Scrubber Manufacturing

Scrubbers are important equipment used in industrial facilities to control air pollutants and reduce emissions. Scrubber manufacturing is a meticulous process that requires complex engineering procedures and specialized materials.

Scrubber systems are air pollution control equipment that effectively treat harmful particulates, gases, and chemical components in flue gases before they are released into the atmosphere in industrial facilities. They are especially used in sectors such as chemical, petrochemical, fertilizer, energy production, waste treatment, metallurgy, and textiles in order to comply with environmental regulations, increase occupational safety, and meet legal emission limits. Scrubber manufacturing is a multi-stage process that combines process design, material engineering, and automation, requiring special engineering calculations depending on system flow rate, gas composition, operating conditions, and the pollutants to be removed. In this article, we examine every stage of scrubber production in detail, reviewing all steps from design to testing from a technical perspective.

Scrubber systems are industrial air cleaning equipment that prevent harm to the environment and human health by treating harmful chemicals, particulates, dust, and vapors contained in gases released into the atmosphere from industrial facilities. These systems, which can operate wet or dry, provide a highly efficient solution in cases where traditional filtration methods are insufficient. Scrubber systems are specially designed according to the flow rate, temperature, content of process gases, and the type of pollutants that need to be removed. Therefore, different dimensions, materials, and system architectures are applied for each facility.

Scrubber systems are generally classified according to their operating principle and structural design:

WET SCRUBBER

Polluted gases are passed through a medium in which liquid circulates. Harmful substances in the gas are typically captured using water or chemical solutions. Wet scrubbers are especially used for the treatment of acidic, alkaline, and water-soluble gases.

Subtypes:

• Venturi Scrubber: Provides particulate removal through high-velocity gas flow and liquid injection.

• Packed Bed Scrubber: Packing materials placed inside the scrubber body increase liquid–gas contact surface area, improving efficiency.

• Spray Scrubber: Cleaning is achieved by contacting gas with rotating or sprayed liquid inside the system.

DRY SCRUBBER

Pollutants are removed by chemical reaction with solid adsorbent materials (e.g., activated carbon, soda ash). Since no liquid is used, maintenance requirements are lower, and they are preferred in processes sensitive to moisture.

HORIZONTAL AND VERTICAL SCRUBBERS

• Vertical Scrubbers: Generally preferred in areas where space saving is not critical. Gas flow moves upward while liquid flows downward by gravity. Spray systems or packed sections operate from top to bottom. They are effective in high-flow processes.

• Horizontal Scrubbers: Used in areas with limited ceiling height or where horizontal installation is required outdoors. Their compact design allows easy installation in limited spaces.

Who Needs Them?

The main groups that require scrubber systems include:

• Production facilities subject to environmental regulations

• Companies located in Organized Industrial Zones (OIZ)

• Organizations seeking emission permits and environmental licenses

• Process owners requiring flue gas treatment

• Industrial facilities and biogas plants involved in waste management

• Projects subject to Environmental Impact Assessment (EIA) reports

Chemical Industry: Treatment of acidic and alkaline gases (removal of gases such as HCl, SO₂, NH₃).

Petrochemical: Removal of hydrocarbon vapors and volatile organic compounds (VOCs).

Power Plants: Control of ash, SOx, and NOx emissions in flue gases.

Fertilizer Plants: Capture of harmful gases such as ammonia (NH₃) and nitric acid vapors.

Metal Processing: Cleaning of corrosive gases originating from acid baths (e.g., HCl vapor).

Waste Incineration Plants: Treatment of dioxins, furans, and other toxic components before atmospheric release.

Food and Pharmaceutical Production: Control of organic solvents, evaporating chemicals, and odors.

Treatment Plants: Removal of odor and gas emissions originating from wastewater and sludge processes.

Additionally, scrubber systems are of great importance in terms of occupational health and safety (OHS). By preventing harmful gases from leaking into working environments, they reduce toxic exposure and create safer workplaces.

Below is a detailed overview of scrubber manufacturing:

1. Design and Engineering
The scrubber manufacturing process begins with the design and engineering phase. Since scrubbers can use different cleaning methods to remove air pollutants, each scrubber design may be unique. The design process is customized according to facility requirements, pollutant types, and emission targets.

2. Material Selection
Scrubbers are typically manufactured from corrosion-resistant materials because they operate in contact with polluted gases and chemicals. Stainless steel, fiberglass-reinforced plastic (FRP), polypropylene, and glass fiber materials are commonly used. Material selection is critical for durability, efficiency, and long service life.

3. Manufacturing Process
Scrubber manufacturing involves various production stages such as cutting, forming, welding, assembly, and testing. Cutting and shaping form the main body of the scrubber. Welding joins components and ensures leak-tightness. During assembly, additional parts and components are installed. Finally, the scrubber undergoes testing and quality control.

4. Cleaning System
Scrubbers remove air pollutants using different cleaning systems. Wet scrubbers clean pollutants by washing them with water or chemical solutions. Dry scrubbers remove pollutants through adsorption or chemical reactions. Each cleaning system is designed to effectively control specific types of pollutants.

5. Painting and Coating
Scrubbers are usually painted or coated to protect them against external conditions. Painting protects metal surfaces from corrosion and provides an aesthetic appearance. Coating protects internal surfaces and enhances sealing performance. Painting and coating methods are selected according to operating environment and conditions.

6. Testing and Approval
In the final stage of scrubber manufacturing, the system undergoes various tests and quality control checks. Pressure tests, leak tests, and performance tests are conducted to ensure safe and effective operation. Once compliance with relevant regulations and industry standards is confirmed, the scrubber is ready for use.

Scrubber manufacturing plays a critical role in controlling air pollutants and reducing environmental impact in industrial facilities. Proper design, material selection, and manufacturing processes are essential for building an effective scrubber system.