furthermore, ultraviolet (UV) disinfection was utilized to eliminate any remaining bacteria, viruses, or other harmful microorganisms in the treated water, adding an extra layer of safety before consumption. In addition to providing safe and potable water, the package incorporated a water-cooling system to enhance the drinking experience for workers in the desert heat. The cooling system ensured that the water was refreshing and chilled, contributing to the well-being and comfort of the field personnel.

Implementing CECO Peerless’ potable water treatment package yielded significant benefits for the oil and gas provider. The optimized design, supported by reverse osmosis simulation software, facilitated the selection of suitable membrane types and compliance with global health guidelines. Consequently, the results were twofold.

Firstly, implementing the containerized filtration system provided a durable and trustworthy source of potable water, eliminating the need to transport water to the desert site. This saved time and resources and ensured a consistent water supply for the workers.

Secondly, adopting this water treatment solution enabled the oil and gas provider to comply with global health guidelines, safeguarding the health and well-being of its workforce. The advanced technologies employed in the treatment process ensured the removal of contaminants and the delivery of safe drinking water.

Furthermore, by reducing the reliance on bottled water, the availability of a reliable potable water source resulted in a significant reduction in plastic waste generated at the desert site. This environmentally sustainable practice is aligned with the growing global concern for plastic pollution and waste management.

What Is A Wet Scrubber?

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Wet scrubbers are an effective technology for the control of harmful airborne pollutants and odors in process exhaust streams…

Introduction to Industrial Scrubbers

If you are a plant manager, a process engineer, or a purchasing or Environmental Health and Safety (EHS) professional who works in industrial manufacturing or the wastewater treatment industry, then you may be seeking a solution to remove harmful pollutants and odors from your process exhaust streams before they are released into the atmosphere and contaminate the outside air. One technology worth strong consideration is the industrial scrubber.

Industrial scrubbers are pollution filtration systems that utilize solids (in “dry scrubbers”), or water or other liquids (in “wet scrubbers”) to remove gas pollutants and odors from exhaust streams. In general, the main advantages of industrial wet and dry scrubbers to clean gas exhaust streams include:

  • Low-risk processing of incendiary gases
  • Ability to handle high-temperature, high-humidity gas streams without temperature limit or condensation problems
  • Small space requirements mean lower capital costs and site location flexibility – scrubbers reduce the temperature and volume of unsaturated exhaust streams, permitting vessel sizes, fans and ducts to be more compact. This also enables retro-fitting into existing systems
  • No secondary dust sources – once particulate matter is collected, it cannot escape from hoppers or during transport
  • Ability to absorb gas and solid particulate matter via a single device
  • Ability to neutralize corrosive gases

Dry Vs. Wet Scrubbers

Industrial scrubbers are categorized as either “dry” or “wet”. It’s important to understand the differences between wet vs. dry scrubbers. Dry scrubbers generally cannot achieve the same level of pollutant removal as wet scrubbers, but they are well-suited for applications in facilities that lack the infrastructure to properly handle produced wastewater.

Dry scrubbers remove pollutants from exhaust gases without the use of liquids. Instead, they utilize a dry reaction material known as “sorbent”, such as alkaline slurry, and they are primarily implemented for removal of acid from gas by moving the gas through the sorbent “dust” to maximize binding.

In contrast to dry scrubbers, wet scrubbers move contaminated gas through a liquid that is designed to remove pollutants. Wet scrubbers constitute a versatile and cost-effective pollution control technology that can eliminate more than 99% of airborne particulate matter.

How Wet Scrubbers Work

Water is the most common solvent used to remove inorganic contaminants. In the most basic form of wet scrubbers, water is encapsulated in a metal or composite container, contaminated gas is moved through the water, the water then absorbs the contaminates, and clean gas exits the scrubber.

Aside from water, other liquids can be used as absorbing solutions to effectively remove varied contaminates. Manipulating the chemical composition of the absorbing solutions changes the overall charge, which can be highly positively charged, negatively charged, or non-charged. Because pollutants differ in their charge, wet scrubbers are packed with the liquid that will bind most effectively to remove the contaminate from the gas. Caustic solution (sodium hydroxide, NaOH) is the most common scrubbing liquid used for acid-gas control (e.g., HCl, SO2, or both), though sodium carbonate (Na2CO3) and calcium hydroxide (slaked lime, Ca[OH]2) are also used.

