I’m seeking advice from experts regarding the issue of blockage in the packing layer of spray towers.
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This primary alkali spray packing tower has been clogged several times. According to feedback from the department, the possible reason is that the salt solution resulting from acid-base neutralization becomes saturated, causing the salts to precipitate and adhere to the surface of the packing; this leads to increasingly narrow gaps in the packing layer, thereby causing air blockage. Based on observations using a sight glass at the site, the upper layer of packing is unobstructed, while ventilation is difficult in the lower layer. The image shows workers using steam to purge the filler in order to dissolve the salt (purging does indeed help, and this was the method used before). Is there any better way to achieve this without having to disassemble anything? Replace the packing? Or reduce the cycle time for using alkaline water? ? ? ?
Your situation is quite typical: the lower part of the spray tower is blocked while the upper part is fine; it’s most likely that salt crystals have gotten stuck in the gaps of the packing in the lower section. Steam purging can provide a temporary solution, but repeated disassembly and assembly is indeed troublesome. Several approaches that do not involve dismantling the tower can be tried: 1. **Optimize the spray liquid**: The concentration of the alkaline solution can be reduced slightly, or the amount of water in circulation can be increased, so that the salt content does not easily reach saturation. If the water quality is hard, it is also helpful to carry out softening treatment in advance. 2. **Adjustment procedures**: Try increasing the spray volume intermittently to wash the packing, or regularly use hot water instead of steam for backwashing at the bottom of the tower, which can disperse the salt that has not yet solidified. 3. **Add anti-clogging agents**: There are dispersants available on the market for crystalline salts; adding them to the circulating fluid can delay salt deposition, but it is necessary to first confirm that the agent is compatible with the system. 4. **Packaging upgrade**: If you are facing problems over a long period, choose packing with a larger pore size and a smooth surface for the next replacement (such as PP multi-faced hollow spheres), as it is less likely to get clogged compared to traditional Raschig rings. For the short term, try flushing and adjusting the concentration first; if that doesn’t work, then consider replacing the filler. After all, a complete replacement requires shutting down the system, so it is the last option to consider. .
For reference: Increase the spray volume； Tracking the batches of acid and base required for the saturation concentration may make process adjustments easier
Thank you, boss. How exactly is the second point implemented? Does it mean connecting a hot water pipe at the bottom of the tower?
Thank you, boss. We can consider this; we’ll take into account the saturation concentration each time it’s replaced
Won’t this affect the spraying effect? The back-end resin adsorption system may need to be adjusted