Description
Product Overview
Industrial packed bed wet scrubber with high-surface-area packing media for maximum gas absorption efficiency. Where spray-only towers achieve 90-95% single-stage removal, a packed bed design pushes past 98% for highly soluble gases — enabling compliance with the strictest emission limits without adding a second tower. Air volume 100-150000 m3/h, custom-configured to your gas composition and discharge target.
| Application | High-efficiency acid gas and soluble pollutant removal (HCl, HF, NH3, SO2, H2S, Cl2, NOx) |
| Material | Virgin PP, FRP, or SS — matched to gas corrosivity and temperature |
| Packing options | PP Pall rings, Tellerette rings, Raschig rings, structured packing, ceramic saddles |
| Air volume | 100 – 150,000 m3/h single tower; parallel for larger flows |
| Efficiency | over 98% for soluble gases (HCl, HF, NH3); over 95% for moderately soluble (SO2, Cl2) |
| Lead time | Standard 15-25 days; large custom 25-40 days |
| Warranty | 12 months structure; packing media warranted per application |
Why a Packed Bed Scrubber
A spray tower relies on droplet surface area — fine, but limited. A packed bed adds structured or random media with 90-350 m2 of surface area per cubic meter of packing. That’s the difference between a scrubber that just meets the spec and one that beats it with room to spare.
Packed beds are the right call when:
- Your emission limit is tight. If the regulation says under 5 PPM HCl and a spray tower gets you to 6-8 PPM, a packed bed gets you to 2-3 PPM. The extra mass transfer stages inside the packing buy you the margin.
- Gas solubility is low. SO2 is about 40x less soluble in water than HCl — you need the extra contact time and surface area that packing provides. Open spray towers struggle here; packed beds don’t.
- Turndown matters. Production lines don’t always run at 100 percent. At partial gas flow, spray nozzle patterns collapse and efficiency plummets. Packed beds maintain liquid distribution across the full operating range because the media itself holds and redistributes the liquid film.
- Footprint is constrained. A packed tower handles the same air volume in a 30-40 percent smaller diameter than an open spray tower — the packing’s surface area does the work that tower height would otherwise need.
Read our guide: Scrubber Packing Media Selection
Why Xicheng
16 years, 2600+ systems shipped worldwide. Packed bed scrubbers live or die by their packing selection and liquid distribution design. Get either wrong, and you’ve built an expensive vessel that channels gas straight through the packing without actually scrubbing it. We’ve seen competitors’ towers where 40 percent of the gas bypasses the packed section entirely because the liquid distributor wasn’t matched to the packing type. We don’t make those mistakes.
- Packing matched to your gas, not our inventory. We stock six packing types in multiple sizes and don’t push one over the other. Pall rings for general acid gas. Tellerette rings for high liquid rate. Structured packing for lowest pressure drop. Ceramic saddles for high-temperature or fluoride service. We size the packing type, size, and bed depth to your specific Henry’s law constant and mass transfer coefficient — not to what’s sitting on the shelf.
- Liquid distribution that actually distributes. The most common packed bed failure mode is maldistribution: liquid finds a path, gas finds the dry spots, and efficiency collapses. We use computational fluid dynamics to verify distributor coverage at your turndown ratio before cutting metal. For beds over 2 meters diameter, we use multi-point spray headers with overlapping coverage zones — not a single nozzle hoping for the best.
- Packing that doesn’t collapse. Inexpensive packings can settle, crush, or channel within the first year of operation — especially under the weight of scale or bio-growth. We specify packing with verified crush strength and void fraction stability, and we install it in segmented trays with intermediate support grids. When it’s time to replace packing in 3-5 years, you pull individual trays, not the entire bed.
Tell us your gas composition and emission target: xicheng023@outlook.com. We’ll tell you honestly whether a packed bed is worth the additional cost over a spray tower for your specific case — because we build both.