Wet Scrubbing of Particulate Matter

Wet scrubbers can remove particulate matter by capturing them in liquid droplets. The droplets are then collected, with the liquid dissolving or absorbing the pollutant gases. Any droplets that are in the scrubber inlet gas must be separated from the outlet gas stream using a mist eliminator. Also, the resultant scrubbing liquid must be treated prior to any ultimate discharge or being reused in the plant.

A wet scrubber’s ability to collect particulate matter is often directly proportional to the power input into the scrubber. Additionally, a properly designed and operated mist eliminator is important to achieve high removal efficiencies.

If the gas stream contains both particulate matter and gases, wet scrubbers are generally the only single air pollution control device that can remove both pollutants.

Packed-Bed Wet Scrubbers

Wet scrubbers that remove gaseous pollutants are referred to as absorbers. Good gas-to-liquid contact is essential to obtain high removal efficiencies in absorbers. Various wet-scrubber designs are used to remove gaseous pollutants, with one of the most popular sub-categories of wet scrubber known as Packed-Bed, Packed-Tower, or “acid gas” (when they are used to control inorganic gases).

Although they can also collect solid particulate matter, Packed-Bed scrubbers are generally used more for the treatment of gas. Packed-bed scrubbers are typically used in the chemical, aluminum, coke and ferroalloy, food and agriculture, and chromium electroplating industries, in acid plants, fertilizer plants, steel mills, and asphalt plants.

Applicable Pollutants for Packed-Bed Wet Scrubbers

Packed-Bed wet scrubbers are used to control:

Inorganic fumes, vapors, and gases (e.g., chromic acid, hydrogen sulfide, ammonia, chlorides, fluorides, and SO2) – Inorganic fumes, vapors and gases are the primary pollutants controlled by Packed-Bed wet scrubbers. They typically achieve removal efficiencies in the range of 95-99%.

Volatile Organic Compounds (VOC) – Wet scrubbers are occasionally used to control volatile organic compounds (VOCs). Removal efficiencies for gas absorbers vary for each pollutant-solvent system and with the type of absorber used. Most absorbers have removal efficiencies in excess of 90%, and packed-tower absorbers may achieve efficiencies greater than 99% for some pollutant-solvent systems. The typical collection efficiency range is from 70% to greater than 99%.

Particulate Matter (PM) and Hazardous Air Pollutants (HAP) in particulate form (PMHAP) – Packed-bed wet scrubbers are limited to applications in which dust loading is low, and collection efficiencies range from 50-95 %, depending upon the application.

How Packed-Bed Scrubbers Operate

Packed-Bed scrubbers remove air pollutants through inertial or diffusional impaction, reaction with a sorbent or reagent slurry, or absorption into liquid solvent.

Packed-bed scrubbers consist of a chamber containing layers of variously-shaped packing material (e.g., spiral rings) that provides a large surface area for liquid-particle contact. The packing’s shape, weight, surface area and cost all influence the efficiency of the low gas-phase pressure drop and gas-liquid contact. The packing is held in place by wire mesh retainers, and is supported by a plate near the bottom of the scrubber.

Waste gas is forced into the bottom of the scrubber’s chamber and flows vertically or horizontally through the packing while scrubbing liquid is simultaneously and evenly introduced above the packing and flows down through the bed to coat the packing and establish a thin film. In vertical designs (packed towers), the gas stream flows up the chamber (“counter-current” to the liquid). However, some packed beds are designed horizontally for gas flow across the packing (“cross-current”).

The cleaned gas is then passed through a mist eliminator built into the top of the structure, and the waste slurry drops to the bottom of the chamber.

Advantages of Packed-Bed Wet Scrubbers

The advantages of Packed-Bed wet scrubbers are consistent with industrial scrubbers in general and include:

  • Relatively low pressure drop – Pressure drop is the pressure difference that occurs as exhaust gas is pushed or pulled through the scrubber, disregarding the pressure that would be used for pumping or spraying the liquid into the scrubber.
  • Fiberglass-reinforced plastic (FRP) construction permits operation in highly corrosive atmospheres
  • Capable of achieving relatively high mass-transfer efficiencies
  • The height and/or type of packing can be changed to improve mass transfer without purchasing new equipment
  • Relatively low capital cost
  • Relatively small space requirements
  • Ability to collect Particulate Matter (PM) as well as gases

Classification, Categories and Types of Packed-Bed Wet Scrubbers

As wet scrubbers can vary considerably in their complexity and method of operation, creating standard categories into which all of them fit is challenging. Some people classify scrubbers for particle collection by the gas-side pressure drop of the system. However, most scrubbers operate over a wide range of pressure drops, depending on their specific application, thereby making this type of categorization difficult.

