Rotary Atomizer Gas Scrubber for Ultrafine Particle Removal
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Solution Overview
Problem
Conventional gas scrubbers are ineffective in removing ultrafine particles from waste gases, especially those with diameters less than 1 μm, due to their large size, weight, and high pressure drop, making them difficult to transport and install, and they often require additional media like compressed air for atomization.
Innovation Solution
A compact gas scrubber design featuring a rotary atomizer with a circular plate member and alternating rotor-stator arrays that generates turbulence and fine droplets without the need for high pressure or compressed air, using a shared shaft for rotor arrays and a motor with high power density for efficient operation, and incorporating baffle plates for enhanced separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional gas scrubbers are used to remove ultrafine particles, then particle removal is attempted, but the device size and weight become large making transport and installation difficult
Solution Approach 1:
The gas scrubber is divided into multiple functional sections: a pre-separation section with a pre-separator for larger particles, and a fine separation section with a centrifugal separator for ultrafine particles. This segmentation allows each component to be compact while collectively achieving high removal efficiency, avoiding the need for a single large heavy unit.
Solution Approach 2:
The pre-separator and centrifugal separator are arranged in a nested configuration where the pre-separator handles initial particle removal and the centrifugal separator is positioned to handle the remaining ultrafine particles. This nested arrangement maximizes space utilization and reduces the overall device footprint and weight.
2Reliability
If conventional gas scrubbers are used to remove ultrafine particles, then particle removal is attempted, but the device size becomes large making transport and installation difficult
Solution Approach 1:
The gas scrubber is divided into multiple functional sections: a pre-separation section with a pre-separator for larger particles, and a fine separation section with a centrifugal separator for ultrafine particles. This segmentation allows each component to be compact while collectively achieving high removal efficiency, avoiding the need for a single large heavy unit.
Solution Approach 2:
The centrifugal separator utilizes rotational motion in a third dimension to achieve particle separation, rather than relying solely on linear flow paths. This dimensional change allows for more compact device design as the separation process occurs through rotation rather than extended linear travel.
3Reliability
If conventional gas scrubbers are used to atomize liquid, then atomization is achieved, but high pressure and additional media like compressed air are required
Solution Approach 1:
The patent replaces conventional high-pressure mechanical atomization systems with a centrifugal atomization system. Liquid is fed onto a rotating centrifugal disk where centrifugal force naturally atomizes the liquid into fine droplets. This substitution eliminates the need for high-pressure pumps and compressed air, significantly reducing energy consumption while maintaining effective atomization quality.
Solution Approach 2:
The centrifugal separator and atomizer are designed to utilize the kinetic energy of the rotating components themselves to perform separation and atomization functions. The rotation of the centrifugal disk provides both the separation force for particles and the atomization force for liquid, making the system self-sufficient without requiring additional energy inputs from external compressed air or high-pressure systems.
4Reliability
If conventional gas scrubbers are used to remove particles, then some particle removal is achieved, but pressure drop becomes high reducing system efficiency
Solution Approach 1:
The gas scrubber is divided into multiple functional sections: a pre-separation section with a pre-separator for larger particles, and a fine separation section with a centrifugal separator for ultrafine particles. By segmenting the removal process, each section handles a specific particle size range, allowing optimized low-pressure-drop designs for each stage rather than one high-pressure-drop stage handling all particles.
Solution Approach 2:
The patent replaces conventional high-pressure mechanical atomization systems with a centrifugal atomization system. Liquid is fed onto a rotating centrifugal disk where centrifugal force naturally atomizes the liquid into fine droplets. This substitution eliminates the need for high-pressure pumps and compressed air, significantly reducing energy consumption while maintaining effective atomization quality.
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 design achieves improved particle removal efficiency with reduced pressure drop and size, allowing for more compact and efficient waste gas treatment systems that can be easily integrated into existing systems, while minimizing the formation of new droplets and reducing maintenance costs.
Implementation Method 1
The gas scrubber has an outlet nozzle for purposes of spraying a liquid, especially a cleaning liquid or a scrubbing liquid, onto the plate member in order to create a turbulent mixture consisting of waste gas and liquid in front of the plate member
Implementation Method 2
The gas scrubber has at least one inner rotor array and one outer rotor array arranged at a distance from the inner rotor array, both of which can be rotated around the axis. Moreover, there is at least one inner stator array and one outer stator array arranged at a distance from the inner stator array
Data Source
AI summary
A gas scrubber and a waste gas treatment system with a gas scrubber for removing particles from a waste gas has a housing with a waste gas inlet and a waste gas outlet. The gas scrubber with a rotary atomizer is arranged vertically and centrally in the housing downstream from a wet scrubber. The housing may be a pipe or tube of a same or substantially a same diameter in both the wet scrubber section and the gas scrubber section. An outlet nozzle sprays a cleaning or scrubbing liquid onto a cup-shaped rotor with a tear-off edge of the rotary atomizer to create a turbulent mixture of waste gas particles and liquid. Liquid droplets with entrained particles are propelled from the rotor onto the outer wall of the housing and/or are captured by a droplet separator. The rotor is turned by a spindle motor aligned centrally in the housing.