三方機械工業股份有限公司

AI-Driven + Digital Twin Empowerment:
The Intelligent Purification Revolution of the Hybrid Electrochemical Scrubber Apparatus (HESA)

In 2026, as our company reaches the milestone moment of its 64th anniversary since establishment, looking back to January 1, 1962, when the company was founded, with the long-term trust and support from all sectors, the enterprise has achieved leapfrog growth; the Scrubber Apparatus, after 35 years of repeated technological iteration and accumulation, successfully broke through the bottleneck of traditional exhaust gas treatment technologies one and a half years ago, developing an internationally leading energy-saving Hybrid Electrochemical Scrubber Apparatus; today, it further integrates dual-membrane technology, digital twin, AI, and fuzzy control technologies, creating a new-generation Hybrid Electrochemical Scrubber Apparatus (HESA), opening a new intelligent era of industrial exhaust gas governance.

Under the industrial environmental protection context of deep advancement of dual-carbon targets and increasingly stringent ESG disclosure standards, HESA relies on four core technological genes of “dual-group multi-layer array electrode plates precise regulation + physical electrochemical breakthrough + dual-membrane synergistic enhancement + AI intelligent evolution” to break the passive pattern of traditional end-of-pipe treatment. It is no longer a single pollution treatment device, but an intelligent environmental hub deeply integrating fuzzy control, holographic digital twin, and cutting-edge composite treatment technologies. Through a full-chain solution of graded treatment, precise decomposition, deep interception, intelligent regulation, and data traceability, HESA redefines the value dimension of industrial exhaust gas treatment, assisting enterprises in achieving a disruptive upgrade from “compliance achievement” to “value creation.”

I. Technical Principles and Structural Design: Five-Stage Treatment Chain Building the Foundation of Precise Purification

The core technical advantages of HESA originate from the precise design of the full process of “gas–liquid intensified contact – electrochemical deep degradation – solid–liquid efficient separation,” constructing a five-stage treatment chain of stabilized-pressure decelerated gas inlet → accelerated vortex scrubbing → electrochemical deep degradation → decelerated gas–liquid separation → solid–liquid separation circulation. Each stage is supported by fundamental physical theories, striving to design an energy-saving and highly efficient industrial dust and exhaust gas treatment equipment to the greatest extent possible.

1. Stabilized-Pressure Decelerated Gas Inlet Stage: Uniform Gas Distribution Laying the Foundation for Efficient Treatment

Exhaust gas enters the stabilized-pressure chamber under negative/positive pressure drive. The chamber adopts an “expanded-diameter buffering” structural design, achieving gas flow deceleration and stabilization by enlarging the flow cross-sectional area. According to fluid mechanics principles, this design allows the velocity of turbulent gas flow to become uniform, completely avoiding interference of local airflow disturbance with subsequent scrubbing efficiency, while effectively reducing system pressure loss. Compared with traditional straight-cylinder inlet structures, pressure loss is reduced by more than 30%.

2. Accelerated Vortex Scrubbing Stage: Gas–Liquid Vortex Intensified Mass Transfer, Enhancing Pretreatment Efficiency

The stabilized gas flow enters the helical vortex water scrubbing chamber. The inner wall of the chamber is designed with spiral guide grooves, and the gas flow rotates at high speed along a spiral trajectory; scrubbing water is injected at high speed from the tangential direction, surrounding the rotating gas flow within the treatment chamber to form a “gas–liquid vortex flow.” Under shear force, water mist particle size is refined to ≤50 μm.

This structure significantly increases the gas–liquid contact area (5–10 times higher than traditional scrubber towers) and extends gas–liquid contact time to 2–3 seconds (traditional scrubber towers only 0.5–1 second). According to the Lewis–Whitman dual-film theory, increases in gas–liquid contact area and contact time directly drive a leap in mass transfer efficiency: removal efficiency for dust particles ≥1 μm reaches over 99.5%, and capture efficiency for polar VOCs such as alcohols and aldehydes reaches over 85%, firmly establishing the pretreatment foundation for subsequent deep degradation.