Other ways to classify packed-bed wet scrubbers are by their use – to primarily collect either particulates or gaseous pollutants, or by the energy source used for gas-liquid contact. At CECO Environmental, we classify packed-bed wet scrubbers in a variety of ways. One example is by design configuration. Whether horizontal or vertical, packed-bed wet scrubbers provide a reliable and practical means of removing acidic and caustic mists and gases from corrosive exhaust streams, with maximum efficiency and minimum pressure loss:

Wet Packed Bed Scrubber System, Horizontal

  • Low profile design
  • “Cross-flow” design

Wet Packed Bed Scrubber System, Vertical

  • “Counter-current flow” design

Other classification categories are by application:

Fume and Gas Wet Scrubbers

  • Fume and gas wet scrubbers are designed for most industrial air pollution applications, including scrubbing ammonia gas, chlorine gas, hydrochloric acid (HCL). They are especially effective on water-soluble fumes and odors.
  • Fume and gas wet scrubbers are manufactured with premium materials and quality thermoplastic construction for maximum corrosion resistance, plus UV-resistant PVC, polypropylene and polyethylene available for all outdoor installations.

Packed-Bed Scrubbers for Municipal and Industrial Odor Control

  • Offers great design flexibility
  • Horizontal “cross-flow” designs and vertical “counter-current” designs
  • On demand chemical addition minimizes operating costs
  • Economically treats large volumes of process air with infinite turndown ratio, accommodating virtually all choices of chemistry
  • No solid waste disposal

NOx Control Wet Scrubbers

  • High-efficiency wet oxidation/reduction approach to controlling nitrogen oxide (NOx) emissions
  • Single and multiple stage systems can provide more than 99% efficiency total NOx removal and elimination of the red/brown NOx exhaust plume
  • Minimal maintenance if thermoplastic construction is used for complete corrosion resistance

Quencher Scrubber

  • Two-stage scrubber solution for applications involving corrosive air from hot processes and corrosive air contaminants from processes such as thermal or catalytic oxidizers – HCl, HF, SO2, Cl2, HB
  • High efficiency – Up to 99.9% removal efficiency of acid or toxic gases
  • Maximum reliability and value with corrosion and chemical resistance materials
  • Two-stage system consists of:
    • Quencher stage designed to cool the hot gases – constructed of a suitable metallic material
    • Scrubber stage to remove the corrosive gases and mists – constructed of FRP material and is filled with a high efficiency packing material, mist eliminator and liquid distribution system

Venturi Scrubbers

Another popular type of wet scrubber is the Venturi scrubber. Venturis can be used to collect both particulate and gaseous pollutants, but they are more effective in removing particles than gaseous pollutants.

With Venturi scrubbers, the dirty gas entering a scrubber is forced at high velocity through a Venturi where it collides with scrubbing water. The tiny water droplets capture particles through impaction and diffusion. The mist eliminator for a Venturi scrubber is often a separate device called a cyclonic separator. The dirty water is then removed in the cyclonic separator and discharged into a recycle tank. Some of the liquid is continuously purged to limit the solids concentration and allow recirculation back to the Venturi section.

A Venturi scrubber typically consists of three sections:

  • Converging section – Inlet gas stream enters the converging section and, as the area decreases, gas velocity increases. Liquid is introduced either at the throat or at the entrance to the converging section.
  • Throat section – In the small throat section, the inlet gas is forced to move at extremely high velocities in the small throat section, and shears the liquid from its walls, producing an enormous number of very tiny droplets.
  • Diverging section – in the diverging section, particle and gas removal occurs as the inlet gas stream mixes with the fog of tiny liquid droplets. The inlet stream then exits through the diverging section, where it is forced to slow down.

