Visioneer Solutions

Scrubber Design Overview

• Shell:
  Constructed in mild steel (MS), diameter 1800 mm (1.8 meters), built as a vertical cylinder to withstand gas flow and facilitate spray coverage.
• Lining:
  Interior surface is acid-proof tile lined to resist highly corrosive conditions from SOx, NOx, and acid fumes in DG exhaust gas.
• Spray Nozzle Array:
  Stainless steel (SS) spray nozzles are mounted at the top port, creating a downward mist to scrub the flue gas as it enters. These nozzles atomize the scrubbing liquid for improved gas-liquid contact.
• Baffle Plate:
  A final baffle or distribution plate is provided before the exhaust outlet. This compels the flue gas to pass through the sprayed scrubbing fluid multiple times, increasing residence time and enhancing removal efficiency.
• Gas Immersion & Filtration:
  The baffle creates a region where the gas is immersed and forced to interact thoroughly with the scrubber liquid (often alkaline or water). Only the cleaned (filtered) gas escapes upwards through the final port and is discharged to the chimney, while pollutants are absorbed by the liquid phase.

Process Sequence

1. Exhaust gas from the DG set enters the MS scrubber shell.
2. Acid-proof tile lining prevents corrosion and material degradation.
3. SS spray nozzles at the top deliver scrubbing liquid, ensuring fine mist for optimal gas-liquid interaction.
4. A flue gas baffle plate directs flow for maximum spraying and immersion.
5. The flue gas is scrubbed (SOx, NOx, particulates removed), and only filtered gas exits through the chimney.

Performance

• Such a system is designed to meet stringent environmental norms, with typical collection efficiency exceeding 99% for particulate and acid gases.
• The final exhaust discharged through the chimney is compliant with emission regulations for DG sets and industrial gas streams.

This design combines robust construction (MS shell, acid-proof tile lining) with engineered internals (SS spray nozzles, baffle plate), providing reliable long-term operation and high scrubbing efficiency for DG exhaust gas streams

The ceramic bag filter system is a high-efficiency particulate removal unit designed for hot gas filtration applications, typically used in flue gas handling systems where temperatures exceed the limits of conventional fabric bag filters. It is ideal for processes involving corrosive gases, high particulate loading, and continuous high-temperature exposure.