Scrubbers

Operating costs include makeup water to replace evaporation and blowdown, chemicals for neutralization, and energy for recirculation pumps and fans. Makeup water is designed for 5% of recirculated GPM—the actual amount depends on your system size and evaporation rate. Chemical costs depend entirely on your contaminant loading. Treating acid gases requires caustic (sodium hydroxide) for neutralization—the more contaminants you process, the more chemical you consume. 

Standard Viron scrubbers recirculate at 4 GPM per square foot of packing area. Automated pH control systems reduce chemical waste by dosing only what's needed for proper neutralization, preventing both under-treatment and expensive chemical overuse.

Viron's specification sheets request: actual CFM at operating conditions, specific chemical to be removed, scrubber loading rate (lbs/hour input), chemical temperature, installation location (inside/outside), required removal efficiency, and mist eliminator removal efficiency. Vague requests like "5,000 CFM acid scrubber" lead to wrong sizing. 

We need to know your actual loading rate—10 lbs/hour versus 100 lbs/hour of sulfuric acid determines whether you need 24" or 60" packing depth. Temperature matters because it affects actual CFM. Location determines if you need self-contained recirculation (for warm climates or indoor installation) or remote recirculation (for cold winter regions where freezing is common)—the more specific your data, the more accurate our system design and pricing.

Yes. Viron fully assembles and tests every scrubber before shipment to ensure performance and quality. Customers who visit our facility to inspect their scrubber disassembled before shipment find their field installations run smoother and faster. 

You'll see spray header layouts, packing installation, pump mounting, and flanged connections—knowledge that prevents installation mistakes and delays. Larger scrubbers may ship in pre-assembled sections to simplify onsite installation. Seeing your system beforehand lets your contractors plan rigging, verify clearances, and identify potential site conflicts before equipment arrives. Plant visits also catch any specification mismatches while changes are still simple and inexpensive.

The scrubbing solution continuously recirculates through the system—spraying down through packing material, collecting contaminants, then returning to the recirculation pump. Eventually, the solution requires treatment or disposal as it accumulates neutralized salts and reaction products. Most facilities either discharge to sewer under industrial pretreatment permits or collect for offsite disposal. Viron can integrate pH control systems with automated chemical dosing to maintain proper neutralization levels. 

Optional equipment includes pH monitors with probes, neutralizing chemical control systems (pH, ORP, or TDS monitoring), dual redundant pumps for reliability, and secondary containment systems. However, obtaining discharge permits and managing wastewater disposal remains your responsibility and should be addressed during project planning.

Integration depends on whether your existing fan and ductwork can handle additional system resistance and whether materials are compatible with your air chemistry. Adding a scrubber increases system static pressure—your existing fan may lack capacity for this added resistance. 

Viron engineers calculate total system pressure including your existing ductwork, the new scrubber, and all fittings to determine if fan replacement is necessary. Material compatibility is critical—connecting different materials requires proper transition sections with compatible gaskets. Standard packing depth ranges from 12" to 180" depending on required removal efficiency, with VBS blower-scrubber units using 12" to 60" packing. 

The best approach: provide your existing system drawings, fan specifications, and duct material details so we design proper integration before fabrication starts.