Fumes Pre - Scrubber

Tinita Engineering Pvt. Ltd. offers a high-performance Fumes Pre-Scrubber designed to remove harmful gases and particulates from industrial exhaust streams. It is built for efficiency and reliability, this scrubber plays a key role in neutralizing emissions from chemical storage and combustion processes. We manufactured a fume pre-scrubber that featured a volume of 24.73m³, operated at a working temperature of up to 110°C, and had a delivery weight of 5,000 kg. It is ideal for use in petrochemical, chemical, pharmaceutical, oil & gas refineries, fertilizer, and pulp & paper industries.

Contact Us

For more information about Tinita Engineering Pvt. Ltd. and the Fumes Pre-Scrubber, please get in touch with us today. We’re here to assist with all technical and product-related inquiries.

Technical Specifications

Tinita fabricates each unit to project-specific process conditions. Standard design parameters are listed below.

Parameter	Standard Range
Gas Flow Capacity	500 to 50,000 Nm³/hr
Operating Temperature	Up to 200°C
Operating Pressure	Atmospheric to 4 bar (g)
Scrubbing Efficiency	60–85% particulate and gas removal
Material of Construction	SS 304, SS 316L, FRP, PP, Hastelloy C-276, Titanium
Throat Velocity	15–90 m/s
Liquid-to-Gas Ratio	0.5 to 3.0 L/Nm³
Customization	Per process datasheet and P&ID
Types of Fumes Handled	– Acidic gases such as HCl, SO₂, and HF require alkaline scrubbing liquid contact before reaching packed absorbers. Pre-scrubbers cut acid loading at the downstream stage by 65–80%. – Toxic vapors, including H₂S, Cl₂, and NH₃, need precise liquid-to-gas contact under controlled residence time. Venturi-based pre-scrubbers achieve this at throat velocities that maximize mass transfer. – Furnace and drying operation exhaust is laden with particulates and contains fine dust and condensables. Pre-scrubbers remove particles larger than 1-5 microns to avoid fouling of packed tower internals. Solvent fumes and VOC mixtures also benefit, with adsorbent bed life extending by 30–40% when aerosol content drops at the inlet stage.

Types of Venturi

Why Choose a Fumes Pre-Scrubber?

High-concentration gas streams carrying HCl, SO₂, HF, NH₃, or NOx overload final scrubbers fast. A pre-scrubber reduces inlet concentrations by 60–85% before gas reaches the downstream stage, cutting chemical consumption, maintenance frequency, and unplanned downtime.

Safety is equally critical. Pre-scrubbers create a first containment line for chlorine compounds, solvent vapors, and corrosive off-gases, keeping ambient concentrations below OSHA PEL thresholds. Facilities also meet CPCB, MOEF, and equivalent regional consent conditions more consistently when particulate and gaseous pollutant loads drop before the emission measurement point.

Plants retrofitting pre-scrubbers ahead of existing absorption towers report 20–35% improvement in final scrubber efficiency. That translates into longer service intervals and lower operating cost per unit volume of gas treated.

Industry Applications

Petrochemical: Reactor vents and distillation column off-gases carry mixed H₂S and entrained droplets. Pre-scrubbers reduce thermal oxidizer load and cut caustic consumption by up to 25%.
Chemical Processing: Chlor-alkali and acid manufacturing units produce aggressive HCl, Cl₂, and SO₃ streams requiring PP-lined, FRP, or Hastelloy C-276 construction, all materials Tinita fabricates routinely.
Pharmaceutical: Solvent recovery and API synthesis exhaust have aerosol with high concentration of VOCs. Pre-scrubbers reduce the loading to carbon adsorbers, which helps facilities remain in compliance with Schedule V consent conditions.
Fertilizer: Prilling towers and ammonia storage vents release NH₃ and urea dust. Pre-scrubbers cut ammonia slip to below 30 mg/Nm³ at the absorber outlet.
Oil and Gas: Sour gas streams at separator vent lines can carry H₂S above 3,000 ppm. Pre-scrubbers reduce concentration peaks before amine contactors, protecting solution quality and lowering regeneration energy.
Metal Processing: Pickling and electroplating lines generate HCl and HNO₃ fumes at low flow rates. Compact Venturi pre-scrubbers handle these streams with minimal footprint.

Working Principle

Contaminated gas enters the converging inlet and accelerates toward the Venturi throat. At 15–90 m/s, scrubbing liquid injected at the throat atomizes across the full gas cross-section. Particulates impact liquid droplets through inertial impaction; soluble gases dissolve into the liquid phase in milliseconds.

Past the throat, the diverging section slows the stream and promotes droplet coalescence. A separation chamber then strips the liquid phase from the gas. Liquid carrying dissolved gases and captured particulates discharges to a recirculation tank or neutralization pit. Clean gas exits through the outlet nozzle at particulate loads 60–85% lower than at the inlet.

Tinita sizes the recirculation system and chemical dosing arrangement as part of the complete package.

Advantages of Tinita Fumes Pre-Scrubber

Tinita holds ASME U, R, and NB stamps alongside ISO 9001:2015 certification. Third-party inspection by BV, TUV, Lloyd’s, and DNV covers every unit before shipment.

Tinita has a production capacity of 1,500 MT/year in exotic metals. Tinita supplies Hastelloy, Inconel and Titanium constructions for HF service, concentrated acid streams and high temperature corrosive environments. Each unit is supplied with a documentation package comprising MTRs, weld procedure qualifications, hydrostatic test certificates and third-party inspection reports, which can be used for regulatory submissions without any further effort from the client’s side.

Fabrication at the Dahej facility supports faster dispatch to the Middle East, Southeast Asia, and Africa, with custom nozzle orientations, drain arrangements, and instrumentation taps configured to match site P&IDs exactly.

FAQ's

What is a Fumes Pre-Scrubber?

A pre-scrubber removes the bulk of particulates, soluble gases, and reactive vapors from an exhaust stream before it reaches a final treatment stage. It protects downstream equipment and reduces overall treatment cost by handling the high-concentration portion of the contaminant load first.

How does a Fumes Pre-Scrubber work?

Gas accelerates through a Venturi throat, where injected scrubbing liquid atomizes and contacts the stream at high velocity. Particulates stick to droplets; soluble gases dissolve into the liquid. A separator discharges the liquid with captured contaminants, and the partially cleaned gas exits to downstream treatment.

Why is a pre-scrubber important in continuous industrial processes?

High-concentration inlet loads degrade packed tower internals faster and push scrubber performance outside its design envelope. Pre-scrubbers keep downstream units at rated efficiency by limiting inlet concentration to within their design window.

What fumes can a pre-scrubber handle?

Acidic gases (HCl, SO₂, HF), toxic vapors (Cl₂, H₂S, NH₃), particulate-laden exhausts, solvent fumes, corrosive mixed-gas streams. The scrubbing liquid chemistry and material selection are modified to the specific contaminant profile.

Which industries use Fumes Pre-Scrubbers the most?

Petrochemical, chemical processing, pharmaceutical, fertilizer, oil and gas, and metal surface treatment use these fume pre-scrubbers a lot. Any process generating high-concentration gaseous pollutants ahead of an existing scrubbing system benefits from pre-scrubber installation.

What is the difference between a Fumes Pre-Scrubber and a Venturi Scrubber?

The Venturi Scrubber is a final treatment unit. It is designed to satisfy the full emission requirements on its own . A Fumes Pre-Scrubber is only designed for bulk removal and is the first step in a multi-stage train. Pre-scrubbers can accept higher inlet concentrations and lower final efficiency in exchange for higher contaminant throughout capacity.