Horizontal Cross-Flow (HFC) Scrubbers

Whether it be a small compact system for a laboratory or test plant or a large multi-stage complex system for a metallurgical processing facility Polimatrix has the necessary expertise and skills to offer our clients the right solution to their air pollution problems. Through our partnerships with various South African and International companies we are able to provide an economical, cost effective and reliable solution for the majority of odor and fume scrubbing applications.

Main areas of Application:

  1. Water Treatment
  2. Rendering Plants
  3. Waste plants
  4. Mineral Processing Plants (Mining and Industrial)
  5. Metal Finishing (Galvanizing, Anodizing, Plating etc)
  6. Chemical Production
  7. Research Laboratories
  8. Commercial and Industrial Laboratories
  9. Forensic Laboratories
  10. Designs to solve unique process applications

Polimatrix provides standard and custom Fume (Gas) Scrubbing solutions for various applications.

HCF Scrubbers are used where a small compact system is required and available height is limited. HCF scrubbers are also particularly suited to multi-stage odour scrubbing applications and larger scrubbing applications where the scrubber system must be installed indoors. HCF Scrubbers are also useful in applications requiring a very high liquid flow rate.

HCF scrubbers have a slightly lower efficiency than VCF scrubbers however this can be taken into account in the design. HCF scrubbers feature a horizontal inlet, a pre-wetting spray chamber, a packed bed chamber with liquid distributor above and a packing support below, a demister (droplet eliminator) chamber and a horizontal outlet to the fan. An HCF scrubber is usually rectangular in cross-section and sits on a rectangular base tank which contains the scrubber solution.

HCF Scrubbers are ideally suited for the following applications:

HCF Scrubbers are ideally suited for the following applications:

  • Compact Laboratory Gas Scrubbers
  • Indoor installations
  • HCL Scrubbing
  • Multi-stage odour removal
  • H2SO4 Scrubbing
  • Unique Features
  • Basic Components
  • Models
Unique Features

POLIMATRIX ALWAYS INSTALLS THE EXTRACTION FAN ON THE CLEAN SIDE OF THE SCRUBBER.

This ensures that the duct and column containing contaminated air are always under negative pressure so that no contaminated air can escape the system. It also increases the longevity of the fan and ease of fan maintenance resulting in lower operational costs.

ALL POLIMATRIX SCRUBBERS FEATURE A CARTRIDGE TYPE DEMISTER ARRANGEMENT.

This eliminates the need to remove the top or end section of a fume scrubber to access the demister for inspection and maintenance. This reduces the time required for maintenance and inspection and makes this a low safety risk operation. The maintenance personnel are not directly exposed to the fumes inside the scrubber.

UNIQUE IN-LINE DOSING MECHANISM.

Most Polimatrix scrubbers which require chemical dosing feature a unique proprietary in-line dosing mechanism which eliminates the need for chemical dosing pumps thus reducing the initial cost and the total long term operational cost due to lower power consumption and virtually maintenance free operation.

IN-LINE pH, ORP and CONDUCTIVITY MEASUREMENT.

Polimatrix utilizes an in-line bypass arrangement for the installation of pH, ORP and Conductivity sensors where these are required. This arrangement allows for accurate measurement of the scrubbing solution without the effect of “dead” areas within the tank and ensures that the scrubbing solution is always maintained within the optimum range. Eliminates the risk of leaks at threaded joints in the tank wall.

THERE ARE OTHER PROPRIETARY FEATURES WHICH GREATLY REDUCE MAINTENANCE AND INCREASE EASE OF OPERATION AND TOTAL EFFICIENCY SPECIFIC TO EACH SCRUBBER TYPE.

These features will be highlighted when Polimatrix discusses the application with each client.

Basic Components

Scrubber Base Tank

A rectangular base tank usually incorporated into the scrubber body on smaller versions or a separate flanged tank on larger versions.

Pre-Wetting Section. This section includes:

  • the Gas Inlet Nozzle (the extraction duct connects to this nozzle)
  • A Spray chamber. This saturates the incoming air stream using the scrubbing solution and ensures proper wetting of the packed bed on the inlet side.
  • The Gas Injection Support Plate. This supports the tower packing and is specially designed to provide a low pressure drop and maximum air diffusion across the packed bed.