3. Multi-Layer Array Metal Electrode Electrochemical Deep Degradation Stage: Authoritative Theory Support Achieving Ultimate Pollutant Decomposition

The gas–liquid mixture after the first-stage treatment enters the multi-layer array metal electrode electrolysis reaction zone, which is the core unit for HESA to achieve deep pollutant degradation. The technical principle is based on electrochemical redox theory and free radical reaction mechanisms. Through the triple effects of “anodic metal ion catalysis + cathodic radical oxidation + pulsed current enhancement,” complete mineralization of organic pollutants and stable solidification of heavy metals are achieved.

• Anodic Reaction: Metal Ion Catalytic Oxidation, Targeted Degradation of Organic Pollutants

The electrode assembly adopts iron/aluminum composite anodes. After energization, anodic oxidative dissolution reactions occur:

Fe − 2e⁻ = Fe²⁺
Al − 3e⁻ = Al³⁺

Under acidic conditions, Fe²⁺ is further oxidized to Fe³⁺:

4Fe²⁺ + O₂ + 4H⁺ = 4Fe³⁺ + 2H₂O

The generated Fe³⁺ and Al³⁺ possess strong catalytic oxidation capability and can directionally attack functional groups of organic pollutants such as aldehydes and ketones. Taking formaldehyde degradation as an example, the reaction pathway is:

HCHO + 2Fe³⁺ + H₂O = CO₂↑ + 2Fe²⁺ + 4H⁺

This reaction mechanism references the “metal ion catalytic oxidation mechanism” in the Electrochemical Engineering Handbook (3rd Edition, USA), ensuring high efficiency and stability of the degradation process.

• Cathodic Reaction: Non-Selective Radical Oxidation, Destroying Refractory Pollutant Structures

At the metal cathode under energized conditions, water electrolysis reduction reactions occur:

2H₂O + 2e⁻ = H₂↑ + 2OH⁻

Simultaneously, under a strong electric field of 5–20 V, highly active hydroxyl radicals (·OH) are generated on the cathode surface, with a redox potential as high as 2.8 V, capable of non-selectively destroying stable organic structures such as benzene rings and ester groups. Taking toluene degradation as an example, the reaction pathway is:

C₇H₈ + 16·OH = 7CO₂↑ + 12H₂O

Testing shows that this technology’s degradation efficiency for refractory VOCs is 3–5 times that of traditional chemical oxidation methods (data referenced from Japan’s Industrial Oil Mist Treatment Technology White Paper, 2023 Edition).

• Pulsed Current Enhancement: Anti-Passivation + Efficiency Improvement, Balancing Performance and Lifetime

The system applies radio-frequency pulsed current (duty cycle 30%–70%). Instantaneous high voltage rapidly breaks chemical bonds of pollutant molecules, increasing ·OH concentration by 2–4 times. Meanwhile, the “on–off alternation” characteristic of pulsed current prevents formation of dense oxide films on the anode surface, completely solving the industry pain point of up to 30% monthly electrode passivation rate in traditional DC electrolysis processes. This technology complies with the EU CE certification standard for “pulsed electrochemical treatment technology” (EN 61010-2-061:2015).

• Synergistic Action of Electrolysis Byproducts: Coagulation – Flotation – Sedimentation, Strengthening Solid–Liquid Separation

Hydroxides such as Fe(OH)₃ and Al(OH)₃ generated during electrochemical reactions possess extremely strong adsorption and flocculation capability, synchronously capturing suspended particles, oil droplets, and organic degradation residues in the liquid phase. Through the synergistic action of “coagulation – flotation – sedimentation,” the processing load of subsequent solid–liquid separation stages is reduced.

