Description
XiCheng EP is a professional manufacturer of PP spray towers (also known as wet scrubbers) designed for efficient treatment of corrosive industrial waste gases. Our polypropylene spray towers are widely used in chemical plants, electroplating workshops, pharmaceutical factories and semiconductor facilities to remove acid mist, alkaline fumes, chlorine gas and other harmful pollutants.
This model is specially engineered for chlorine leakage emergency treatment, featuring an automatic closed-loop system that ensures 100% harmless disposal of leaked chlorine without any atmospheric emissions. Made from 100% virgin PP material, it offers exceptional chemical resistance (pH 1-14) and a service life of over 15 years in harsh industrial environments.
All our spray towers are fully compatible with our PP ventilation duct systems and anti-corrosion pipe fittings, providing a complete turnkey solution for your waste gas treatment needs.
Core Advantages of XiCheng PP Spray Towers
1. Specialized Chlorine Treatment Capability
- Closed-loop emergency system: Forms a sealed treatment circuit with chlorine cylinder rooms, preventing any chlorine escape to the atmosphere
- Self-regenerating absorption system: Absorbent is continuously recycled and regenerated, eliminating the need for frequent replacement
- Dynamic absorption capacity: Treatment efficiency increases as ferric chloride concentration rises, handling unexpected large-scale leaks
2. Superior Material & Construction
- 100% virgin polypropylene construction: Resists corrosion from over 150 chemicals including strong acids, alkalis and organic solvents
- One-piece welded structure: No leakage points, ensuring long-term reliable operation
- UV-stabilized material: Suitable for both indoor and outdoor installations
3. High Efficiency & Low Operating Cost
- Countercurrent flow design: Maximizes gas-liquid contact time, achieving up to 99% removal efficiency for soluble gases
- Low energy consumption: Optimized spray nozzle and fan design reduce power usage by 20% compared to conventional models
- Minimal maintenance: No moving parts inside the tower, only periodic pump and nozzle inspections required
4. Intelligent Automation
- Automatic emergency activation: Triggers instantly when chlorine leakage alarms detect gas presence
- Real-time monitoring: Equipped with pH sensors, liquid level sensors and pressure gauges for continuous system status tracking
- Remote control capability: Allows operators to monitor and control the system from a central control room
Waste Gas Treatment Principles
General Acid/Alkali Waste Gas Treatment
For most industrial applications, our PP spray towers use neutralization reactions to remove harmful pollutants:
- Acid gas treatment: Alkaline absorbent (NaOH solution) reacts with acidic gases (HCl, H₂SO₄, HNO₃) to form harmless salts
- Alkaline gas treatment: Acidic absorbent (H₂SO₄ solution) reacts with alkaline gases (NH₃) to form ammonium salts
Specialized Chlorine Gas Treatment (Exclusive Feature)
Our chlorine absorption tower uses a unique redox reaction system with ferrous chloride solution as absorbent and iron filings as regenerant:
- Chlorine absorption reaction:
2FeCl₂ + Cl₂ = 2FeCl₃ - Absorbent regeneration reaction:
2FeCl₃ + Fe = 3FeCl₂
This closed-loop system ensures that the absorbent never needs to be replaced, significantly reducing operating costs and environmental impact.
Internal Structure & Working Process
Tower Internal Structure
Our PP spray towers consist of five key components from bottom to top:
- Liquid storage tank: Stores absorption liquid and provides circulation for the spray system
- Air inlet section: Distributes incoming gas evenly across the tower cross-section
- Packing layer: Filled with PP Pall rings or Raschig rings to maximize gas-liquid contact area
- Spray system: Multiple layers of high-efficiency nozzles that atomize absorption liquid into fine droplets
- Demister layer: Removes liquid droplets from the treated gas before discharge
Two Operating Modes
Mode 1: Continuous Industrial Waste Gas Treatment
- Contaminated gas is drawn into the tower through the air inlet by a centrifugal fan
- Gas flows upward through the packing layer, countercurrent to the downward-spraying absorption liquid
- Pollutants are absorbed into the liquid phase through mass transfer
- Treated gas passes through the demister to remove entrained droplets
- Clean gas is discharged through the exhaust stack
- Absorption liquid is collected in the tank and recirculated by the pump
Mode 2: Chlorine Leakage Emergency Treatment
- Chlorine leakage alarms in the cylinder room and chlorination room detect gas presence
- System automatically activates, closing ventilation dampers and starting the fan and pump
- Contaminated air is drawn from the sealed room into the absorption tower
- Chlorine reacts with ferrous chloride solution in the packing layer
- Treated air is returned to the sealed room, creating a closed circulation
- Reaction liquid flows to the regeneration tank where iron filings convert ferric chloride back to ferrous chloride
- Regenerated absorbent is pumped back to the spray system for continuous use
Comprehensive Technical Specifications
| Parameter | Standard Options | Customization Available |
|---|---|---|
| Treatment Air Volume | 1,000 – 50,000 m³/h | Up to 200,000 m³/h |
