Project Case Study
Advanced Zinc & Acid Fume Extraction and Wet Scrubbing System
Acid Fume Scrubbing Technology
Complaince:
Designed to support compliance with SEPA environmental permit requirements, BAT guidelines, the Pollution Prevention and Control (Scotland) Regulations 2000 (SSI 2000/323), and BS ISO 9096:2003 particulate emission monitoring standards.
Certification
UKCA and CE marking
Corrosive Operating Conditions
The presence of acidic fumes and moisture demanded highly corrosion-resistant construction materials throughout the system, including ducting, scrubber internals, and blower components.
Overview
UK based client engaged Kapwell to design and supply a complete Zinc & Acid Fume Extraction Scrubber System for its industrial plant in the Scotland. The project aimed to upgrade the existing fume extraction infrastructure with a modern, high-efficiency scrubbing solution capable of safely handling zinc oxide particulates, ammonium chloride fumes, and acid vapours generated during the industrial process. The industrial process generates extremely fine sub-micron zinc oxide particles which are hygroscopic and difficult to remove efficiently using conventional extraction systems. In addition, the operating environment involved corrosive fumes, high airflow requirements, and limited installation space within the existing plant layout.
Kapwell developed a complete engineered solution incorporating a zinc dust collection cyclone, wet packed bed scrubber, corrosion-resistant ducting system, high-capacity centrifugal blower, and automated electrical control system designed specifically for continuous industrial operation. The project was delivered with full CE/UKCA compliance and modular construction for simplified installation and maintenance.
Key Challenges
High Fine-Particulate Loading
The industrial process produced fine zinc oxide particulate and ammonium chloride fumes that required efficient pre-separation and wet scrubbing to minimize environmental emissions and equipment fouling.
Corrosive Operating Conditions
The presence of acidic fumes and moisture demanded highly corrosion-resistant construction materials throughout the system, including ducting, scrubber internals, and blower components.
Large Airflow and Pressure Requirements
The system was required to process approximately:
- 69,320 CFM airflow
- 325 mmWG static pressure
while maintaining stable extraction performance and operational efficiency.
Limited Installation Space
The equipment needed to fit within an existing operational facility while remaining transportable and modular for installation.
Environmental and Safety Compliance
compliance with SEPA environmental permit conditions.
Solution
Kapwell engineered a complete fume extraction and scrubbing package utilizing a multi-stage separation approach designed specifically for zinc and acid fume applications..
Key Features:
- Wet packed bed scrubber with integrated water recirculation
- Zinc dust collection cyclone separator
- High-efficiency centrifugal blower system
- Corrosion-resistant PP-FRP and PP-CP ducting
- Integrated mist eliminator section
- Variable Frequency Drive (VFD) control system
- Modular transport-friendly construction
- CE / UKCA compliant package
- SS316 fasteners and corrosion-resistant internals
Key
Features
Zinc Dust Collection Cyclone
Kapwell designed a dedicated cyclone separator upstream of the scrubber system to remove heavier zinc particles before wet scrubbing.
The cyclone utilized centrifugal separation principles to:
- Induce controlled vortex airflow
- Separate zinc particulate from the gas stream
- Reduce particulate loading on the scrubber
- Prevent dust re-entrainment
- Improve overall system efficiency
The conical cyclone geometry maintained stable air velocity while directing separated dust particles into a sealed collection section for safe removal.
Wet Packed Bed Scrubber System
The wet scrubber system consisted of a vertical packed vessel incorporating:
- Integrated water storage tank
- Pall ring packing media
- Water spray system
- Mist eliminator
- Recirculation pump system
The upward gas flow combined with downward recirculated water created efficient gas-liquid contact, allowing zinc particulate and acidic contaminants to be captured within the packed bed section. Positioned above the packing media, the mist eliminator removed entrained droplets and residual particulate before clean air discharge.
Corrosion-Resistant Construction
Due to the aggressive chemical environment, the system was fabricated using carefully selected materials to ensure long-term durability and operational reliability.
Quality Assurance and Testing
Kapwell implemented a comprehensive QA/QC and inspection program throughout manufacturing and assembly.
Inspection and Testing Included
- Material verification and MTC review
- Lamination and curing inspections
- Dimensional inspections
- Hydrotesting
- Air leak testing
- Mechanical run testing
- Factory Acceptance Testing (FAT)
All primary materials were supplied with EN 10204 3.1 certification.
Standards and Compliance
The package was engineered in accordance with recognized European and international standards including:
- EN 13121
- EN ISO 12100
- EN 60204-1
- EN 61439
- EN 13480
- IEC 60034
- ISO 9001
Results
The upgraded scrubber system delivered:
- Improved zinc particulate removal
- Enhanced acid fume scrubbing efficiency
- Reduced environmental emissions
- Improved plant safety
- Long-term corrosion resistance
- Reduced maintenance requirements
- Energy-efficient airflow control
- Modular installation advantages
The project demonstrated Kapwell’s capability to engineer and deliver complex industrial air pollution control systems tailored to demanding process environments.
Kapwell Capability
Kapwell provides advanced engineered solutions for:
- Wet scrubbers
- Cyclone separators
- Industrial ventilation systems
- Fume extraction systems
- Corrosion-resistant process equipment
- Dust collection systems
- Environmental compliance upgrades
Gas and particulate separation technology