NEO MAKİNA ve MÜHENDİSLİK A.Ş. designs and manufactures wet scrubbing systems (wet scrubbers) for cleaning process gases laden with dust, aerosols and sticky particles using water or chemical solution. Venturi scrubbers, wet cyclones, spray towers and packed-tower combinations capture fine particulate including PM2.5 together with accompanying acid gases in a single unit where dry filters cannot operate: hot, humid, explosive or sticky dusts. An emission and safety solution for metallurgy, chemical, food, drying and waste-incineration plants.
Where Is Wet Scrubbing Preferred?
- Hot and humid gases: Dryer, roaster, furnace and boiler outlets; the gas is quenched and cleaned at the same time.
- Sticky and hygroscopic dusts: Sugar, fertiliser, chemical and oily dusts that blind bag filters.
- Explosive dusts: Fire and explosion risk of aluminium, magnesium, flour and coal dust eliminated in the liquid phase.
- Mixed dust + gas pollutants: Single-stage removal of particulate together with SO₂, HCl, HF, NH₃ or odour compounds.
System Types
Venturi Scrubber
- Principle: Gas is accelerated to 40–120 m/s in a narrow throat; injected water atomises into fine droplets and particles are captured by impaction.
- Efficiency: 99%+ above 1 micron, 90–98% on PM2.5 (depending on pressure drop: 15–60 mbar).
- Applications: Metal melting and foundry furnaces, dryer exhausts, fertiliser granulation, chemical reactor gases, boiler fly ash.
- Adjustable throat: Variable-throat design for constant efficiency at varying flow.
Wet Cyclones and Dynamic Scrubbers
- Economical pre-separation of dust above 5 microns by centrifugal force and water film; low pressure drop; spark and ember quenching.
Spray Towers and Packed Towers
- Droplet capture, gas cooling and acid-gas absorption after the venturi; SO₂/HCl removal with caustic or lime-milk dosing. For absorption-focused applications see Waste Gas Scrubber Systems.
Multi-Stage Wet Systems
- Quench + venturi + packed tower + mist eliminator; particulate, acid-gas and heavy-metal removal on waste incineration, sludge incineration and metallurgical gases.
System Components
- Vessel and tower: AISI 304/316L, duplex, PP, PVC or GRP/FRP; refractory- or rubber-lined steel inlet for hot gas.
- Nozzles and distributors: Non-clogging full-cone nozzles, ceramic or stainless; easily removable.
- Mist eliminator: Chevron or mesh type; 99.9% droplet removal, clean stack discharge.
- Recirculation and sludge system: 1+1 pumps, recirculation tank, settling cone or lamella clarifier, filter press/decanter for sludge dewatering; closed-loop water use.
- Chemical dosing: pH/ORP-controlled NaOH, lime milk or other reagent dosing.
- Fan and stack: Corrosion-resistant (stainless or FRP) fan; connection for continuous emission monitoring.
- Automation: Differential pressure, pH, conductivity, level and flow monitoring; automatic bleed and make-up; SCADA integration.
Typical Application Range
- Gas flow: 1,000 – 300,000 m³/h
- Inlet temperature: up to 1,000 °C (with quench); outlet 40–70 °C saturated gas
- Dust load: up to 100 g/Nm³; outlet <10–30 mg/Nm³ (depending on venturi pressure drop)
- Sectors: steel and foundries, aluminium and copper smelting, fertiliser and chemicals, food (sugar, starch, roasting), biomass and coal boilers, waste and sludge incineration, drying plants
- Standards: national industrial air-pollution regulation, EU IED/BAT, ATEX 2014/34/EU, EN 1092 flanges
Advantages and Points to Consider
- Advantage: Safe operation with hot, humid, sticky and explosive dusts; dust and gas pollutants removed in one unit; compact layout; low investment cost.
- Consider: Water consumption and sludge/wastewater management must be included in the operating plan; venturi pressure drop (fan energy) rises with efficiency; correct material selection is critical for corrosion; stack plume may need reheating in cold climates.
Why NEO MAKİNA?
The system is designed by calculating venturi throat velocity, liquid-to-gas ratio (L/G) and tower dimensions from gas flow, temperature, particle-size distribution and pollutant analysis; flow is verified by CFD. Quench, scrubber, sludge treatment, fan, stack and automation are delivered from a single source; see Dust Collection and Filtration for the dry alternative and Flue Gas Filtration Systems for complete flue-gas treatment.
Frequently Asked Questions
Wet or dry dust collection?
For dry, cool, non-sticky dust a bag filter is more economical with lower emissions and less water/wastewater. For hot, humid, sticky, explosive or acid-gas-laden dust, wet scrubbing is the safe and effective choice.
How much water is consumed?
In a recirculating system only evaporation and bleed are lost: typically 0.2–1 L per m³ of gas; water is recovered through sludge dewatering.
Can PM2.5 be captured?
Yes. A high-energy venturi (40–60 mbar pressure drop) achieves over 90% on sub-micron particles; for stricter limits a wet electrostatic precipitator (WESP) is added as final stage.
For wet scrubbing system design and a quotation based on your gas and dust analysis, contact us.