Horizontal Gas Scrubber Without Flow Deflectors
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Solution Overview
Problem
Existing systems for removing gaseous pollutants, such as sulfur dioxide, from industrial waste gases are costly and inefficient, particularly due to the need for vertical scrubbing towers and flow deflection members that increase operational expenses and reduce pollutant removal rates.
Innovation Solution
A horizontal gas-liquid scrubber system without flow deflection members, utilizing spiral jet nozzles and a demister to create a substantially unrestricted gas-liquid contacting zone, achieving high sulfur dioxide removal rates with a small footprint and low liquid-to-gas ratios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vertical scrubbing towers are used to remove gaseous pollutants, then pollutant removal effectiveness is improved, but capital cost and operating expenses increase
Solution Approach 1:
The patent inverts the conventional vertical scrubbing tower configuration by using a horizontal scrubbing system. This inversion maintains pollutant removal effectiveness while significantly reducing capital cost and operating expenses, directly resolving the technical contradiction between removal effectiveness and system cost.
Solution Approach 2:
The patent transitions from a vertical dimension (traditional scrubbing towers) to a horizontal dimension (horizontal scrubbing system). This dimensional change allows the system to achieve the same pollutant removal function with reduced complexity and lower costs, addressing the contradiction between effectiveness and expense.
2Productivity
If flow deflection members are added to horizontal scrubbers to increase gas-liquid contact, then pollutant removal rate is improved, but pressure drop increases and operational complexity increases
Solution Approach 1:
The patent extracts and eliminates flow deflection members from the horizontal scrubbing system. By removing these components, the system achieves pollutant removal rates comparable to or exceeding traditional designs without the associated pressure drop and operational complexity, directly resolving the technical contradiction.
Solution Approach 2:
The horizontal scrubbing system relies on the natural interaction between gas flow and liquid spray to achieve effective pollutant removal. By eliminating flow deflection members, the system uses the inherent properties of the gas-liquid contact process itself to accomplish pollutant removal, reducing complexity while maintaining productivity.
3Device complexity
If horizontal scrubbers without flow deflection members are used, then operational costs and complexity are reduced, but pollutant removal rate may decrease
Solution Approach 1:
The patent optimizes parameters such as liquid-to-gas ratio, spray nozzle configuration, and horizontal contactor design to achieve high pollutant removal rates without flow deflection members. These parameter changes ensure that the simplified system maintains or improves productivity compared to traditional designs with deflection members.
Solution Approach 2:
The horizontal scrubbing system performs multiple functions effectively: pollutant removal, gas-liquid contact, and flow management all within a single simplified configuration. This multi-functionality allows the system to maintain high pollutant removal rates without requiring additional components like flow deflection members, resolving the contradiction between simplicity and effectiveness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system achieves sulfur dioxide removal rates of up to 95% with a low liquid-to-gas ratio, reducing operational costs and increasing efficiency compared to traditional systems.
Implementation Method 1
removing gaseous pollutants, such as sulfur dioxide, from a waste gas stream via a horizontal gas-liquid scrubber
Implementation Method 2
create a substantially unrestricted gas-liquid contacting zone
Implementation Method 3
a demister downstream of the liquid inlet manifold
Data Source
AI summary
Horizontal gas-liquid scrubbing systems and associated gas scrubbing methodologies are provided. In one embodiment, a horizontal duct scrubbing system includes a horizontally disposed housing having a waste gas inlet and a treated gas outlet, a liquid inlet manifold disposed within the horizontally disposed housing, the liquid inlet manifold comprising a plurality of nozzles oriented to spray a scrubbing liquor co-current to the flow of a gas stream flowing through the horizontally disposed housing, and a demister located proximal the treated gas outlet, where the horizontally disposed housing is substantially free of flow deflection members between the liquid inlet manifold and the demister. The gas stream may include sulfur dioxide, and the system may be capable of removing at least 71 vol. % sulfur dioxide from the gas stream.