Monroe Environmental can provide complete multi-stage air scrubbing systems for a wide variety of applications. High temperature and volatile chemical processes often require a more complex, customized air scrubbing solution than what a simple packed tower scrubber or venturi particulate scrubber can provide.
Air Pollution Control Expertise
In many cases, several technologies must be integrated together to provide adequate removal and treatment efficiencies. Monroe’s experience includes the engineering and fabrication of customized Multi-Stage Scrubbers utilizing the following equipment:
- Packed Bed Scrubbers
- Venturi Particulate Scrubbers
- Wastewater Clarifiers
- Oil Recovery Units
- Carbon Adsorbers
- Quench Towers
- Cyclonic separators
- Heat exchangers and temperature controls
- Sub-cooling systems
- Dry injection fabric filters (DIFF)
- Fiberglass filters
- WESP and submicron particulate filters
- Specialty ducting systems
Customized Scrubbing Solution
Monroe has the experience and knowledge to evaluate your process and recommend a customized scrubbing solution for your specific application. We have successfully treated contaminated air streams from nearly every high temperature emissions application across a variety of industries and processes.
Multi-Stage Scrubbing System Example Configurations
Most Cost-Efficient and Effective Fume Scrubbing Solutions
Monroe Environmental engineers analyze each application individually to determine the most cost-efficient, effective solution. Monroe has an extensive arsenal of standard wet air scrubbing equipment offered in a variety of standard and special construction materials backed up by over forty years of experience in solving such complex problems.
Dual-Train Wet Scrubbing System
Flame Laminating Exhaust Treatment Multiple Venturi and Caustic Scrubbing
- Train (1) — 5,500 CFM
- Train (2) — 7,600 CFM
Air Composition
- HCl
- HCN
- CO2
- CO
- Particulate
Flame Laminator Scrubbing Process
Process Flow Diagram
Solutions for High Temperature Scrubbing Processes
Monroe Environmental provides gas scrubbing systems for combustion processes including incineration, oxidation, flame laminating, glass coating, and other high temperature operations exhausting dryers, ovens, furnaces, gassifiers, reactors, and kilns.
Monroe Scrubbing System at Industrial Waste Facility
20,000 CFM — Incinerator Exhaust Scrubbing, Stainless and Mild Steel Construction
- Ceramic-lined steel ducting – Corrosion and temperature control
- Rapid water quench – 2,000°F to less than 200°F
- Adjustable Venturi Scrubber – Particulate removal
- Horizontal Clarifier tank – Solids settling
- Packed Tower Scrubber – HCl scrubbing
- Carbon/filter housing – Final filtration and discharge polishing
Glass Coating Line Exhaust Scrubbing
Process Flow Diagram
Scrubbing Systems for Chemical and Compound Reclamation
Contaminants formed in these processes are frequently highly corrosive, hazardous, and/or difficult to remove. Removal often requires contaminant incineration at temperatures exceeding 1,500°F. Through proper quenching and gas conditioning techniques, Monroe can provide reclamation of costly chemicals and compounds contained within the off-gasses.
Monroe Scrubbing System at Grease Production Plant
15,000 CFM — Mild Coated Steel Construction
- Dual‑Throat Venturi Scrubber to remove particulate
- Drag conveyor to remove settled material
- Oil Skimmer (right) to recover condensed grease
- Packed Tower Scrubber to remove hydrocarbon vapors
Gas Resin Reactor Exhaust Scrubbing
Process Flow Diagram
Multiple Packed Bed Scrubbing Systems
For some applications, multiple Packed Bed Scrubbers in series provide the best contaminant removal solution. This type of scrubbing system is common when there is a high pollutant loading or when removal efficiencies greater than 99.9% are required. Having multiple scrubbing stages also allows the use of different scrubbing solutions within a single scrubbing system for removal of different contaminates within the same air/gas stream.
Multi-Tower Scrubber — Toxic Gas Incineration
1,253 SCFM — Stainless and mild, coated steel
- Quench stack: 2,000°F to less than 190°F
- (3) Phase Packed Bed Scrubber with sub-cooling loop: metals, condensables, HCl, SO2, and NOX removal
- High energy Venturi Scrubber: submicron particulate/aerosol removal
- Electric gas reheater
- Dry injection fabric filter baghouse with PAC for final acid gas removal
- Carbon Adsorber housing: final filter/polishing
Multiple Packed Tower Scrubbers
Process Flow Diagram
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- Wet Scrubbers, DIFF, Carbon
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- Venturi + Packed Tower + heat exchanger
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- H2S & VOC removal
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- PM & hydrocarbon removal
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- Haz. waste incineration
Recent Projects
Multi-Stage Scrubbing System for Chemical Manufacturing Facility
Multi-Stage Scrubber to treat HBr, HCl, and HF gas downstream of a thermal oxidizer at a specialty chemical manufacturing facility.
Quench Tower and SO2 Scrubber for ReBoiler Expansion
A chemical plant that produces coal tar pitch was expanding operations and needed to control flue gas emissions from a new boiler.
Wet Scrubber Treats Dryer Exhaust
Monroe Multi-Stage Scrubbing System to remove particulate from a food dryer prior to VOC destruction with a regenerative thermal oxidizer.
Multi-Stage Scrubbing System – H2S & VOCs
Multi-Stage Scrubbing System to remove H2S and VOCs from rubber vulcanizing production exhaust. The system is rated for 3,000 ACFM.
Multi-Stage Scrubbing Systems Applications
Resources & Literature
Recent Case Studies
Air | Multi-Stage Scrubbing System for Incinerator Exhaust
Monroe Environmental provided a multi-stage wet air scrubbing system for HCl and particulate removal from incinerator exhaust at an industrial waste plant.
Air | Halide Recovery at a Major Glass Products Plant
Custom designed Multi-Stage System – process gasses treated with a series of scrubbers, and wastewater was treated with a Monroe compact clarifier.
Air | Glass Resin Scrubbing System
Custom designed Multi-Stage System to provide high efficiency scrubbing of the phenol & formaldehyde, as well as separation and removal of the dust particulate.
