Spray towers are commonly used in industrial dust purification and organic waste gas treatment, making them a popular treatment equipment in air pollution control. Below are 9 common issues with spray towers and their solutions:

1. Nozzle Clog

The cause is the excessive amount of dust and impurities in the liquid within the water tank.

Solution: First, inspect if the water tank filter plate is cracked, if the pump inlet is equipped with a filter screen, and if the bottom filter screen of the pump is damaged. Assume any issues are present and repair or replace them promptly. To remove the nozzle, first unscrew the window screws and remove the window panel. Enter the tower and remove the nozzle counterclockwise. Open the pump (replace the water in the tank with clean water) and work for two minutes, then close it. Finally, reattach the nozzle clockwise.

2. Filler Clogging

The cause is the accumulation of dust and sticky impurities on the surface of the filling balls, such as paint spray waste gas, sanding waste gas, organic waste gas, and so on.

Solution: First, we check for the mentioned causes. Add cleaning fluid and a small amount of dishwashing liquid to the spray tower tank for a brief liquid spray cleaning. If the packing is excessively sticky with dust, replace the packing or clean it out. Cleaned packing or new packing can then be reinstalled. Moving forward, add a moderate amount of cleaning fluid and a little dishwashing liquid to the spray tower (referring to the tank) and regularly remove floating debris. If there are substances at the bottom, use a flocculant to maintain clean water in the tank free of dust and impurities.

3. Dehumidification layer water-through

The cause may be insufficient demisting media, possibly due to the fan's excessive air volume and non-compliance with the planned requirements for the demisting layer's height specifications.

Solution: Fill the demister bed to capacity, possibly adjust the grille plates (inside the tower) of the filling layer downward, add more demister bed filling material, or reduce the air volume by adjusting the variable frequency drive of the fan equipment.

Material blown into a pile

The reason is that the fan air volume is too large, and the mismatch between the spray tower planning specifications and the fan air volume constitutes the issue.

Solution: Remove the window by unscrewing it, then take off the window panel. Spread the packing evenly on top and press down a grille, or perhaps adjust the frequency converter of the fan unit to reduce air volume.

5. After the fan is activated and the enclosure is sealed, water from the tank will leak out through the overflow outlet.

The reason is that the gas import/export regulations are not aligned with the fan air volume planning, and the spray tower planning specifications do not match the fans.

Solution: Reducing the airflow by adjusting the frequency converter of the fan equipment, possibly enlarging the gas inlet and outlet, or regulating the float ball valve to control water level.

6. The sprinkler tower nozzle not producing water may be due to a very low water volume.

Reason: Possible causes include the pump's rotation, insufficient water level for the pump to draw water, clogged nozzle, or a blocked inlet of the pump.

Solution: Check if the pump is operating properly and whether the water level is too low to pump water. If so, add water promptly.

7. Emission Recovery Issue

Long-term observation reveals that the spray layer from the sprinkler nozzles appears uniform, but when waste passes through the water layer, the water curtains at the junctions between multiple nozzles are pushed apart by air currents, creating multiple air channels. In high airflow conditions, the water curtains are blown into deformed shapes by the air, resulting in the direct exhaust of waste without any absorption.

8. Spray Head Usage Issues

Currently, the equipment is set up below the spray tower for the spray nozzles.

Fan issue

Due to the varying sizes of fans equipped by the company, some have insufficient air volume to fully extract waste, causing emissions to disperse in the work area. Others have excessive air volume, which increases the loss of acidic liquid, raises the concentration of acid in the mist, and also sucks up the water droplets from the spray nozzles, rendering the spray layer ineffective. Consequently, the exhaust gas is bound to fail to meet standards. Therefore, scientifically and reasonably sizing the fans is also crucial.