At CECO, we classify Venturi scrubbers a number of ways:

Eductor Venturi Scrubbers

  • Eductor scrubbers are designed to remove soluble gases and particulate by inducing a gas flow using high pressure liquid focused into a Venturi throat, which eliminates the need for a separate exhaust fan or blower to transport the contaminated gas stream to the filtration device.
  • Design incorporates a high pressure spray for maximum entrainment and scrubbing efficiency, and is the optimal choice where high temperatures, heavy contaminant loads, and corrosive conditions are present.
  • Maximum efficiency – up to 99% removal efficiency of mists 3 microns or larger

Wet Particulate Venturi Scrubbers

  • Static pressure induced by an exhaust fan draws the sump water and dust-laden air stream into an inverted Venturi throat.
  • Turbulent mixing of dust and small droplets form an agglomerate, which is returned to sump where water is reused and particulate matter settles out or is dissolved.
  • Entrained mists and dust are collected on a chevron blade mist eliminator.
  • The collected dust forms sludge at the conical bottom of the scrubber.
  • High efficiency >99% on very fine particulates
  • Energy savings – no pumps
  • Maintenance savings – no moving parts, spray nozzles, or recirculation piping
  • Floor space – efficient geometry
  • Water savings – integral water saving sludge concentrator, the sump liquor need not be diluted
  • Ideal applications include:
    • Aluminum, titanium and other metal machining operations
    • Sodium Azide propellant manufacturing and handling
    • Pharmaceutical powders and dusts
    • Calcium chloride dusts
    • Hygroscopic dusts
    • Corrosive dusts
    • Food processing with Clean in Place (CIP) option
    • Bulk solids drying process
    • Battery lead pasting

High-Velocity Super Venturi Scrubbers

  • Combination particulate collection and gas absorption
  • Vertical or horizontal gas entry
  • Various throat and water injection designs
  • Integral or external recirculation tanks
  • Compact cyclonic separator design
  • High temperature quench section
  • High solids concentration separator design
  • Carbon steel, stainless, nickel alloys, or FRP construction
  • Package systems complete with tanks, pumps, instrumentation, piping, fans, stack and controls
  • Ideal applications include:
    • Chemical
    • Food / Dairy Industry
    • Paper
    • Dryer
    • Pharmaceutical
    • Roofing materials
    • Asphalt
    • Mining
    • Steel
    • Brick & Tile
    • Fiberglass Insulation
    • Power Generation
    • Plastic Extrusion

Contact Us for Air Quality Improvement Solutions

To learn more about how wet or dry scrubbers may help solve your challenges, please visit our HEE-Duall brand (packed-bed scrubbers and Venturi scrubbers) and our Fisher-Klosterman brand (Venturi scrubbers). To learn more about all of the ways that CECO Environmental can help you grow your business while improving your air quality, please view this brief video. When it comes to controlling your industrial airborne pollutants, check out our variety of wet and dry scrubbers, and contact CECO. We have a solution for you.

Beyond Clean – Odor Control In Bakeries

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Odor Control in Bakeries

Beyond the Oven: Are RTOs the Secret Ingredient You’re Missing from Your Business?

One industry that often faces challenges related to Volatile Organic Compound (VOC) emissions and odor control is commercial bakeries. These applications release VOC-laden odors into the atmosphere, which can negatively impact human health and the environment, and cause strife in communities surrounding the facility. Adwest has over three decades of experience supporting these challenging applications with efficient and reliable odor control technologies.

Adwest is a global leader in thermal and catalytic solutions for air pollution and odor control. They specialize in the custom designing and manufacturing of Regenerative Thermal Oxidizers (RTOs), VOC concentrators, Direct Fired Thermal Oxidizers (DFTOs), and catalytic oxidation solutions for industries worldwide. These systems are highly efficient at removing volatile organic compounds (VOCs), toxic fumes, odors, hydrocarbons, and hazardous air pollutants (HAPs), making industrial processes safer for the environment and community. RTOs are one of the most cost-effective and reliable technologies for efficient VOC abatement. These sophisticated systems not only excel in eliminating dangerous and odor-causing VOCs but also exhibit impressive Destruction and Removal Efficiency (DRE) rates, reaching up to 99% DRE.

The most common challenge that Adwest addresses in bakery applications is nuisance odor. Nuisance odor refers to unpleasant or offensive smells that are considered bothersome to individuals in a particular environment or location. These odors are often regulated by environmental protection agencies and laws. In the case of commercial bakeries, the smell of bread and other baked goods can be perceived as a nuisance odor by residents living in the surrounding neighborhoods. These odors are the result of the VOCs released during the fermentation and baking processes. The fermentation of yeast in bread production generates ethanol and other VOCs, which are released at high temperatures during baking. While the smell of freshly baked bread may be pleasant to some, the perception of odor is subjective, so it can become bothersome, especially if it becomes too intense or lingers in residential neighborhoods for extended periods. Strong, persistent, or frequent odors can lead to physical discomfort, annoyance, headaches, respiratory issues, and even psychological distress among affected individuals, as well as potential fines or potential shutdowns for the offending facility.

