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International Journal of Environmental Planning and Development
Vol. 2: Issue 1
www.journalspub.com
Abstract
Wet scrubbers are compatible and effective air pollution control devices to arrest particulate
matters and polluting gases coming out of industrial processes as air polluting emissions.
There are various types of wet scrubbers but the present paper deals with Spray Towers and
its design. The author of the present paper designed the Spray Tower for a 100 TPD cement
plant based on Vertical Shaft Technology (VSK) after monitoring the air emissions in regard
to designed parameters under variable conditions on a time scale. The efficiency of the
designed Spray Tower has been to the tune of more than 95 percent.
spray towers and cyclonic chambers. cyclonic motion inside the chamber. This
Spray towers are cylindrical or rectangular motion contributes to higher gas
chambers that can be installed vertically or velocities, more effective particle and
horizontally. In vertical spray towers, the droplet separation, and higher collection
gas stream flows up through the chamber efficiency. Tangential inlet or turning
and encounters several sets of spray vanes are common means of inducing
nozzles producing liquid droplets. A de- cyclonic motion.
mister at the top of the spray tower
removes liquid droplets and wetted PM The scrubbing liquid, usually water for
from the exiting gas stream. Scrubbing particulate matter removal, is sprayed into
liquid and wetted PM also drain from the the chamber from a series of nozzles
bottom of the tower in the form of slurry. located at the top chamber while the air-
Horizontal spray chambers operate in the particle mixture enters the bottom of
same manner, except for the fact that the chamber and flows upward, encountering
gas flows horizontally through the device. the droplets formed from the sprays which
A typical spray tower is shown in Figure fall to the bottom by gravity. The droplets
1.[810] remove the particles by scrubbing action,
the resulting slurry so formed is collected
A cyclonic spray chamber is similar to a at the bottom and sent for treatment for
spray tower with one major difference. removal of collected particles and treated
The gas stream is introduced to produce water is recirculated.
2
= Density of water droplet
= 8.811* *(v/V *D) *((y / ) D
di 2 2
4 D= Water droplet = 1 kg/m3
1/6*(y / ) ) D = water droplet size = 2 mm
2 2
when y < msc = flow of water = 0.01 m3/s
2 2 C= Cunnigatum correction factor =1.0
and
= Attachment coefficient =1.0
7.342* *v/V *D, when y =
di = 2 2 ps = Initial pressure drop = 200 N/m2
and V= viscosity of fluid = 1.55105 m2/s
di = 7.342* *v/V *D+(2*
)*(y2/D) Spray Tower Design
2/D)*(3+6*y2/D+4*(y2/D)2), when y2 Asc = Dc2/4
> 2 = 3.14 22/4
= 3.14 m2
= combined efficiency of all the
droplet Va = Q/Asc
= 6.94/3.14
1 (1 di)n
=2.21 m/s
Power requirement
Red = 1.020 107 (D)3/2
W= 9.807 (dxQsxAscxL) + QPs
= 1.020 107 (0.002) 3/2
Asc Q/V
= 912
where Ps = Pressure drop of water
2 V = Red V/D
droplets (N/m ) = 912 x 1.55 105
0.002
DESIGN OF SPRAY TOWER FOR V =7.02
VSK BASED CEMENT PLANT Vd = V Va
An effort has been made in the present = 7.06 2.21
paper by the Author to design a Spray = 4.85 m/s
Tower for a 100 TPD (Tonne per day) n = 1.5 m L [1/Q + 1/Asc (V
capacity cement plant based on Vertical s
Which is much below the standard of 250 4. Sun J., Liu B.Y.H., McMurry P.H., et
mg/m3 al. A method to increase control
Hence safe efficiencies of wet scrubbers for
Now Power requirement = W submicron particles and particulate
W= 9.807 xQsxAscx2 + Q Ps metals, J Air Waste Manag Assoc.
Asc Q/V 1994; 44: 2p.
= 9.087 1500 0.01 3.14 5 + 6.69 5. Control Techniques for Particulate
200 Emissions from Stationary Sources
3.14 6.94/7.06 Volume 1 (EPA - 450/3-81-005a,
= 2458 watts NTIS PB83-127498). U.S.
Environmental Protection Agency,
CONCLUSIONS Office of Air Quality Planning and
An effort has been made by the author to Standards. Research Triangle Park,
design Spray Tower as wet scrubbing North Carolina. September 1982.
device to control particulate matter 6. U.S. Environmental Protection
emitted from a 100 TPD capacity cement Agency. Compilation of Air Pollutant
plant based on Vertical Shaft Kiln Emission Factors (AP-42). Vol I., 5th
Technology (VSK) located in the State of Edn. Research Triangle Park, North
Rajasthan. Since the particulate matter Carolina: U.S. Environmental
from such VSK plants are having Protection Agency; 1995.
moistures, the selection of Spray Tower 7. Lerner B.J. Particulate wet scrubbing:
was considered suitable for the control of the efficiency scam, In: The
particulate matters. Hence, the Spray Proceedings of the A&WMA
Tower was designed which gives the Specialty Conference on "Particulate
efficiency to the tune of 95 percent by Matter; Health and Regulatory Issues
reducing the initial concentration of 2000 (VIP- 49). April 46, 1995,
mg/Nm3 to outlet concentration of 100 Pittsburgh, Pennsylvania, A&WMA,
mg/Nm3 of particulate matter after the Pittsburgh, Pennsylvania, 1995.
Spray Tower. This has resulted in bringing 8. Woodard K., U.S. Environmental
the pollutants level well below the Protection Agency. Source Category
prescribed limit of 250 mg/Nm3 and hence Emission Reductions with Particulate
found safe. Such Spray Towers can be Matter and Precursor Control
designed and installed in VSK based mini Techniques., Research Triangle Park,
cement plants to control particulate matter North Carolina (AQSSD/IPSG),
with in the permissible norms. under Work Assignment II-16 (EPA
Contract No. 68-03-0034),
REFERENCES Evaluation of Fine Particulate
1. Cooper C.D., Alley F.C. Air Pollution Matter Control. September 30, 1996.
Control: A Design Approach. 2nd 9. Vatavuk W.M. Estimating Costs of
Edn. Prospect Heights, Illinois: Air Pollution Control. Chelsea,
Waveland Press; 1994. Michigan: Lewis Publishers; 1990.
2. The Scrubber Manual (Revised). 10. Vatavuk W.M., Neveril R.B. Factors
Northbrook, Illinois: The McIlvaine for estimating capital and operating
Company; 1995. costs, Chem Eng. 1980, 15762p.
3. Perry R.H., Green D.W. Perry's 11. Schifftner K.C., Hesketh H.E. Wet
Chemical Engineers' Handbook. 6th Scrubbers: A Practical Handbook.
Edn. New York: McGraw- Hill Chelsea, Michigan: Lewis Publishers,
Publishing Company, Inc.; 1984. 1986.