Key Specifications
| Model No. | XC-1 |
| Material | New PP (Polypropylene) Material |
| Function | Waste Gas Treatment (Chemical Treatment) |
| Purifying Technology | HEPA |
| Automation | Automatic |
| Service Life | 8-10 Years |
| Color | Beige / Dark Grey |
| Environmental Temperature | Normal Temperature |
| Brand / Origin | Xicheng / China |
Core Advantages
- High Purification Efficiency: Delivers high dust removal and desulfurization efficiency. Effectively removes various industrial organic and inorganic waste gases, including HCL, HF, NH3, H2SO4, CrO3, HCN, NAOH, H2S, and HCHO.
- Durable and Premium Material: Manufactured using new PP material, offering excellent anti-corrosion and wear-resistant properties, ensuring a long service life and high cost-performance.
- Compact Design and Low Consumption: Features a simple structure that occupies minimal space. Operates stably with low energy consumption.
- Easy Installation and Operation: Improved with a floating packing layer, it is highly practical, easy to install, and simple to operate, making it ideal for acid-base waste gas treatment.
- Flexible Customization and After-Sales Service: Supports personalized customization; sizes and specifications can be adjusted according to customer needs and drawings. Comes with a 1-year warranty (free replacement of damaged consumables), professional installation guidance from engineers, and comprehensive overseas after-sales support.
Certifications and Compliance
- CE Certified – Wet Scrubber, Exhaust Fan, Air Valve
- RoHS Compliant – Adsorption Tower materials
- ISO 9001 – Quality Management System
- ISO 14001 – Environmental Management System
- SGS Tested – PP Sheet, PPS Flame Retardant Sheet, PP Pipe, PPS Flame Retardant Pipe, PVC Sheet
- Design Compliance – Systems designed to meet EU Industrial Emissions Directive (2010/75/EU) and US EPA Chemical Manufacturing NESHAP per project requirements
Packing Media Options
| Media type | Surface area (m2/m3) | Best for | Pressure drop |
|---|---|---|---|
| PP Pall rings 25mm | 210 | General acid gas (HCl, H2SO4); best balance of efficiency vs pressure drop | Low-Medium |
| PP Pall rings 50mm | 110 | High-dust gas streams; lower fouling risk | Low |
| PP Tellerette rings | 180 | High liquid loading; good turndown; resists flooding | Medium |
| PP Raschig rings | 90-120 | Economy option; lower efficiency but lowest cost per m3 | Low |
| PP structured packing | 250-350 | Maximum efficiency; lowest pressure drop; highest cost | Very Low |
| Ceramic saddles | 150-250 | High-temperature or fluoride-containing gas | Medium-High |
Not sure which packing fits your application? Scrubber Packing Media Selection Guide walks through the decision step by step.
Model Selection Table
Standard model range — all dimensions in millimeters. Custom sizes outside this range available on request.
| Air Volume (m3/h) | Diameter (mm) | Thickness (mm) | Drain Outlet | Water Tank (mm) | Inlet/Outlet Pipe | Pump (kW) | Air Resistance (Pa) |
|---|---|---|---|---|---|---|---|
| 3,000 | 800 | 8 | DN32 | 600x700xH700 | 315 | 0.75 | 500 |
| 5,000 | 1,000 | 8 | DN40 | 600x800xH700 | 400 | 1.5 | 500 |
| 8,000 | 1,200 | 8 | DN40 | 600x1000xH700 | 500 | 2.2 | 500 |
| 10,000 | 1,500 | 10 | DN40 | 700x1000xH700 | 550 | 2.2 | 500 |
| 12,000 | 1,600 | 10 | DN50 | 700x1000xH700 | 600 | 3.75 | 500 |
| 15,000 | 1,800 | 10 | DN50 | 700x1200xH700 | 650 | 3.75 | 500 |
| 20,000 | 2,000 | 10 | DN50 | 700x1200xH700 | 750 | 5.5 | 500 |
| 25,000 | 2,200 | 10 | DN50 | 700x1200xH700 | 950 | 5.5 | 600 |
| 30,000 | 2,500 | 12 | DN65 | 700x1200xH700 | 1,000 | 5.5 | 600 |
| 35,000 | 2,700 | 12 | DN65 | 1000x700xH700 | 1,100 | 7.5 | 600 |
| 40,000 | 2,900 | 12 | DN65 | 1000x700xH700 | 1,200 | 7.5 | 600 |
| 45,000 | 3,000 | 12 | DN65 | 1000x700xH700 | 1,250 | 7.5 | 600 |
Custom sizes: Up to 215,000 m3/h air volume. Contact our engineers for sizing beyond the standard model range — xicheng023@outlook.com.
