UltraScrub Acid Fume Scrubber
A Tri-Mer technology for controlling sulfuric acid fume from dry charge formation operations offers the highest collection efficiencies possible at all loading levels. (View a brochure of a Horizontal Crossflow UltraScrub Model in Acrobat pdf file format.) Developed for East Penn-Deka, (Lyon Station, PA), the system relies on mechanical separation, and does not use chemicals.
Goals set by East Penn included operation "24/7" with zero shutdown, and collection efficiency greater
East Penn consulted Tri-Mer, whose Fan/Separator, Crossflow fume scrubber and Whirl Wet lead oxide collector systems all had solid track records within battery forming. What emerged was UltraScrub, a hybrid, scaleable technology that incorporated key features from those systems.
At East Penn, the first phase of a 3-phase program employed six UltraScrub units, installed side-by-side. Each is ducted to a single 9' diameter plenum. This configuration allows any unit to be shut down for annual maintenance or other purposes and restarted seamlessly. Five units operate continuously,
one is a maintenance back-up. The acid fume scrubber units, which are UV-stabilized polypropylene, each have a capacity of 32,000 cfm.
UltraScrub units have four stages, arranged as a series of cartridges. The first stage is a proprietary rigid tube packing, a media first proved on Tri-Mer's Fan Separator. The Fan / Separator is a low energy, low water use acid scrubber for the control of sulfuric hydrochloric, hydrofluoric and nitric acids. Its packing media performs at 99%+ efficiency on sulfuric acid fume at all loading levels. Engineered for battery forming mist, it sacrificially prefilters the air prior to the scrubber section. There is no visual carryover
from stage one forward.
Mists next contact a stage containing 1" Tri-Packs "random-dump" packing media. This media prevents the formation of dry spots and compression interlock, two problems common to packing media that cause liquid and air to channel, thereby reducing system efficiency. Tri-Packs develops a very low static pressure per foot of depth, so both tower size and the amount of scrubbing liquid can be minimized.
The third stage is an interwoven polypropylene Kimre pad; stage four is a rigid chevron blade mist eliminator which removes droplets from the system. The dual mist eliminator developed by Tri-Mer has a minimum performance requirement of 99% on 2 micron droplets. The captured sulfuric acid mists are sent with other process wastewaters to the company's waste treatment plant.
The UltraScrub acid fume scrubber systems operate "dry" at least 99% of the time. Each stage has an independent magnehelic gage to indicate when cleaning is necessary. To prevent the corrosion of the fan from exposure to sulfuric acid mists, the fan is installed at the back end of the scrubber; any fume drawn through is cleaned and exhausted before contact.
The order to design, build and install the first three UltraScrub units, along with plenums, fans and stacks, was fast-track: a major contract that held East Penn to firm delivery dates kept lead time to just 65 days.
All of the units operate as engineered. Additional UltraScrub acid fume scrubber units will be installed as part of the second and third stages of the project.* East Penn is a leading manufacturer of lead-acid batteries for the automotive, telecommunications, marine, commercial, industrial and stationary market.
1400 Monroe Street • P.O. Box 730 • Owosso, MI 48867; USA
Phone: (989) 723-7838 • Fax: (989) 723-7844
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