Volatile Organic Compounds (VOCs) released during the baking process contribute to the distinct aroma of yeast. The primary VOC emitted is ethanol, which is produced as a byproduct of yeast fermentation. Other VOCs, such as aldehydes and organic acids, can also contribute to the smell. Regulatory agencies and local authorities impose regulations and guidelines on bakery operations to address nuisance odors from commercial bakery emissions. These measures often involve limiting odor concentrations or requiring businesses or facilities to implement odor control technologies and practices. These regulations aim to protect the community and ensure that odor emissions are controlled to acceptable levels. Bakeries may be required to install odor control technologies, such as Catalytic Oxidizers or Regenerative Thermal Oxidizers (RTOs), which effectively remove VOCs and mitigate odor.

One such bakery in California was forced to confront this issue when they were notified of the need to install an RTO within a strict timeframe. They also required a customized ductwork system design, fabrication, and installation and turned to CECO Environmental for a solution.

The large bakery, running a 24/7 operation, faced potential fines and shutdown when the South Coast Air Quality Management District (SCAQMD) notified them that they were required to install an RTO unit to reduce VOC emissions from their bread ovens. With no availability for downtime and little schedule flexibility, they needed a system designed and installed quickly to process the exhaust from their bread ovens. Turnaround time and efficiency were key.

This challenge was significant, as the plant only shut down for a maximum of six hours every Friday. CECO Kirk & Blum, a leading global supplier of air pollution control technologies, was tasked with tying into seven existing oven exhaust stacks within the strict time frame while also designing and fabricating the necessary ductwork within two months of issuance of the purchase order.

To conquer this situation, CECO Kirk & Blum developed an “elbow cap” design that allowed the installation crew to tap into the seven stacks during the shutdown period and continue the installation while Gold Coast’s production commenced. The design, packaging, and installation of CECO Effox-Flextor-Mader dampers with a CECO Adwest RTO and control logic provided a complete solution that fit the bakeries’ urgent needs in the timeframe they required.

As a result of this innovative and collaborative approach, CECO accomplished the installation within the limited timeframe, achieving compliance with SCAQMD regulations. Additionally, the Adwest RTO unit reduced VOC emissions by approximately 504,000 pounds of ethanol annually, providing significant environmental and societal benefits.

CECO Environmental provided a dynamic, customizable solution, demonstrating the value of working with an experienced air pollution control technology provider. As more and more businesses face increasingly stringent regulations and environmental pressures, complete and total solutions like those provided by the CECO family brands are critical to maintaining compliance and reducing environmental impact.

How To Reduce NOx Emissions: 6 Tips For Reducing NOx Emissions

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Check out the 6 tips for reducing NOx emissions to keep in mind while researching NOx control systems and technologies, SNCR systems and oxidizers.

Many industrial processes utilize the combustion of natural gas, oil, or coal. However, the combustion of these fossil fuels produces nitrogen oxide or NOx, which contributes to smog and air pollution, leaving you to wonder, “How can I reduce NOx emissions?”. Finding an effective and efficient solution for reducing NOx emissions can be frustrating and time-consuming. In addition, federal regulations and energy standards can change, impacting your operational processes.

While conducting research on NOx control systems and technologies, here are 6 tips to keep in mind to help you answer the question “How to reduce NOx emissions”

How To Reduce NOx Emissions

  • Choose your NOx reduction technology based on the fuels and equipment design.
    • This will allow you to select the lowest cost method for each unit.
  • Maximize your NOx reduction with expert tuning up front.
    • Doing so will ensure that your burners and boiler are operating cleanly and efficiently while minimizing the additional controls needed to meet your future requirements.
  • Consider upgrading your burners.
    • This will save operating expenses with minimal capital and installation costs. Stable and modern combustion designs will reduce NOx and increase efficiency.
  • Flue Gas Recirculation (FGR) can be very effective for reducing thermal NOx formation, but it may not be feasible for some units.
    • FGR recirculates flue gases from the boiler exhaust duct into the main combustion chamber, reducing peak flame temperature and lowering the percentage of oxygen in combustion air/flue gas mixture.
    • However, while FGR is highly effective for natural gas, it carries added operating costs and may not be feasible for some units.
  • Water injection can be applied as a low capital cost NOx reduction technique for peak load conditions.
  • Selective Non-Catalytic Reduction (SNCR) systems provide a low cost technique to reduce NOx emissions by 30%-60% for both boilers and lime kilns, but it is highly temperature dependent.
    • The SNCR process involves injecting a reagent into the flue gas in the appropriate temperature window.
    • The reagent then reacts with NOx to form harmless nitrogen and water.
    • However, SNCR is highly temperature dependent
    • Advanced designs support effective operation over a wide range of loads.

