The spray tower is commonly used in industrial dust purification and organic waste gas treatment. It is a frequently employed treatment equipment in waste gas processing.

The following are 9 common problems of spray towers and their solutions.

Nozzle blockage

Reason: The liquid in the water tank contains excessive dust and impurities.

Solution: First, check if the water tank filter plate is cracked, if the water pump inlet is equipped with a filter screen, and if the bottom filter screen of the water pump is damaged. If any of these issues are found, repair or replace them promptly. The method for disassembling the nozzle: First, remove the screws of the viewing window and take off the viewing window panel. Then, enter the tower and, in a counterclockwise direction, remove the nozzle. After flushing the water pump (replace the water in the water tank with clean water), let it work for two minutes and then close it. Finally, install the nozzle in a clockwise direction.

2. Clogging of packing material

Reason: Dust and viscous impurities in the exhaust gas adhere to the surface of the packing balls, such as paint exhaust gas, grinding exhaust gas, and organic exhaust gas, etc.

Solution: First, we need to check if any of the above reasons exist. Add cleaning solution and a small amount of detergent to the spray tower water tank for a simple liquid spray cleaning. If there is excessive sticky dust on the packing, replace the packing immediately or remove it for cleaning. Clean the packing and then put it back. Afterwards, add an appropriate amount of cleaning solution and a little detergent to the spray tower (referring to the water tank) and regularly remove the floating debris in the water tank. If there are bottom materials, add a suspending agent to maintain the water in the tank clean without dust and dirt.

3. Water passing through the dehumidification layer

Reason: The insufficient number of dehumidification fillers might be caused by either the excessive air volume of the fan or the inconsistency between the height of the dehumidification layer and the planning requirements.

Solution: Fill the demisting layer packing completely. Or lower the grid plates of the packing layer (inside the tower), add more packing material for the demisting layer, or reduce the air volume by adjusting the frequency converter of the fan equipment.

4. The filler is blown into a pile.

Reason: The air volume of the fan is too high, and the planning specifications of the spray tower do not match the air volume of the fan.

Solution: Remove the screws of the window, take off the window panel, spread the packing material on it and press a layer of grid plate, or reduce the air volume by adjusting the frequency converter of the fan equipment.

5. After the fan is started and the cover is closed, the water in the water tank will flow out through the outlet.

Reason: The reason is that the gas inlet and outlet specifications do not match the wind volume planning of the fan, and the planning specifications of the spray tower do not match the fan.

Solution: One possible approach is to reduce the air volume by adjusting the frequency converter of the fan equipment. Alternatively, the gas inlet and outlet can be enlarged, or the float valve can be adjusted to control the water level.

6. If the spray nozzles of the spray tower do not dispense water, it might be because the water flow is very low.

Reason: The pump might be rotating, or the water level might be too low, preventing the pump from drawing water. There could also be issues such as a clogged nozzle or a blocked water inlet of the pump.

Solution: Check if the water pump is functioning properly. If the water level is too low and water cannot be drawn, add water immediately.

7. Waste Gas Recovery Issue

After a long period of observation, I found that the water layer sprayed by the spray nozzle seemed to be very uniform. However, when the water passed through the layer, at the junctions of multiple spray nozzle water layers, the water curtain would be pushed apart by the air flow, forming multiple air flow channels. If the air volume is large, the water curtain will be blown out by the air flow, resulting in the waste gas being directly discharged without being absorbed.

8. Issues related to the use of water spray

Currently, the spray nozzles are all installed below the spray tower.

9. Fan issues

Due to the different sizes of the fans equipped by the enterprises, some have insufficient air volume to completely remove the waste, causing the waste gas to spread throughout the working area. Others have excessive air volume, which increases the loss of acid solution, raises the concentration of acid in the acid mist, and also removes the water droplets sprayed by the spray device.

This results in the spray layer being unable to function properly, and the exhaust gas will definitely not meet the standards. Therefore, it is also very important to scientifically equip with reasonable fans.