Spray towers are frequently utilized in high-temperature environments where flammable industrial waste gases and organic pollutants need to be treated. They are widely adopted in modern waste gas purification systems today. Below are six common issues encountered with spray towers and their corresponding solutions.
1. Nozzle Blockage
Cause: Excessive dust and impurities in the Water Tank can lead to clogged nozzles.
Solution: Begin by checking if the filter plate in the water tank is damaged, ensuring the water pump inlet has a filter net, and confirming the integrity of the bottom filter net of the water pump. Address these issues promptly by repairing or replacing them as needed. To dismantle the nozzle, first remove the window screw and take off the window panel. Enter the tower and unscrew the nozzle counterclockwise. Turn on the water pump (using clean water instead of the original water in the tank) and run it for about two minutes before reinstalling the nozzle clockwise.
2. Packing Material Blockage
Cause: Exhaust gases containing dust and sticky impurities, such as those from spraying or grinding, can accumulate on the packing balls.
Solution: Inspect the aforementioned causes and add a cleaning solution along with a bit of dish soap to the spray tower's water tank for cleaning. If the packing material becomes excessively dirty or sticky, consider replacing it or removing it for cleaning. After cleaning, refill the tower with fresh packing material. Regularly add cleaning agents and a small amount of dish soap to the water tank to keep the tank clear of floating debris. If any sediment accumulates, use a flocculant to maintain clean water in the tank.
3. Water Overflowing from the Demisting Layer
Cause: A shortage of demisting filler might result from excessive fan airflow or improper specifications regarding the height of the demisting layer.
Solution: Increase the amount of demisting filler or lower the grid plate within the tower. Alternatively, adjust the fan equipment inverter to reduce the airflow.
4. Packing Material Piling Up
Cause: Excessive fan airflow and mismatched specifications between the spray tower and fan can cause the packing material to pile up.
Solution: Remove the screws from the window, take off the panel, lay the packing material on it, and cover it with a layer of grid panel. Another option is to reduce the fan's airflow using its inverter.
5. Water Flowing Out from the Tank After Fan Operation
Cause: Mismatched gas inlet and outlet specifications with the fan airflow plan, or improper spray tower design relative to the fan.
Solution: Use the fan equipment inverter to reduce airflow, potentially widen the gas inlet and outlet, or adjust the float valve to regulate the water level.
6. Insufficient Water Emission from the Nozzle
Cause: The water pump may malfunction, the water level might be too low for the pump to draw water, the nozzle could be blocked, or the pump inlet might be obstructed.
Solution: Check if the water pump is functioning correctly. Ensure the water level isn’t too low; if it is, add more water immediately.
In conclusion, maintaining a spray tower requires regular checks and maintenance to prevent operational issues. These solutions help ensure the system operates efficiently and effectively.
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