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6 common problems and solutions for water spray towers
Spray towers are widely used in industrial waste gas purification for high-temperature flammable environments, particularly for treating organic waste gases. These systems are essential tools in modern waste gas treatment.
Here are six common issues and their solutions related to spray towers:
1. Nozzle Blockage
Problem: The nozzles become obstructed due to excessive dust and impurities in the water tank.
Solution: First, inspect the filter plate of the water tank for damage, confirm if the water pump's inlet has a filter mesh, and check the condition of the bottom filter. Replace or repair any faulty components promptly. To disassemble the nozzle, unscrew the window and remove the panel. Enter the tower, then detach the nozzle counterclockwise. Turn on the water pump using clean water (replace the existing water in the tank) and run it for two minutes before reinstalling the nozzle clockwise.
2. Filler Blockage
Problem: Dusty and sticky impurities adhere to the filler balls, especially in waste gases like spraying and grinding.
Solution: Check for these causes and add cleaning agents along with a bit of detergent to the spray tower's water tank for a basic cleaning. If the filler becomes excessively clogged, replace it or remove it for cleaning. Cleaned fillers can either be reused or swapped with new ones. Regularly maintain the water tank by adding an appropriate amount of cleaning solution and detergent, and remove floating debris. Add a flocculant if there is sediment to keep the water clean and free of particles.
3. Defogging Layer Water Leakage
Problem: Insufficient defogging filler could result from excessive fan airflow or improper design specifications for the defogging layer's height.
Solution: Increase the defogging filler, possibly lower the filler layer's grid plate inside the tower, or add more filler to the defogging layer. Alternatively, reduce the fan's air volume using its inverter.
4. Filler Piling Up
Problem: Excessive fan airflow and mismatched spray tower specifications cause the filler to pile up.
Solution: Remove the screws, take off the window panel, lay the filler on it, and place a grid panel on top, or decrease the fan's air volume via its inverter.
5. Water Overflowing from the Tank After Fan Operation
Problem: Mismatched gas inlet and outlet specifications with the fan's air volume, or improper spray tower design relative to the fan.
Solution: Adjust the fan's inverter to reduce air volume, increase the gas inlet and outlet, or use a float valve to regulate the water level.
6. Minimal or No Water Emission from Nozzles
Problem: The water pump might be running without drawing water due to low water levels, nozzle blockage, or a blocked water pump inlet.
Solution: Ensure the water pump is functioning correctly, check the water level, and add water if necessary. Verify the pump's inlet for blockages.
These solutions aim to keep spray towers operating efficiently and effectively, ensuring proper waste gas treatment while minimizing downtime.