Scrubbing Section. This section includes:

  • The Support Plate. This supports the scrubber packing and allows scrubbing solution to drain back to the tank.
  • A Top Sight Glass Nozzle. This sight glass nozzle serves as an inspection point at the top of the packed bed and as a packing filling point if the lid plate is not removed. In the case of multiple backed beds each packed bed will have such a nozzle.
  • The Liquid Distributor. Liquid distributors come in various forms depending on the contaminant being scrubbed, the size of the packing chamber and the liquid flow rate required. Their primary function is to evenly distribute the scrubbing solution over the packed bed to maximise wetting of the packing and to eliminate channelling (uneven flow through the packing resulting “dry” areas). The three main types of distributors are: Spray, Ladder and Trough types. There are many variations within and combination of these main types in order to maximise distribution. Correct liquid distribution is absolutely critical to a successful scrubber design.
  • The Tower Packing Material. This tower packing is of the “random” type in that the injection moulded or formed packing shapes are supplied in bulk and the chamber is filled to the required design height. The individual packing pieces are thus randomly arranged throughout the packed bed providing maximum liquid and gas distribution and thus maximum contact.
  • A Demister (Droplet Eliminator). This is the final stage in the scrubber column and is required to remove liquid droplets carried up by the air-stream. This is critical to reduce water losses through the scrubber and to extend the life of the scrubbing solution. The demister can be in the form of a knitted mesh pad (plastic or metallic) or a chevron plate configuration (plastic or metallic). Selection is based on each particular scrubber design. The most common demister used is a knitted mesh pad usually in Polypropylene.

Top Column Section, This section includes:

  • The Liquid Distributor. Liquid distributors come in various forms depending on the contaminant being scrubbed, the diameter of the column and the liquid flow rate required. Their primary function is to evenly distribute the scrubbing solution over the packed bed to maximize wetting of the packing and to eliminate channeling (uneven flow through the packing resulting “dry” areas). The three main types of distributors are: Spray, Ladder and Trough types. There are many variations within and combination of these main types in order to maximize distribution. Correct liquid distribution is absolutely critical to a successful scrubber design.
  • A Demister (Droplet Eliminator). This is the final stage in the scrubber column and is required to remove liquid droplets carried up by the air-stream. This is critical to reduce water losses through the scrubber and to extend the life of the scrubbing solution. The demister can be in the form of a knitted mesh pad (plastic or metallic) or a chevron plate configuration (plastic or metallic). Selection is based on each particular scrubber design. The most common demister used is a knitted mesh pad usually in Polypropylene.
  • Column Exhaust Nozzle. This nozzle is the outlet from the top of the column and is connected to the duct which is in turn connected to the extraction fan.

Extraction Fan

In the majority of cases this fan will be a COLASIT fan in a corrosion resistant thermoplastic material suited to the application. This fan will discharge into an exhaust stack.

Circulating Pump

This pump circulates the scrubbing solution and can also be used for blow-down (partial dumping of spent/contaminated scrubbing solution) and draining/transfer of the scrubbing solution. These pumps feature corrosion resistant materials of construction suited to each specific application.

Models

X-Vent Fume Scrubbers are available in the following standard sizes

  • X-Vent 1000 – Up to 1000m3h Scrubbing Capacity.
  • X-Vent 1500 – Up to 1500m3h Scrubbing Capacity.
  • X-Vent 2000 – Up to 2000m3h Scrubbing Capacity.
  • X-Vent 2500 – Up to 2500m3h Scrubbing Capacity.
  • X-Vent 3000 – Up to 3000m3h Scrubbing Capacity.
  • X-Vent 3500 – Up to 3500m3h Scrubbing Capacity.
  • X-Vent 4000 – Up to 4000m3h Scrubbing Capacity.
  • X-Vent 5000 – Up to 5000m3h Scrubbing Capacity.
  • X-Vent 6000 – Up to 6000m3h Scrubbing Capacity.
  • X-Vent 8000 – Up to 9000m3h Scrubbing Capacity.
  • X-Vent 10000 – Up to 10,000m3h Scrubbing Capacity.

Most custom designed equipment is for use in one-off applications. These applications require a unique understanding of the various engineering plastic materials, solid design experience and an intuitive understanding of the practical application of the equipment.

Open and honest communication with our clients ensures that there is a full understanding of what is expected and what can be achieved.

Such projects are uniquely challenging but in the end very rewarding for both the client and Polimatrix.

Contact Polimatrix to discuss your unique requirements and we will gladly assist you.

Enquire About This Product