Challenge: Reducing Acid and Toxic Gas Emissions

An automotive battery manufacturing plant producing high-performance batteries for electric and hybrid vehicles was experiencing elevated emissions of acid fumes and other hazardous gases. These emissions, primarily generated during electrode and electrolyte processing, posed serious health, safety, and environmental concerns. Compounds such as HF (hydrofluoric acid), H₂SO₄ (sulfuric acid), HCl (hydrochloric acid), and trace levels of various toxic metals were detected in concentrations that exceeded local and national regulatory limits.

Further complicating the situation:

• The scrubber would need to operate continuously, around-the-clock, with minimal downtime for maintenance.
• The system had to be installed outdoors to conserve valuable indoor plant space.
• The plant’s environmental compliance team employed a stringent evaluation process to ensure that any new pollution control technology met their rigorous performance, durability, and cost criteria.

Reason for Choosing a Packed Tower Wet Scrubber

Given the complexity and variability of the acid gas streams, a Packed Tower Wet Scrubber was selected due to:

1. High Mass Transfer Efficiency
   The packing media maximize contact between the contaminated air and scrubbing liquid, ensuring efficient absorption and neutralization of acid vapors and toxic compounds.
2. Chemical Versatility
   Depending on the emissions profile, the scrubbing liquid can be plain water or an alkaline solution (e.g., sodium hydroxide) adjusted to target the specific contaminants. This flexibility is especially important for processes involving multiple acid gases.
3. Continuous Operation
   Packed tower scrubbers are well-suited for 24/7 operation with proper recirculation and instrumentation, making them ideal for manufacturing plants that cannot afford frequent process shutdowns.
4. Compact, Modular Design
   A horizontal or vertical packed bed can be configured to fit the available outdoor footprint, meeting the plant’s space constraints.

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Solution: SAZ ENVIRO’s 28,000 CFM Horizontal Packed Bed Scrubber

SAZ ENVIRO supplied a custom-engineered, 28,000 CFM Horizontal Packed Bed Scrubber designed to remove up to 98% of acid fumes and other hazardous compounds. The key features and components of the solution are outlined below:

1. Robust Construction
   • UV-resistant polypropylene housing to withstand outdoor conditions and exposure to corrosive chemicals.
   • Reinforced structural elements to ensure mechanical stability and long-term durability.
2. Advanced Scrubbing Process
   • Utilizes fresh water and, when necessary, a neutralizing agent (such as NaOH) to absorb and chemically neutralize acidic gases.
   • Random packing media provides a large surface area, optimizing mass transfer and contaminant removal.
3. Redundant Equipment for 24/7 Operation
   • Dual fans and automated dampers guarantee consistent airflow and allow for maintenance on one fan while the other remains operational.
   • Multiple recirculation pumps, ensuring continuous liquid flow through the packed bed even in the event of an isolated pump failure.
4. Comprehensive Controls Package
   • A PLC-based control system with integrated sensors for pH, conductivity, flow rate, and system pressure.
   • Real-time data monitoring and automated adjustments to the scrubbing liquid chemistry, ensuring optimal efficiency with minimal operator intervention.
5. Pre-fabrication and Testing
   • Subsystems were assembled and tested at SAZ ENVIRO’s facility prior to delivery, reducing on-site installation time and ensuring a smoother startup.

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Installation and Startup

• Outdoor Installation
  The scrubber was positioned on a specially prepared concrete pad adjacent to the production building. This open-air setting helped streamline ductwork routing while preserving critical indoor space.
• Collaborative Commissioning
  SAZ ENVIRO’s field service technicians worked alongside the plant’s environmental and maintenance teams to integrate the new system with existing infrastructure. During commissioning, technicians verified:
  • Correct mechanical alignment of ductwork and fan assemblies
  • Optimal spray nozzle function within the packed tower
  • Proper PLC configuration and fail-safe parameters
• Operator Training
  Plant personnel received comprehensive training on the scrubber’s operation, including how to interpret system data, adjust chemical feed rates, and conduct routine inspections.

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Result: Achieving and Sustaining Compliance

1. 98% Removal of Hazardous Compounds
   The installed system consistently achieves a destruction & removal efficiency (DRE) of up to 98% for the target acid gases. Post-installation testing confirmed emission levels are well below applicable regulatory limits.
2. Regulatory Success
   The plant now meets stringent EPA and local environmental standards, avoiding potential fines and reinforcing its reputation as an environmentally responsible automotive battery supplier.
3. Enhanced Workplace Safety
   By effectively controlling acid fumes and toxic vapors, the new scrubber has improved indoor and outdoor air quality, safeguarding plant workers and surrounding communities.
4. Uninterrupted Production
   Thanks to the redundant design and real-time controls, the system operates continuously without the need for frequent shutdowns, supporting the plant’s high production demands.
5. Strong Supplier Partnership
   SAZ ENVIRO’s ongoing service support, including periodic inspections and system optimization, ensures the scrubber maintains peak performance over its lifecycle.

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Conclusion

The SAZ ENVIRO Packed Tower Wet Scrubber project at the automotive battery manufacturing plant underscores the value of choosing a robust, flexible, and efficient control technology for managing complex acid emissions. By incorporating high-quality materials, redundant equipment, and advanced automation, SAZ ENVIRO delivered a solution that secures compliance, protects worker health, and supports uninterrupted production. This success story demonstrates how modern scrubbing solutions can help battery manufacturers meet today’s strict environmental regulations while staying competitive in a rapidly evolving industry.

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