Hybrid cyclone spray tower

The Hybrid Cyclone Tower (also known as a "Cyclone Hybrid Spray Tower" or "Hybrid Cyclone Tower")

This is a wet purification device that integrates high-speed cyclonic centrifugal separation with multi-layer spray absorption within a single tower. It couples five mechanisms: inertia, centrifugation, collision, emulsification, and absorption, completing the entire process of "particulate matter capture + gaseous pollutant absorption + demisting and dehydration" within the same device.

I. Working Principle (Four-Step Integration)

1. Cyclonic Entrainment

Dust- or pollutant-laden exhaust gas, under the negative pressure of the fan, enters the "cyclone generator" (guide vanes + cyclone) at the bottom of the tower tangentially. The airflow is instantly accelerated to 15-25 m/s, creating a highly swirling flow field.

2. Gas-Liquid Emulsification

A circulating water pump at the bottom of the tower delivers the absorption liquid (water, alkali solution, or oxidant) to the spiral nozzle at the top of the tower, where it is sprayed in a countercurrent direction. Under the action of the high-speed cyclonic flow, the liquid droplets are sheared and atomized into micron-sized droplets, which are then thoroughly mixed with the swirling airflow to form a "gas-liquid emulsion system." • Particles: Centrifugal force throws them toward the tower wall, where they collide with the liquid film and are carried downward.
• Gaseous pollutants (HCl, NH₃, BTEX, etc.): Dissolve, neutralize, or oxidize in the emulsification zone.

3 Centrifugal Separation
The emulsified system enters the "converging-diverging" centrifuge cylinder, where the flow radius gradually decreases and the centrifugal force increases exponentially. High-density droplets and dust particles are thrown toward the walls, flowing downward along the walls into the sump. The purified dry gas converges toward the central axis and rises.

4 Packing Fine Washing + Demisting
The rising airflow then passes through one or two layers of packing (Pall rings or hollow balls) and a secondary spray to further remove residual contaminants. A corrugated plate or wire mesh demister at the top intercepts entrained droplets, and the clean gas is finally discharged by the fan to meet standards.
The entire process involves a closed-loop liquid cycle, and sediment is regularly removed by a scraper or sludge removal device.

II. Structural Features
• Integrated design: Swirl section + spray section + filler section + demisting section, integrating four functions, occupying less than 60% of the footprint of a conventional spray tower with the same air volume.
• Non-clogging nozzle: Utilizes a large-diameter spiral nozzle with an internal filter cartridge, making it less susceptible to clogging by paint residue and fibers.
• Detachable swirl module: Made of SUS304/316L or FRP, it can be removed and replaced entirely if worn.
• PLC variable frequency control: Automatically adjusts fan speed based on pressure differential, saving over 30% energy.

III. Applicable Gas/Dust Applications
Industry Typical Pollutants Design Considerations
Automotive/Furniture Spray Painting Paint mist, benzene-based VOCs, sticky dust Tower body: SUS304, paint mist flocculant added to circulating water
Hardware Grinding/Polishing Metal dust (oil-containing) Pre-cyclone to remove large particles, tower equipped with scrapers
Chemical/Pharmaceutical HCl, NH₃, HF, dichloromethane Two-stage absorption: pre-water + post-alkali/oxidizing solution
Waste Incineration/Sewage Treatment Plant Odor, NH₃, H₂S Tower body: FRP corrosion protection, circulating water added with sodium hypochlorite
Boiler/Kiln Exhaust: Smoke, SO₂, NOₓ Cooling to <80°C before tower entry

IV. Technical Performance Indicators (Typical Values)
• Airflow: 5,000–80,000 m³/h (parallel expansion possible)
• Dust Removal Efficiency: ≥99% (particles ≥1 μm)
• Demist Removal Efficiency: ≥95%
• Pressure Drop: 800-1200 Pa
• Operating Temperature: ≤80°C (FRP); ≤150°C (SUS316L)

V. Advantages Compared with Conventional Spray Towers
① Centrifugal pre-separation reduces filler load by 70%, making it less prone to clogging.
② Rotating airflow enhances mass transfer, increasing purification efficiency by over 15% for equipment of the same volume.
③ No moving parts, simplifying maintenance, with annual maintenance costs less than 2% of the equipment investment.

The hybrid cyclone tower utilizes a coupled mechanism of "high-speed cyclone + multi-stage spraying" to simultaneously capture particulate matter and absorb gaseous pollutants even under complex operating conditions such as highly viscous dust, oily mist, clogging, and high air volume. It is a highly effective choice for waste gas pretreatment or deep purification in industries such as spraying, chemical engineering, and metallurgy.