Technical Specifications
| Air volume | 100 – 150,000 m3/h (single tower) |
| Material | Virgin PP (0.92 g/cm3); FRP overwrap for outdoor/UV duty; SS304/316 for high-temp |
| Wall thickness | 8 – 25 mm (per size and material) |
| Tower diameter | 300 mm – 4,500 mm; sized for 1.0-2.5 m/s superficial gas velocity through packing |
| Structure | Vertical: gas inlet – sump – packing support grid – packed bed(s) with intermediate redistribution – liquid distributor – demister – gas outlet |
| Packing bed depth | 0.5 – 3.0 meters per stage; 1-3 stages; deeper beds for low-solubility gases |
| Liquid distributor | Multi-point spray headers with overlapping coverage; drip-point density over 60 points/m2 for structured packing |
| Spray system | PP/FRP full-cone nozzles; 0.3-0.5 MPa operating pressure; anti-clog design |
| Recirculation pump | Chemical-duty PP/FRP centrifugal, 1.5-18 kW (per stage) |
| Demisting | PP chevron or mesh pad; outlet moisture under 75 mg/Nm3 |
| Max inlet temp | 60 C standard PP / 80 C reinforced PP / 120 C FRP / 200 C+ with ceramic packing |
| Particle tolerance | under 100 mg/m3 with 50mm packing; under 50 mg/m3 with structured packing; pre-scrubber for higher loads |
| Purification efficiency | over 98% for highly soluble gases (HCl, HF, NH3); over 95% for moderately soluble (SO2, Cl2, H2S) |
| Turndown ratio | 4:1 (25-100% design flow) with maintained efficiency |
| Pressure drop | 200-800 Pa per meter of packing (media-dependent) |
| Scrubbing media | NaOH, KOH, Na2CO3, H2SO4, NaOCl, water — per your gas chemistry |
| Design standard | GB/T 13931-2017; CE certified. See US EPA Chemical Manufacturing NESHAP for applicable emission requirements. |
| System includes | Tower body + packing support grid + packing media (per spec) + liquid distributor + demister + sump + recirculation pump + level control; optional pH/dosing/Modbus RTU |
Custom options: Multi-stage with intermediate scrubbing chemistries . FRP overwrap for outdoor installation . Integrated quench for hot gas . Ceramic internals for fluoride service . Explosion-proof configuration . Containerized skid package.
Gas Purification Rate
| Gas Name | Formula | Cleaning Agent | Removal Efficiency |
|---|---|---|---|
| Hydrochloric Acid | HCl | H2O | 90-95% |
| NaOH | 95-99% | ||
| Hydrofluoric Acid | HF | H2O | 90-95% |
| NaOH | 95-99% | ||
| Ammonia Gas | NH3 | H2O | 90-95% |
| H2SO4 | over 99% | ||
| Cyanic Acid | HCN | NaOH | 90-98% |
| Sulfur Dioxide | SO2 | NaOH | 95-99% |
| Chlorine | Cl2 | NaOH | 95-99% |
| Hydrogen Sulfide | H2S | NaOH | 95-99% |
| Sulfuric Acid | H2SO4 | H2O | 95-99% |
| Chromic Acid | CrO3 | H2O | 95-99% |
| Sodium Hydroxide | NaOH | H2O | 95-99% |
| Nitric Acid | HNO3 | H2O | 90-99% |
Not sure which configuration fits your gas? Gas Scrubber Selection Guide (Multi-Stage)
PP vs FRP material decision: PP vs FRP Wet Scrubber Comparison
How to Order
- You send – Gas composition and inlet concentration, air volume (m3/h), emission limit (mg/Nm3 or PPM), site conditions (temperature, available footprint, indoor/outdoor)
- We analyze – Mass transfer calculation to determine packing type, bed depth, and liquid-to-gas ratio. If your gas has low solubility, we’ll confirm packed bed is the right call and size accordingly.