Researching the most efficient and economical solution to reduce NOx emissions for your operational processes can be time-consuming. Learn more about cost-effective solutions with our Webinar Presentation on NOx Reduction Methods and complying with PA NOx RACT 2 for more information on how to reduce NOx emissions.

Powergen International Show

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Join our Effox-Flextor-Mader (EFM) & General Rubber teams at the PowerGen International show in Dallas, TX, May 23rd – 25th, 2022. This event is the largest network and business hub for electricity generators and solution providers engaged in power generation.

What: PowerGen Internaitonal Show

Where: Kay Bailey Hutchinson Convention Center – Dallas, TX

When: May 23-25, 2022

CECO Booth: #5426

If you would like to schedule a time to meet with one of our experts, please contact us, or stop by our booth during the event. Register here!

Effox-Flextor-Mader (EFM) is the international leader in the design and manufacture of dampers and expansion joints for use in flue gas and process air handling systems. Our team includes a skilled staff of engineers, designers, fabricators, and field service personnel to ensure the highest quality engineered-to-order products.

As you work to control emissions, you can trust we are working just as hard for your company. Protecting the environment is a commitment for Effox-Flextor-Mader that is matched only by our commitment to building quality equipment for our clients. From start to finish, we craft and install products that are unparalleled in value and reliability and can comply with the strictest regulations in the industry. When you need a custom, specific solution for emissions, we can meet your needs.

Since 1950, General Rubber Corporation has been at the forefront of innovative rubber expansion joint design. With our experienced engineers and sales team, we are able to provide powerful solutions to even the most demanding applications across multiple industries and sectors.

We are committed to being a leader in the design and manufacture of rubber expansion joints, providing engineered solutions, superior customer service, and competitive prices. General Rubber is both ISO 9001 and 14001 certified and has differentiated itself as a leader in the industry. We leverage our state-of-the-art United States manufacturing facility to lower operating costs while respecting the environment

Aquatic Animal Life Support Operators Show

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Join Direct of Global Business Development, Jerry D’Alterio, and Director of Engineering, Steve Rose, at the Aquatic Animal Life Support Operators Show in Albuquerque, New Mexico. This event takes place March 5th-9th at the ABQ Biopark Aquarium.

Join Director of Global Business Development, Jerry D’Alterio, and Director of Engineering, Steve Rose, at the Aquatic Animal Life Support Operators Show in Albuquerque, New Mexico. This event takes place March 5th-9th at the ABQ Biopark Aquarium.

Hosted by AALSO (Aquatic Animal Life Support Operators), this symposium & workshop showcases vendors that supply the zoo and aquarium industry with pumps, valves, filters, heat exchangers, sensors, and every other piece of equipment that keep animals and their habitats healthy.

If you are interested in meeting with a member of our team at this event, please contact [email protected]

To register for this event, please click here.

CECO addresses the challenges of aquariums with products and solutions within the following categories:

  • Corrosion-Resistant Fiberglass Pumps
  • Corrosion-Resistant Thermoplastic Pumps

To discover how CECO can help aquariums with other challenges that they may be facing, please click on the link below.

Meeting Industrial Product Recovery And Clean Air Emissions Challenges

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An in-depth look at CECO Fisher-Klosterman Emtrol helps customers meet industrial product recovery and clean air emissions challenges.

From waste incineration and pharmaceutical to building products and petrochemical applications, companies need to recover as much product as possible during production, while ensuring dangerous gases are captured and clean air is emitted into the environment. The solution is to utilize either industrial cyclones or scrubbers as stand-alone systems, or in combination with each other—offered in various arrangements based on customer requirements and applications.

Industrial cyclones are primarily used for particulate removal and product recovery, utilizing centrifugal force to capture, recover or remove large and high-volume dust from industrial applications. Scrubbers are primarily used for emissions control, by utilizing water, or other liquid, to remove particulate or fumes from an exhaust stream. However, in many cases both a cyclone and scrubber are paired to maximize product recovery, while meeting strict emissions standards depending on industry application.