4. Decelerated Gas–Liquid Separation Stage: Gravity Sedimentation + Anti-Mist Droplet Removal, Avoiding Secondary Pollution

The gas–liquid mixture after electrochemical degradation enters the pressure-reduction deceleration chamber. The chamber adopts an “expanded-volume deceleration” design, causing gas flow velocity to sharply decrease, and water mist rapidly settles back into the water tank under gravity. High-efficiency anti-mist plates are installed at the top of the chamber to further intercept fine droplets. Liquid separation efficiency is ≥98%, ensuring that discharged clean gas is free from secondary mist carryover pollution. This process fully complies with Stokes’ settling law, achieving efficient gas–liquid separation.

5. Solid–Liquid Separation and Resource Circulation Stage: Flocculation Sedimentation + Water Recycling, Practicing Circular Economy

Gelatinous precipitates Fe(OH)₃ and Al(OH)₃ generated by electrochemical reactions combine with pollutants in the liquid phase to form flocs, entering the flocculation sedimentation zone to complete solid–liquid separation:

• Flocculation stage: Metal hydroxides adsorb oil droplets, suspended particles, and degradation products in the liquid phase, forming dense flocs with particle size ≥100 μm. According to the national standard Water Treatment Chemicals – Polyferric Sulfate, flocculation efficiency exceeds 95%.
• Resource circulation stage: The supernatant after sedimentation, after secondary treatment by array electrode plates, is recycled for use in the water scrubbing chamber, with water recycling utilization rate ≥95%. A small amount of floating oil is decomposed into small-molecule substances through radical bond-breaking action of the secondary array electrodes and integrated into the aqueous phase, achieving zero hazardous waste discharge.

II. Dual-Group Multi-Layer Array Electrode Plates + Physical Electrochemistry + Dual-Membrane Synergy:

Five Core Breakthroughs Reconstructing the Underlying Logic of Exhaust Gas Purification**

The core competitiveness of HESA originates from the innovative integration of graded treatment logic and core technologies, constructing a full-chain treatment system of “dual-group multi-layer array electrode plate graded regulation + electrochemical decomposition + dual-membrane interception + closed-loop purification,” realizing a leap in exhaust gas treatment from “extensive processing” to “precise, refined, and deep purification,” with technical advantages far exceeding traditional single-process treatment technologies.

1. First Group of Multi-Layer Array Electrode Plates: Flow Diversion Cutting + Refinement Treatment, Adapting to Diverse Operating Conditions

HESA innovatively integrates the first group of multi-layer array modular electrode plates, whose core functions are “diverted water treatment + processing capacity cutting and refinement,” improving treatment precision from the source. These electrode plates adopt a modular split design and can, according to real-time changes in exhaust gas flow rate and pollutant concentration, realize multi-channel intelligent diversion through AI algorithms.

On one hand, the circulating water treatment system is synchronously divided, enabling more uniform gas–liquid contact, reducing system pressure loss, and avoiding excessive local treatment load. On the other hand, processing capacity is precisely segmented, decomposing large-flow, high-concentration exhaust gas into multiple small units for refined electrochemical treatment, ensuring more sufficient reactions between pollutants and electrodes and active substances, completely overcoming the industry pain point of “large-flow but insufficiently refined treatment” in traditional equipment.

Whether under low-concentration stable operating conditions or high-concentration fluctuating conditions, the first group of electrode plates can flexibly adapt through graded cutting, laying a solid foundation for subsequent deep purification.

2. Gas–Liquid–Electric Ultra-Efficient Synergistic Decomposition: Precisely Severing Pollutant Chemical Bonds

Based on the refined diversion of the first group of array electrode plates, HESA’s gas–liquid mixed electrochemical transient decomposition technology becomes the core engine for high-efficiency pollutant degradation. The system generates ultrafine water droplets at the 5–10 μm scale through atomization technology, which fully integrate with the segmented exhaust gas units, significantly increasing the contact surface area between pollutants, electrodes, and active substances.

