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Düsenbodenwäscher

PlasmaAir AG plans, develops and builds Düsenbodenwäscher to reliably remove volatile hydrocarbons from industrial exhaust air streams.

Nozzle-floor scrubber

PlasmaAir AG has developed Düsenbodenwäscher specifically designed and optimised to remove volatile hydrocarbons such as ethanol from exhaust air streams. The Düsenbodenwäscher consists of a column with several sieve trays and removes alcohols from the exhaust gas stream through physical absorption.

Each Düsenbodenwäscher is individually tailored to the specific exhaust air challenge and designed to suit the raw gas concentration, flow rate and required clean gas values.

The procedure

In the absorption process, water-soluble components are removed from the gas phase of the exhaust air using a liquid. Water is used as the absorbent, without any added chemicals.

Water is used as the liquid to dissolve the alcohol. The water is discharged to the wastewater treatment plant. The Düsenbodenwäscher ensures compliance with the clean-gas values specified in TA Luft, even at high raw-gas concentrations.

Benefits

Minimal equipment requirements – simple, robust design

Low pressure drop thanks to the design

No water circulation pump required

Corrosion-resistant – plastic equipment

Low capital and operating costs

Ethanol separation

Ethanol was the key medium used for process qualification. Several measurement series demonstrated that even high raw gas concentrations can be safely reduced to below the limit values with comparatively low water consumption.

Laboratory qualification: At an exhaust air flow rate of 1,200 m³/h and a raw gas ethanol concentration of 1,000 mg C/m³, a clean gas concentration of 40 mg C/m³ was measured, with a water flow rate of just 500 l/h.

Industrial application – colouring chicken eggs: A Düsenbodenwäscher was installed to clean the exhaust air from three roller machines. The operating point is at a volumetric flow rate of 675 Bm³/h and a raw gas concentration of over 3,500 mg C/m³. With a set water flow rate of 0.75 m³/h, a clean gas value of 42 mg C/m³ is achieved. Compliance with the limit values was confirmed by measurements carried out by TÜV.

What is remarkable here is the ratio: despite a raw gas load more than three times higher, the clean gas value remains practically at laboratory level – the separation efficiency is around 99%.

Methanol separation

Since 2015, a spray tower Düsenbodenwäscher has been cleaning methanol-containing exhaust gases from a chemical batch reactor. The raw gas flow rate is 400 Bm³/h.

The special feature of this application is its batch process: the reaction produces pronounced concentration peaks of around 4 g/Bm³ of methanol. The Düsenbodenwäscher must handle these fluctuations without readjustment. With a water consumption of 467 l/h, the methanol concentration is reduced to around 0.09 g/m³, keeping it consistently well below the statutory limit—even during peak concentrations.

This demonstrates that the spray tower Düsenbodenwäscher is suitable not only for constant exhaust air flows, but also operates reliably when pollutant loads fluctuate significantly.

Isopropanol separation

Since 2012, Düsenbodenwäscher have been used to remove isopropanol from the exhaust air at industrial cleaning stations for electrical components. Applicable emission limits are also reliably met in this application.

The several years of operating experience to date demonstrate the process’s long service life: as water is used exclusively as the absorbent and the equipment is made of plastic, the handling of chemicals and corrosion-related wear are largely eliminated.


Implemented plant sizes

Several plants with flow rates of up to 5,000 m³/h are in operation. The largest scrubber built to date was designed for a flow rate of 12,000 Bm³/h and an alcohol concentration of 2 g/m³.

In 2024, a plant with a capacity of 2 × 10,000 Bm³/h was commissioned at Siemens Energy to treat exhaust air from fuel cell production.

Ethanol separation

Ethanol was the key medium used for process qualification. Several measurement series demonstrated that even high raw gas concentrations can be safely reduced to below the limit values with comparatively low water consumption.

Laboratory qualification: At an exhaust air flow rate of 1,200 m³/h and a raw gas ethanol concentration of 1,000 mg C/m³, a clean gas concentration of 40 mg C/m³ was measured, with a water flow rate of just 500 l/h.

Industrial application – colouring chicken eggs: A Düsenbodenwäscher was installed to clean the exhaust air from three roller machines. The operating point is at a volumetric flow rate of 675 Bm³/h and a raw gas concentration of over 3,500 mg C/m³. With a set water flow rate of 0.75 m³/h, a clean gas value of 42 mg C/m³ is achieved. Compliance with the limit values was confirmed by measurements carried out by TÜV.

What is remarkable here is the ratio: despite a raw gas load more than three times higher, the clean gas value remains practically at laboratory level – the separation efficiency is around 99%.

Methanol separation

Since 2015, a Düsenbodenwäscher has been cleaning methanol-containing exhaust gases from a chemical batch reactor. The raw gas flow rate is 400 Bm³/h.

The special feature of this application is its batch process: the reaction produces pronounced concentration peaks of around 4 g/Bm³ of methanol. The Düsenbodenwäscher must handle these fluctuations without readjustment. With a water consumption of 467 l/h, the methanol concentration is reduced to around 0.09 g/m³, keeping it consistently well below the statutory limit—even during peak concentrations.

This demonstrates that the Düsenbodenwäscher is suitable not only for constant exhaust air flows, but also operates reliably when pollutant loads fluctuate significantly.

Isopropanol separation

Since 2012, Düsenbodenwäscher have been used to remove isopropanol from the exhaust air at industrial cleaning stations for electrical components. Applicable emission limits are also reliably met in this application.

The several years of operating experience to date demonstrate the process’s long service life: as water is used exclusively as the absorbent and the equipment is made of plastic, the handling of chemicals and corrosion-related wear are largely eliminated.


Implemented plant sizes

Several plants with flow rates of up to 5,000 m³/h are in operation. The largest scrubber built to date was designed for a flow rate of 12,000 Bm³/h and an alcohol concentration of 2 g/m³.

In 2024, a plant with a capacity of 2 × 10,000 Bm³/h was commissioned at Siemens Energy to treat exhaust air from fuel cell production.

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PlasmaAir AG
Am Lindenberg 8

71263 Weil der Stadt

Email: info@plasmaair.de

Tel: +49 7033 30988 30

Legal notice

Privacy Policy

LinkedIn

PlasmaAir AG
Am Lindenberg 8

71263 Weil der Stadt

Email: info@plasmaair.de

Tel: +49 7033 30988 30

Legal notice

Privacy Policy

LinkedIn

PlasmaAir AG
Am Lindenberg 8

71263 Weil der Stadt

Email: info@plasmaair.de

Tel: +49 7033 30988 30