Project Overview
ADFC was contracted to design, fabricate, and install a corrosive acid gas wet scrubber system for a chemical synthesis and specialty fertilizer blending plant in the Port of Newcastle industrial precinct.
The Engineering Challenge
Batch acidification reactors discharge highly corrosive hydrochloric (HCl) and sulfur dioxide (SO₂) acidic vapors under variable thermal loads. The scrubber plant required 99.5%+ gaseous neutralization efficiency, zero corrosion vulnerability, and automated caustic dosing control.
Our Engineered Solution
ADFC engineered a custom vertical Counter-Current Packed Bed Wet Scrubber fabricated from chemical-resistant thermoplastic materials:
- Corrosion-Proof Polypropylene (PP-H) Construction: High-grade UV-stabilized sheet with continuous fusion welding for extreme chemical longevity.
- High-Surface Random Packing Bed: Tellerette polyethylene packing rings offering maximum gas-liquid contact area with minimal liquid holdup.
- Automated pH Dosing System: Dual redundant industrial glass pH probes connected to digital dosing pumps and automated blowdown solenoid valves.
- High-Efficiency Chevron Mist Eliminator: Blade-type droplet separators preventing caustic liquid carryover into the discharge stack.
Commissioning & Outcome
Third-party stack emission testing confirmed acid neutralization efficiency in excess of 99.8%, fully meeting NSW EPA Environment Protection Licence conditions with zero fugitive odor emissions.