| Tower Diameter | φ500mm – φ3,000mm | Custom diameters |
| Tower Height | 2,500mm – 12,000mm | Custom heights |
| Material | 100% Virgin Polypropylene (PP) | PP-FRP composite, PVDF lined |
| Wall Thickness | 8mm – 20mm (depending on diameter) | Custom thicknesses |
| Spray Layers | 1 – 3 layers | Up to 5 layers |
| Packing Type | PP Pall rings, Raschig rings | Intalox saddles, structured packing |
| Demister Type | PP wire mesh demister | Blade type demister |
| Operating Temperature | -10℃ to 80℃ | Special grades for up to 110℃ |
| Removal Efficiency | 95% – 99% | Customized for specific pollutants |
| Pressure Drop | 500 – 1,500 Pa | Optimized for low pressure drop |
| Power Supply | 380V/50Hz | Custom voltage and frequency |
| Standard Price | $1,300.00 (1,000 m³/h model) | Custom quote based on specifications |
Typical Application Scenarios
General Industrial Applications
- Chemical plants: Treatment of acid mist, alkaline fumes and organic solvent vapors
- Electroplating & metal finishing: Removal of chromic acid, sulfuric acid and cyanide fumes
- Pharmaceutical manufacturing: Exhaust gas treatment from production processes
- Semiconductor industry: Treatment of toxic process gases and chemical fumes
- Wastewater treatment plants: Odor control and hydrogen sulfide removal
Specialized Chlorine Treatment Applications
- Water treatment plants with chlorine disinfection systems
- Chlorine production and storage facilities
- Pulp and paper mills using chlorine bleaching
- Swimming pool chlorination facilities
- Chemical warehouses storing chlorine cylinders
View our project gallery to see our PP spray towers in operation in various industrial settings.
Matching System Components
Complete your waste gas treatment system with our high-quality compatible products:
- PP Ventilation Ducts and fittings
- Anti-corrosion Centrifugal Fans
- Activated Carbon Adsorption Towers for VOC and odor removal
- PP Storage Tanks for absorbent storage
- PP Butterfly Valves for flow control
- Chlorine Leakage Alarms and control systems
Why Choose XiCheng EP?
With 16 years of experience in manufacturing anti-corrosion environmental protection equipment, XiCheng EP has become a trusted supplier to industrial clients worldwide.
- ISO 9001 Certified Manufacturing: All products undergo strict quality control at every stage of production
- Custom Engineering: Our in-house team can design custom spray towers to meet your specific waste gas treatment requirements
- Turnkey Solutions: We provide complete system design, manufacturing, installation and commissioning services
- Fast Delivery: Standard models are in stock and can be shipped within 7-10 days
- Comprehensive Warranty: All our spray towers come with a 12-month warranty against manufacturing defects
- Global Technical Support: Our engineers are available for on-site installation and training worldwide
- Competitive Pricing: Direct factory pricing without middleman markup
For a custom quote or technical consultation, contact our engineering team today.
Operation & Maintenance Guidelines
Regular Maintenance Schedule
- Daily: Check liquid level in the storage tank, monitor pump and fan operation
- Weekly: Inspect spray nozzles for clogging, clean filters
- Monthly: Test emergency operation system for 10 minutes, check pH level of absorbent
- Quarterly: Inspect packing layer for fouling, clean or replace as needed
- Annually: Perform comprehensive inspection of all components, replace worn parts
Safety Precautions
- Ensure the control box has uninterrupted power supply at all times
- Keep chlorine cylinder rooms and chlorination rooms closed when not in use
- In case of chlorine leakage, immediately close all doors and windows and activate the emergency system
- Always wear appropriate personal protective equipment when handling absorption liquid
- If absorption liquid comes into contact with skin or eyes, rinse immediately with plenty of water
- Perform regular maintenance on pumps and fans to ensure reliable operation
Frequently Asked Questions (FAQ)
Q: What pollutants can a PP spray tower remove?
A: Our PP spray towers can effectively remove most soluble inorganic gases including hydrochloric acid, sulfuric acid, nitric acid, hydrofluoric acid, ammonia, chlorine and hydrogen sulfide. They can also be used for pre-treatment of organic gases before activated carbon adsorption.
Q: What is the removal efficiency of your spray towers?
A: Removal efficiency depends on the pollutant type and concentration, but typically ranges from 95% to 99% for most acid and alkaline gases. For chlorine gas, our specialized system achieves over 99.9% removal efficiency.
Q: How often does the absorbent need to be replaced?
A: For our chlorine absorption system, the absorbent never needs to be replaced as it is continuously regenerated by iron filings. For general acid/alkali treatment, the absorbent needs to be replenished periodically based on usage.
Q: Can you design custom spray towers for specific applications?
A: Yes, we have an experienced engineering team that can design custom spray towers based on your specific waste gas composition, flow rate and emission requirements.
Q: Do you provide installation services?
A: Yes, we can provide professional installation and commissioning services by our experienced engineers. We also offer on-site training for your staff on system operation and maintenance.
