Wet Scrubber Nozzle Density and Flow Control
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Solution Overview
Problem
Existing wet scrubbers for removing sulfur dioxide from process gases are costly, require tall structures, and struggle to efficiently control sulfur dioxide removal across varying load conditions, leading to excessive energy consumption and equipment wear.
Innovation Solution
A wet scrubber system with a spray level system featuring atomizing nozzles, operating in multiple modes (HC and LC) with adjustable nozzle density and liquid flow, allowing for optimized sulfur dioxide absorption efficiency and reduced tower height, utilizing independent control of tubular portions and nozzle distribution for precise sulfur dioxide management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the wet scrubber tower is made tall to increase sulfur dioxide removal capacity, then the sulfur dioxide removal efficiency is improved, but the investment cost and maintenance cost increase
Solution Approach 1:
The patent changes the operational parameters of the spray level system, specifically operating nozzles at high liquid flow rates (at least 10 m³/hour per nozzle) with a minimum active nozzle density of 0.7 nozzles per m². This parameter optimization enables high sulfur dioxide removal efficiency in a compact tower configuration, reducing the need for tall structures while maintaining productivity.
Solution Approach 2:
The patent implements dynamic control capabilities that allow the spray level system to operate in multiple modes (high capacity and low capacity modes). This dynamic operation enables the system to adapt to varying sulfur dioxide loads, maintaining high removal efficiency when needed while reducing energy consumption and equipment wear during lower load conditions, thereby improving the overall cost-effectiveness without requiring a tall tower structure.
2Productivity
If the sulfur dioxide removal capacity is increased to handle high sulfur dioxide loads, then the sulfur dioxide removal efficiency is improved, but the energy consumption and equipment wear increase
Solution Approach 1:
The patent implements dynamic control capabilities that allow the spray level system to operate in multiple modes (high capacity and low capacity modes). This dynamic operation enables the system to adapt to varying sulfur dioxide loads, maintaining high removal efficiency when needed while reducing energy consumption and equipment wear during lower load conditions.
Solution Approach 2:
The patent optimizes operational parameters including liquid flow rates per nozzle, active nozzle density, and process gas vertical velocity. By carefully controlling these parameters, the system achieves high sulfur dioxide removal capacity while minimizing excess energy consumption and equipment wear through efficient operation at the optimal parameter boundaries.
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 efficient sulfur dioxide removal with reduced energy consumption and equipment wear by optimizing nozzle density, liquid flow, and operational modes, enabling a shorter scrubber tower and precise control over sulfur dioxide absorption capacity.
Implementation Method 1
The absorption liquid is supplied to the spray level system so as to flow therethrough to the atomizing nozzles and be sprayed from the atomizing nozzles as a multitude of absorption liquid droplets
Implementation Method 2
The limestone absorption liquid droplets capture the sulfur dioxide of the process gas
Data Source
AI summary
A wet scrubber (1) and a method of using the wet scrubber to clean a process gas containing sulphur dioxide comprising at least one spray level system (20) with atomizing nozzles (38) to which an absorption liquid is supplied for atomization by the nozzles (38). The method comprises operating the spray level system (20) in at least a first operating mode with an active nozzle density of at least 0.7 nozzles/m2, an absorption liquid flow of at least 10 m3/hour per nozzle and a Total Flow of at least 30 m3/hour/m2.