Multi-level flooded scrubber heads for multi-pollutant removal
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Solution Overview
Problem
Current scrubbing technologies are limited in efficiently removing multiple contaminants from gas streams due to single interaction zones and lack of flexibility in using different neutralizing reagents, which is inadequate for meeting stringent emission limits.
Innovation Solution
A vertically-oriented scrubber apparatus with horizontally-oriented flooded scrubbing heads that create multiple interaction zones, allowing different scrubbing fluids to be used at each level, supported by a pressure differential that accelerates gas through ports to create turbulent reaction zones for enhanced contaminant removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single interaction zone is used in traditional scrubbing systems, then the system structure is simple, but the removal efficiency of multiple contaminants is insufficient
Solution Approach 1:
The scrubber is divided into multiple interaction zones (first, second, and third zones) stacked vertically, each capable of removing different contaminants. This segmentation allows simultaneous removal of multiple pollutants through different chemical mechanisms (acid gas removal, particulate matter removal, and additional polishing) within a single apparatus, thereby improving overall removal efficiency while maintaining a compact integrated structure.
Solution Approach 2:
The patent transitions from a single horizontal interaction zone to multiple vertically-stacked interaction zones. This dimensional change from 2D to 3D utilization of space enables the system to handle multiple contaminant removal processes simultaneously, increasing productivity without proportionally increasing the device footprint.
2Adaptability or versatility
If the same neutralizing reagent is used throughout the scrubber, then the system operation is simple, but the adaptability to remove different contaminants is limited
Solution Approach 1:
Each interaction zone is equipped with its own scrubbing fluid distribution system that can receive and circulate different neutralizing reagents tailored to the specific contaminants targeted in that zone. For example, the first zone may use alkaline reagents for acid gas removal while the second zone uses different reagents for particulate matter removal. This local customization of scrubbing fluids enhances adaptability to various contaminants while the independent circulation systems maintain operational simplicity.
Solution Approach 2:
The scrubber apparatus is designed with multiple interaction zones that can simultaneously perform different removal functions (acid gases, particulate matter, and other contaminants) using different neutralizing reagents. This multi-functional design allows a single system to adapt to diverse contaminant compositions in flue gas, enhancing versatility without requiring multiple separate scrubbing units.
3Productivity
If multiple traditional scrubbing units are used to remove different contaminants, then the removal coverage is comprehensive, but the capital cost and footprint are large
Solution Approach 1:
The patent combines multiple scrubbing functions (acid gas removal, particulate matter removal, and additional contaminant removal) into a single integrated apparatus with vertically-stacked interaction zones. This merging of previously separate scrubbing units into one compact system maintains comprehensive removal coverage while significantly reducing the capital cost and physical footprint compared to using multiple independent scrubbing units in series.
4Adaptability or versatility
If multiple traditional scrubbing units are used to remove different contaminants, then the removal coverage is comprehensive, but the capital cost is high
Solution Approach 1:
The patent integrates multiple contaminant removal capabilities into a single apparatus with multiple interaction zones, each equipped with its own scrubbing fluid distribution and collection systems. This consolidation eliminates the need for multiple separate scrubbing units, thereby reducing capital costs while maintaining the ability to remove diverse contaminants through different neutralizing reagents in each zone.
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
This approach enables efficient removal of multiple pollutants in a single pass with the ability to use different neutralizing reagents at each level, improving overall removal efficiency, reducing capital costs, and providing a smaller footprint compared to traditional systems.
Implementation Method 1
A pressure differential across the scrubbing head accelerates the gas through the ports and creates a turbulent reaction zone within the scrubbing fluid that improves the removal of particulate matter and provides a reaction zone for chemical interactions
Implementation Method 2
The pressure differential across the scrubbing head accelerates the gas through the ports and creates a turbulent reaction zone within the scrubbing fluid
Implementation Method 3
The interaction between the flue gas and the sprayed slurry is general in nature and is not as efficient or effective as forced wet scrubbing systems
Implementation Method 4
distribute the slurry into the flue gas to remove sulphur dioxide, hydrogen chloride and hydrogen fluoride through reaction with the slurry to form calcium based compounds
Data Source
Figure 1A~1C
Figure 2
Figure 3
AI summary
The present invention relates to a wet scrubbing head design whose horizontal orientation and flooded operating characteristics allow complete wet scrubbing at multiple interaction zones each with different neutralizing reagents. The capacity for multiple scrubbing zones improves overall pollutant removal efficiency by adding polishing interaction zones for particulate and acid gas removal systems or by broadening the range of pollutants being removed by operating with a different neutralizing solution or a combination of these operating conditions. The flooded head design approach allows a single scrubber to accomplish high levels of removal efficiency for multiple pollutants which reduces cost, and footprint interaction complexities of the multiple devices it replaces. Flooded head scrubbers have application in combustion flue gas pollutant removal and in chemical and industrial applications that generate dust, odors and acid gases.