PP spray tower is mainly used to deal with acidic and alkaline waste gas produced in the process of industrial production, through physical and chemical reaction, purify and treat the waste gas, so that it meets the national emission standards. The equipment is made of high-performance polypropylene (PP) material, which has good corrosion resistance, high strength, light weight and other characteristics.
A PP Spray Tower which also called a Polypropylene Spray Tower, Scrubber Tower, Gas Scrubber, Air Pollution Control Tower, Industrial Scrubber, Fume Scrubber, or Acid Gas Scrubber that is an engineered wet‑scrubbing system used to clean harmful industrial exhaust gases. Built from corrosion‑resistant polypropylene, it uses sprayed liquid and high‑surface packing to capture, dissolve, or neutralize contaminants before releasing cleaned air.
Our PP Spray Tower is designed for demanding industrial settings and can be customized for airflow, chemical load, and site conditions. The system is widely used for corrosive fumes or other aggressive gases where traditional steel or less‑resistant materials would fail.
Key advantages for industrial emission control
· Outstanding corrosion resistance. Polypropylene withstands acids, alkalis, salts, and many harsh chemicals—ideal for corrosive fumes from plating, chemical, or battery plants.
· High purification efficiency. Senotay’s design emphasizes thorough gas–liquid contact plus mist elimination, supporting removal levels that meet or exceed strict standards.
· Lower operating costs via smart design. A recirculation pump and efficient liquid use can cut water consumption substantially, helping operations manage both cost and environmental impact.
· Lightweight, durable construction. PP’s combination of strength and low weight simplifies transport, installation, and maintenance compared to heavier metal systems.
· Flexible for different airflow ranges and sites. Models can be sized for small labs, pilot setups, or larger manufacturing operations, indoors or outdoors; supporting portable, rooftop, or fixed installations.
Type No. | Tower diameter | Tower height | Airflow capacity | Packing type | Best use case | Typical efficiency |
1 | 800 mm | 6 m | 2,000–4,000 m³/h | PP rings | Small labs, pilot | ~85–90% |
2 | 1,000 mm | 6 m | 4,000–6,000 m³/h | PP rings | Small chemical plants | ~90–95% |
3 | 1,200 mm | 6 m | 6,000–8,000 m³/h | Structured or high‑area | Corrosive fumes, mid‑size | ~92–96% |
4 | 1,500 mm | 6–7 m | 8,000–12,000 m³/h | High surface packing | Metal finishing, plating | ~93–97% |
5 | 1,800 mm | 6–8 m | 12,000–17,000 m³/h | Layered PP packing | Larger chemical plants | ~94–97% |
6 | 2,000 mm | 6–7 m | 17,000–21,000 m³/h | Grid or mixed | Heavy industries | ~95–98% |
7 | 2,200 mm | 6–7 m | 21,000–25,000 m³/h | Multi‑stage | Large manufacturing | ~96–99% |
8 | 2,500 mm | 6–7 m | 25,000–32,000 m³/h | Hybrid packing | High‑load gas treatment | ~96–99% |
9 | 2,800 mm | 7 m | 32,000–40,000 m³/h | Multi‑stage | Industrial complexes | ~97–99% |
10 | 3,000+ mm | 7–10 m | 40,000+ m³/h | Specialized packing | Major plants, mega‑flows | ~97–99% |
Physical Dimensions | Performance Ratings | Material & Construction | Operational Data | Certifications & Lifecycle |
Tower Diameter: 600–3,000 mm | Pressure Rating: –2 to –5 kPa | PP / PP-H | –1.5 to –4.5 kPa | > 60,000 h |
Tower Height: 3,000–18,000 mm | Removal Efficiency (acid gases): 85–99% | PP Pall Rings (25–50 mm) | 2–25 m³/h | 10–20 years |
Inlet Diameter: 200–1,200 mm | Scrubbing Efficiency (PM ≥ 2 μm): 70–95% | 6–18 mm | 1,500–85,000 m³/h | ISO 9001 / CE |
Outlet Diameter: 250–1,000 mm | Max Temperature: ≤ 80°C | PP/FRPP, Ø 3–6 mm | 1.1–11 kW | Class A (acids/alkali) |
Flange Size: DN200–DN1200 | Gas Velocity: 1.5–3.0 m/s | PP-reinforced | 600–1,300 Pa | ≤ 30 mg/m³ |
(BCD): 300–1,150 mm | Liquid-to-gas Ratio: 3–8 L/m³ | EPDM / FKM | 120–2,800 kg | EPA / EN 12741 |
Access Door: 400×600 / 500×700 mm | pH Neutralization Range: pH 6–8.5 | 8–12 mm | 40–120 Nm | Anti-UV stabilized PP |
Base Plate Size: 800–3,500 mm | Max Gas Concentration: ≤ 450 mg/m³ | Silicone / PTFE | 0.2–1.2 m³/h | Every 6–9 months |
Material Characteristics:
