A large Rubber Plant faced new and more stringent environmental regulations requiring a significant reduction in sulfur dioxide (SO₂) emissions. The facility produced SO₂ primarily from its multiple-hearth incinerator, which combusted waste and off-spec rubber materials. Although the plant had some existing pollution control measures in place, they were no longer adequate to comply with the recent regulatory mandates.

Challenge: Meeting Updated SO₂ Emissions Regulations for a Rubber Plant

To compound the difficulty, the plant’s wet electrostatic precipitator (WESP) — designed to remove particulate matter from the process gas — did not effectively address high SO₂ concentrations. As a result, an additional scrubbing stage was needed to remove the excess SO₂ downstream of the WESP. The Rubber Plant sought an efficient, robust, and reliable scrubbing system that would not only meet new compliance standards but also keep operating costs manageable.

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Solution: SAZ ENVIRO Packed Tower Wet Scrubber

SAZ ENVIRO proposed and supplied a Packed Tower Wet Scrubber specifically engineered to absorb and neutralize SO₂ using a caustic solution. Key highlights of the system include:

1. Caustic Solution with Adjustable Strength
   • Capable of utilizing up to 30% NaOH (sodium hydroxide) to effectively neutralize SO₂ gas.
   • This range provides flexibility to adjust chemical strength in response to fluctuating SO₂ loadings.
2. Construction and Materials
   • Fabricated from stainless steel for corrosion resistance and a long operational life.
   • Designed to integrate seamlessly with existing infrastructure at the Rubber Plant.
3. System Configuration and Components
   • Sized to process 12,500 ACFM (Actual Cubic Feet per Minute) of exhaust gas generated by the incinerator.
   • Equipped with a liquid recycling tank, complete with level sensors to ensure precise flow regulation.
   • Recirculation pumps and spray nozzles to deliver the scrubbing solution across the packing media effectively.
   • Random packing media to maximize gas-liquid contact and promote thorough SO₂ absorption.
   • Mist eliminator to capture entrained droplets, preventing carryover.
   • Flow meters, pressure transmitters, and other instruments integrated with a PLC-based control system for automated operation and real-time performance monitoring.
   • An integrated support frame to streamline installation and maintenance processes.
4. Downstream Integration
   • Strategically installed after the wet electrostatic precipitator to handle SO₂ emissions once particulates had been largely removed.
   • The synergy between the WESP and the Packed Tower Wet Scrubber ensures compliance with both particulate and sulfur dioxide limits.

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Installation and Commissioning

• Turnkey Delivery
  SAZ ENVIRO provided a turnkey approach, delivering all necessary components, detailed engineering drawings, and installation guidelines.
• Close Coordination
  SAZ ENVIRO’s technical experts collaborated with the plant’s engineering team and local contractors to ensure that the scrubber was correctly positioned, piped, and configured for optimal performance.
• Startup and Commissioning
  The scrubber underwent a series of startup procedures and performance tests, supervised by on-site SAZ ENVIRO field service engineers.
• Operator Training
  Plant personnel received hands-on training to become familiar with day-to-day operation, control strategies, and routine maintenance tasks.

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Results and Benefits

1. Successful Emissions Control
   • The Packed Tower Wet Scrubber consistently reduces SO₂ to below 20 ppmv, meeting the new regulatory requirements and ensuring the Rubber Plant’s continued operation.
   • Emissions data confirm that the system maintains high removal efficiency even under varying incinerator loads.
2. Regulatory Compliance
   • With the scrubber in place, the plant complies fully with updated local and national emissions standards, avoiding costly penalties and potential operational disruptions.
3. Operational Flexibility
   • The design allows for quick adjustments to NaOH concentration and flow rates in response to changing process conditions, ensuring maximum SO₂ removal at an optimized cost.
4. Improved Environmental Footprint
   • By substantially lowering SO₂ emissions, the Rubber Plant has significantly reduced its impact on local air quality.
   • The successful installation supports the plant’s broader efforts toward sustainable, community-friendly operations.
5. Reliable Partnership
   • The smooth installation, coupled with SAZ ENVIRO’s responsive field support, fostered a strong working relationship with the Rubber Plant.
   • Ongoing performance monitoring and technical assistance ensure the scrubber continues to operate at peak efficiency.

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Conclusion

The Packed Tower Wet Scrubber delivered by SAZ ENVIRO has proven to be a critical solution for the Rubber Plant’s SO₂ emissions challenge. By installing a well-designed system downstream of the wet electrostatic precipitator, the plant achieved compliance with stringent air quality regulations while maintaining efficient operations. With robust construction, flexible chemical dosing, and integrated control features, SAZ ENVIRO’s scrubbing system underscores the company’s commitment to high-performance emission control solutions that protect both industrial productivity and the surrounding environment.

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