Description
Who Needs Our Wet Scrubber Design Service?
Standard off-the-shelf wet scrubbers often fail to meet the unique requirements of complex industrial exhaust streams. Our custom wet scrubber system design service provides tailored solutions for facilities with non-standard operating conditions, strict emission limits, or complex mixed gas streams. We follow EPA scrubber design standards and OSHA industrial safety guidelines to ensure 100% compliance.
New Industrial Facility Construction: We provide complete turnkey design solutions for new manufacturing plants, from initial feasibility studies to final system commissioning. Our designs integrate seamlessly with your production process to minimize operational disruption.
Existing System Upgrades & Retrofits: If your current scrubber is underperforming, failing compliance tests, or requires increased capacity, we can design a cost-effective upgrade solution that extends the life of your existing equipment.
Regulatory Compliance Remediation: We specialize in designing systems to help facilities meet new or stricter environmental regulations. Our designs guarantee compliance with all local, national, and international emission standards.
Special Operating Conditions: We have extensive experience designing scrubbers for challenging conditions, including high-temperature exhaust, high-concentration pollutants, corrosive atmospheres, and explosive gas mixtures.
EPC Contractor Support: We provide specialized scrubber design services for engineering, procurement, and construction (EPC) contractors, delivering detailed drawings, specifications, and technical support for your projects.
Why Choose XICHENG EP for Your Scrubber Design
1. 16 Years of Experience & 100% Compliance Track Record
With 16 years of specialized experience in industrial air pollution control, we have designed over 500 wet scrubber systems for customers in more than 30 countries worldwide. All our designs are guaranteed to meet or exceed applicable environmental regulations.
Our track record includes zero compliance failures in over 100 regulatory inspections, eliminating the risk of costly fines and production shutdowns for our customers.
2. Fast Turnaround: 3 Days Preliminary, 7 Days Complete Design
We understand that time is critical for industrial projects. Our streamlined design process allows us to deliver preliminary design proposals within 3 business days and complete construction drawings within 7 business days for standard projects.
This fast turnaround time helps you keep your project on schedule and avoid costly delays. For complex projects, we provide detailed timelines and regular progress updates.
3. Complete Turnkey Service from Design to Commissioning
We offer a complete end-to-end service that includes system design, equipment manufacturing, installation supervision, commissioning, operator training, and ongoing technical support. This single-source approach eliminates coordination headaches and ensures project success.
Our team will be with you every step of the way, from the initial consultation to final system acceptance and beyond.
4. Dedicated Engineer 1-on-1 Project Management
Every project is assigned a dedicated process engineer who serves as your single point of contact throughout the entire project lifecycle. Your engineer will work closely with you to understand your specific requirements and ensure that all your needs are met.
This personalized approach ensures clear communication, fast response times, and a design that is perfectly tailored to your facility.
5. Lifetime Technical Support & System Upgrades
We stand behind our designs with lifetime technical support. Our engineers are available to answer questions, provide troubleshooting assistance, and help with system maintenance whenever you need it.
As your facility grows or regulations change, we can also design system upgrades to increase capacity, improve efficiency, or meet new emission requirements.
Our Design Capabilities
| Design Parameter | Capability Range | Notes |
|---|---|---|
| Air Volume | 50 – 215,000 m³/h | Custom designs available for larger volumes |
| Pollutant Types | 12+ industrial gases & particulates | HCl, H₂SO₄, NOₓ, NH₃, SO₂, Cl₂, H₂S, HF, and more |
| Design Standards | EPA, OSHA, EU BREF, GB, CE | Compliant with all major global standards |
| Material Options | PP, FRP, PVC, Stainless Steel | PP recommended for most corrosive applications |
| Design Delivery Time | 3 – 15 business days | Depends on project complexity |
| System Types | Packed bed, spray tower, swirl tower, multi-stage | Custom configurations for specific applications |
Our 7-Step Design Process
1. Initial Consultation & Requirements Gathering
We start with a detailed discussion to understand your production process, exhaust characteristics, emission limits, and project timeline.
2. Site Survey & Data Collection
Our engineers visit your facility to conduct a site survey, collect exhaust gas samples, and measure existing infrastructure.
3. Preliminary Design & Proposal
We develop a preliminary design concept, including system configuration, performance specifications, and a detailed cost estimate.
4. Detailed Engineering Design
Once the preliminary design is approved, we create complete construction drawings, P&ID diagrams, equipment specifications, and material lists.
5. Manufacturing & Quality Control
We manufacture all equipment in our own factory under strict quality control standards. Your engineer provides regular production updates.