Fisher-Klosterman, a CECO Environmental brand, has been developing cyclones and scrubbers since 1948. With its XQ Series Cyclone Dust Collectors and MS Venturi Scrubbers, customers can rest assured that their high temperature, high pressure, erosive particulate and corrosive gases severe process conditions are met.

Understanding the nuances of the various cyclone and scrubber designs and configurations will be a useful guide, whether researching products or simply seeking a primer in this area.

Capturing More Dry Materials

Companies seeking to optimize product recovery find that a cyclone is economical and ideal for use in separating particles from gas streams. This mechanical collector, made of carbon, stainless and other alloy steels, uses centrifugal force on a particulate-laden gas stream to capture product. This force essentially pushes the particles against the walls of the cyclone where they spiral to the bottom of the cyclone cone and are discharged. The cleaned gas then reverses direction and exists the top as clean air through the outlet pipe (or vortex finder). This entire process occurs without using moving parts—providing simple operation and maintenance.

Beyond economy is the efficiency of the cyclone. This stems from how quickly the particles move towards the wall, or collection area, of the cyclone. By optimizing how long the particle stays in the cyclone, or Residence Time, and the force acting on the particle, greater collection efficiencies are generated. Pressure drop and fractional efficiency (a collector’s removal efficiency at a specific particle size) describe the cyclone’s performance. However, these factors are variable based on the specific customer application.

Other features important to consider include:

  • High temperature designs to over 2000°F continuous service
  • Abrasion resistant linings for extended life
  • Break-apart construction or manways for interior access
  • Clean-in-place (CIP) systems
  • Jacketing for heating or cooling of the cyclone shell
  • Ultra-high efficiency designs for product recovery or emission control
  • Internal and/or external insulation materials to minimize heat loss or allow use of lower temperature materials

With ASME Code design and construction for pressure vessels, as well as explosion containment, suppression, or venting per the National Fire Protection Association (NFPA), the seven basic models of CECO Fisher-Klosterman Cyclone Dust Collectors within the XQ Series meet the needs of a myriad applications.

Achieving High Emissions Control

In many industrial applications, a higher level of emissions control is needed than is practical with a cyclone —whether by regulations or other requirements. Applications such as high temperature quenching (up to 2000°F), a higher level of removal efficiency, humid/sticky airstreams and odor removal, among others, necessitate a wet scrubber in many cases.

The goal: to provide the equipment solutions needed to improve manufacturing air quality.

Scrubbers are used for gaseous and particulate control, by means of utilizing water, or other liquid, to remove pollutants from an exhaust stream. CECO Fisher-Klosterman offers its MS Venturi Scrubber as a solution.

The MS Venturi Scrubber is designed to have a low plant space utilization with a compact cyclonic separator design. It is able to effectively quench gas streams and collect particulate in a single package. With vertical and horizontal gas inlets, an adjustable venturi throat forces dust particles to become entrained with water droplets, which are then sent to the separator where they are separated from the gas stream by centrifugal force. The compact mist eliminator of the MS Scrubber creates a high centrifugal force to remove the water droplets (with particulate) through two oversized liquid drains, minimizing the risk for plugging the separator and assisting in cleaning the air flow exiting the exhaust stack.

Other Applications

With a wide spectrum of industrial applications in various markets, there are other cyclone and scrubber types or arrangements. For example, CECO Fisher-Klosterman cyclones come in seven models designed for maximum product recovery; have multiple arrangements; high pressure and temperature applications; and overall have an extremely high level of customization to deliver guaranteed performance in each customer’s specific application.

CECO Fisher-Klosterman Scrubbers come in two types mentioned above. They come with features like vertical or horizontal gas entry, various throat and water injection designs and high solids concentration separator design, among many others. There are also package systems complete with tanks, pumps, instrumentation, piping, fans, stack and controls; and are constructed of carbon steel, stainless, corrosion resistant metal alloys, and FRP construction.

In many cases, cyclones and scrubbers are combined in various arrangements to maximize the product recovery and control emissions due to the severity or complexity of the application within the respective industry. Both offer a low total cost of ownership, as well as easy maintenance, maximum efficiency and performance warranties—offering peace-of-mind and confidence your needs are fully met. To learn more, visit Fisher-Klosterman.