Property | Description |
Material Type | 100% High-Grade Polypropylene (PP) |
Corrosion Resistance | Excellent against acids, alkalis, and salts |
Temperature Resistance | -10°C to 120°C (14°F – 248°F) |
Density | 0.91 g/cm³ |
Tensile Strength | ≥33 MPa |
Flexural Modulus | 1,400 MPa |
Color | Natural / Custom Optional |
Certifications | CE, ISO 9001, ISO 14001, RoHS |
1. Polluted gas entry. Exhaust containing corrosive fumes enters the lower section of the tower.
2. Liquid spray distribution. A pump sends scrubbing liquid to nozzles that spray it downward as a mist.
3. Gas–liquid interaction. Gas rises through the tower, passing through packing layers where it contacts the liquid. Pollutants dissolve, react, or are captured by the scrubbing solution.
4. Mist elimination. Before discharge, a dehydration or mist removal stage strips out entrained droplets to prevent carry‑over or condensation.
5. Clean gas exit. The purified gas is discharged, often through a fan or duct.
6. Liquid recirculation. The spent liquid is collected at the base, pumped back, and reused—minimizing fresh water needs and supporting continuous operation.
This counter‑flow or optimized flow design closely follows proven wet‑scrubber principles widely accepted in air‑pollution control and cited by environmental authorities.
Typical users include industries that generate corrosive or chemically aggressive fumes where regulatory compliance and equipment longevity are critical:
· Metal finishing and electroplating plants.
· Chemical manufacturing and processing facilities.
· Pharmaceutical and fine‑chemical production.
· Printing or spraying operations with acid or alkaline emissions.
· Battery, fertilizer, or pesticide factories.
· Waste gas or odor treatment facilities.
· Electronics and semiconductor production.
· Any factory needing a reliable, corrosion‑resistant industrial scrubber.
· Corrosion‑resistant polypropylene construction.
· High treatment efficiency for acidic, alkaline, or corrosive fumes.
· Compact, high‑strength, lightweight design for easier handling.
· Automated controls, manual debugging, and fault alarms to simplify operations.
· Low running and maintenance costs, designed for economic long‑term use.
· Customizable sizing, air volume, and parameters, tailored to different working conditions.
· Suitable for indoor, outdoor, rooftop, or portable/moveable installations.
A Senotay PP Spray Tower system typically includes:
· Tower body and shell made of PP.
· Packing layer to enhance contact surface.
· Spray nozzles / spraying device.
· Demister / dehydration layer.
· Circulating pump and liquid tank.
· Inspection windows or access points.
· Exhaust fan, piping, and valves.
· Control panel for automation and alarms.
Each element is chosen or sized to ensure high efficiency, strong corrosion resistance, and ease of maintenance.
Works for indoor, outdoor, rooftop, and portable setups. Key steps:
1. Site foundation: prepare a level base or structural support according to tower size.
2. Modular assembly: tower and internals are assembled on-site—often facilitated by PP’s low weight.
3. Alignment and anchoring: fix brackets and ensure vertical alignment for stable operation.
4. Ducting connections: connect inlet and outlet to existing exhaust or ventilation systems.
5. Pump, piping, and electrical setup: install circulation pump, control wires, and valves.
6. Liquid fill and commissioning: add scrubbing liquid, test flow, check for leaks, and calibrate controls.
7. Operator training: ensure staff understand operation, monitoring, and basic maintenance.
For portable or rooftop installations, the light PP structural weight and modular design make transport and positioning easier compared to heavy steel systems.
Senotay emphasizes a combination of field experience, quality control, and advanced materials:
· Long‑term engineering experience in industrial air purification, with a track record of installations across varied industries and geographies.
· ISO‑certified processes supporting consistent manufacturing quality and verified performance claims.
· High‑efficiency design: careful integration of packed beds, mist elimination, and smart recirculation for better cost and environmental outcomes.
· Customization capabilities for airflow ranges, pollution type, and site constraints, ensuring the system matches real operating conditions.
· Robust component selection: PP tower body, packing, and spray devices selected to maximize contact and minimize corrosion issues.
These strengths support systems that are both effective today and future‑proof against tightening emission standards or harsher process conditions.
Q1: What gases can a PP Spray Tower remove?
Answers: It effectively removes acidic gases (HCl, SO₂), alkaline fumes (NH₃), and volatile organic compounds (VOCs).
Q2: How long is the service life of the PP Spray Tower?
Answers: With proper maintenance, the system offers up to 50,000 operational hours or 5 years warranty.
Q3: Is customization available?
Answers: Yes, Senotay provides fully customized tower sizes, inlet configurations, and control systems.
Q4: What maintenance is required?
Answers: Regular inspection of nozzles, pumps, and filtration liquid quality ensures optimal performance.
Q5: Can the PP Spray Tower be used outdoors?
Answers: Yes, it features IP54–IP55 protection, making it suitable for corrosive and outdoor environments.