6. Installation Supervision & Commissioning
Our engineers supervise the installation process and conduct comprehensive system commissioning to ensure optimal performance.
7. Training & Final Acceptance
We provide hands-on operator training and maintenance training. The project is complete only after you are fully satisfied with system performance.
Frequently Asked Questions
Q1: What information do I need to provide for a scrubber design?
To provide an accurate design, we need: exhaust air volume, types and concentrations of pollutants, gas temperature and humidity, available installation space, local emission standards, and any special requirements or constraints.
If you don’t have all this information, our engineers can conduct a site survey and gas analysis to collect the necessary data.
Q2: How much does a custom wet scrubber design cost?
Design costs vary depending on project complexity, air volume, and the number of pollutants. Our design fees typically range from 5-10% of the total system cost.
For turnkey projects that include manufacturing and installation, we often waive the design fee. Contact our sales team for a detailed quote based on your specific requirements.
Q3: What deliverables are included in the design package?
Our standard design package includes: process flow diagram (PFD), piping and instrumentation diagram (P&ID), general arrangement drawings, detailed fabrication drawings, equipment specifications, material list, operation and maintenance manual, and performance guarantee.
We can also provide additional deliverables such as 3D models, CFD simulations, and compliance reports upon request.
Q4: Do you guarantee that your design will meet emission standards?
Yes, all our designs come with a performance guarantee. We guarantee that the system will meet or exceed all applicable local, national, and international emission standards.
If the system fails to meet the guaranteed performance levels, we will make the necessary modifications at no additional cost to you.
Q5: Can you design upgrades for my existing scrubber system?
Yes, we specialize in upgrading and retrofitting existing scrubber systems. We can design modifications to increase capacity, improve efficiency, reduce operating costs, or meet new emission standards.
Our engineers will conduct a thorough evaluation of your existing system and recommend the most cost-effective upgrade solution. Learn more about our methodology in our scrubber selection methodology guide.
Q6: Do you provide on-site installation services?
Yes, we provide complete installation services through our network of certified installation partners. Our engineers supervise the entire installation process to ensure that the system is installed correctly and according to the design specifications.
We also offer installation supervision services for customers who prefer to use their own installation teams.
Q7: Can you design scrubbers for explosive gas mixtures?
Yes, we have extensive experience designing scrubbers for explosive gas mixtures such as ammonia, hydrogen, and organic vapors. Our designs include explosion-proof electrical components, static grounding, pressure relief valves, and other safety features.
All our explosive atmosphere designs comply with ATEX and other relevant safety standards.
Q8: How long does a typical scrubber project take from design to commissioning?
For standard projects, the total timeline from initial consultation to final commissioning is typically 4-8 weeks. Complex projects may take 8-12 weeks.
We also offer expedited services for urgent projects. Contact our sales team to discuss your timeline requirements.
Q9: What kind of after-sales support do you provide?
We provide lifetime technical support for all our designs. Our engineers are available 24/7 to answer questions, provide troubleshooting assistance, and help with system maintenance.
We also offer annual maintenance contracts, spare parts supply, and system upgrade services to ensure that your scrubber continues to operate at peak performance throughout its lifespan. Download our post-installation maintenance guide for more information.
Q10: Do you provide design services for all types of wet scrubbers?
Yes, we design all types of wet scrubbers, including packed bed scrubbers, spray towers, swirl towers, venturi scrubbers, and multi-stage scrubbers. We can design systems for specific applications such as HCl scrubber system design, NOx scrubber system design, and ammonia scrubber system design.
Our engineers will recommend the most appropriate scrubber type based on your specific exhaust characteristics and performance requirements.
About Our Design Team
Our design team consists of 15+ experienced process engineers, mechanical engineers, and environmental engineers with an average of 8 years of industry experience. All our engineers hold professional engineering licenses and receive regular training on the latest design standards and technologies.
We use advanced design software including AutoCAD, SolidWorks, and CFD simulation tools to create accurate, efficient, and cost-effective scrubber designs. Our design process is ISO 9001:2015 certified, ensuring consistent quality and reliability.
Recent Design Projects
- 50,000 m³/h multi-stage SOx/NOx scrubber for a power plant in Vietnam
- 25,000 m³/h HCl scrubber for a stainless steel pickling line in China
- 12,000 m³/h explosion-proof ammonia scrubber for a chemical plant in Singapore
Certifications
- ISO 9001:2015 Quality Management System
- CE Marking for European Union
- China Environmental Protection Product Certification
- ATEX Explosion-Proof Design Certification