- We design – Tower diameter, packing configuration, distributor layout, pump selection, P and ID drawing with mass balance
- You approve – Technical proposal with performance guarantee for your specific gas at your specific inlet concentration, 3D model, and pricing
- We build – 15-25 days standard, 25-40 days large custom. Hydrostatic test, distributor spray pattern test, and quality inspection before shipment
- We ship – Packing media shipped separately in sealed bags to prevent contamination. Installation drawings, packing installation guide, and remote commissioning support included.
Contact our engineers at xicheng023@outlook.com or WhatsApp +86 18927456906 — proposal within 24 hours.
Complete Your System
- Industrial Spray Scrubber Tower – If your gas is highly soluble and emission limits are moderate, a spray tower may be more cost-effective. We’ll help you decide.
- Horizontal Wet Scrubber – Packed bed in horizontal layout for low-headroom applications
- PP Exhaust Duct and Fittings – Corrosion-resistant ductwork sized to tower connections
- PP/FRP Centrifugal Fan – Matched to packed bed pressure drop (typically 800-2500 Pa for multi-stage)
- Scrubber Packing Media – Replacement packing for existing towers; all types in stock
Global Shipping
We ship worldwide with documented export experience across:
- Southeast Asia: Malaysia, Singapore, Indonesia, Philippines, Thailand, Vietnam, Myanmar, Cambodia
- South Asia: India, Pakistan, Bangladesh, Sri Lanka
- Middle East: UAE, Saudi Arabia, Qatar, Oman, Kuwait, Bahrain, Israel
- Africa: Kenya, Nigeria, South Africa, Egypt, Ethiopia, Tanzania, Ghana
- Europe: Germany, UK, France, Italy, Spain, Netherlands, Poland, Turkey, Russia
- Americas: USA, Canada, Mexico, Brazil, Chile, Colombia, Argentina
- Oceania: Australia, New Zealand
Sea freight standard; air freight for small units and replacement packing. Export documentation including Certificate of Origin, packing list, bill of lading, and fumigation certificate provided with every shipment.
FAQ
When should I choose a packed bed over a spray tower?
Three situations: (1) your emission limit is very tight and you need that extra 3-5 percentage points of efficiency, (2) your target gas has low water solubility (SO2, NOx, Cl2, H2S) and needs the extra residence time that packing provides, or (3) your gas flow varies significantly and you need consistent efficiency across a wide turndown range. If none of these apply, a spray tower is usually the more economical choice. Contact us with your gas data and we’ll give you an honest recommendation.
How often does the packing need to be replaced?
Typically 3-5 years for PP packing in clean gas service. Shorter (1-3 years) if your gas carries particulates, scale-forming minerals, or biological growth. We design the packing support system so individual trays can be replaced without disturbing the entire bed. Packing replacement is a routine service item — we stock replacement media and can ship within 3-5 days.
What happens if the packing fouls or channels?
Fouling shows up as increased pressure drop and decreased removal efficiency. Common causes: particulate buildup (fix with pre-filtration), calcium scale from hard water makeup (fix with water softener or chemical descaler), or bio-growth (fix with intermittent biocide dosing in the recirculation loop). Read our troubleshooting guide: Common Wet Scrubber Problems.
Can you retrofit packing into an existing spray tower?
It depends on the tower. The vessel needs a packing support grid (not present in spray-only towers), a liquid distributor above the packing, and sufficient straight height to accommodate the packed bed depth. Some towers can be retrofitted; many cannot. Send us your existing tower drawings and we’ll assess feasibility — retrofit is often 40-60 percent cheaper than a new tower if the vessel can accommodate it.
Gas Scrubber Operating Cost Guide
Acid Scrubber Maintenance Guide
Learn More on Our Blog
Sizing and Design
- Scrubber Packing Media Selection
- How to Size a PP Wet Scrubber
- Scrubber Sizing Calculation and Design Examples
- Acid Scrubber System Design Engineering