Combined with high-precision pulsed current regulation technology, an ultra-strong electrochemical redox field is constructed, precisely severing carbon–carbon bonds and carbon–hydrogen bonds of pollutants such as VOCs, odorous molecules, and polycyclic aromatic hydrocarbons, achieving sufficient primary degradation of pollutants. The combined design of “segmented refinement + sufficient reaction” fundamentally ensures the completeness of pollutant decomposition.

3. Second Group of Multi-Layer Array Electrode Plates: Secondary Deep Purification + Wastewater Flocculation, Building a Near-Zero-Emission Defense Line

To eliminate micro-leakage of pollutants and enhance full-process purification effectiveness, HESA is equipped with a second group of multi-layer array electrode plates, undertaking the dual mission of “secondary treatment of micro-leak exhaust gas + wastewater flocculation purification,” forming a closed-loop purification system across the entire process.

• Exhaust gas treatment side: For trace pollutants that may remain after treatment by the first group of array electrode plates, the second group strengthens electric field intensity and extends reaction pathways, performing secondary electrochemical oxidation on micro-leak exhaust gas to ensure that residual pollutants such as VOCs and ultrafine particles are fully removed.

• Wastewater treatment side: This group of array electrode plates integrates high-efficiency electroflocculation functions. For pollutant-containing wastewater generated during exhaust gas treatment, metal ions generated by the electrodes and electric field effects cause fine particulate matter, colloids, heavy metal ions, and residual organic substances in water to rapidly aggregate into high-density flocs, enhancing solid–liquid separation efficiency. After treatment, the flocculated sludge moisture content is ≤60%, facilitating subsequent disposal; the purified wastewater can be directly returned to the atomization system for recycling or discharged in compliance with standards, truly achieving the near-zero-emission goal of “dual purification of gas and water.”

4. Dual-Membrane Deep Interception Enhancement: Overcoming the Ultimate Challenges of Ultrafine Pollutants and Trace Residuals

On the basis of graded treatment by dual-group array electrode plates, HESA integrates a hydrophobic–hydrophilic composite dual-membrane synergistic interception system, forming the ultimate purification chain of “graded treatment + deep interception.”

Among them, the hydrophobic membrane efficiently intercepts incompletely decomposed VOC small molecules and odorous residues; the hydrophilic membrane selectively blocks ultrafine dust below PM0.5 and fine byproducts generated by electrochemical reactions. Dual-membrane synergy enables final exhaust gas purification precision to reach the ppb level.

Meanwhile, dual-membrane components adopt an electrochemical self-cleaning design. Through micro-current stimulation, membrane fouling and clogging are prevented, extending component service life and reducing replacement and maintenance costs.

5. Broad Applicability: Simultaneous and Precise Removal of Multiple Pollutants

Based on the flexible regulation capability of dual-group multi-layer array electrode plates, adjustable electrochemical reaction platforms, and the dual-membrane synergistic system, HESA possesses broad-spectrum treatment capability for complex industrial exhaust gases, capable of simultaneously addressing the governance challenge of “coexistence of multiple pollutant components,” without the need to additionally install multiple treatment devices or units. Its core treatment scope includes:

• Exhaust gas purification: Ultrafine dust below PM0.5, VOCs (aromatic hydrocarbons, ketones, esters, etc.), heavy metals (mercury, lead, cadmium, etc.), odorous gases (hydrogen sulfide, ammonia, etc.);
• Auxiliary water purification: Redox treatment of high-concentration organic wastewater, oil–water separation of oily wastewater, bacterial inhibition in circulating water, and removal of ammonia nitrogen and nitrates.

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III. AI + Digital Twin: Endowing HESA with a Self-Evolving “Intelligent Brain”

If the dual-group multi-layer array electrode plates + physical electrochemistry + dual-membrane composite technologies are the “muscles” of HESA, then the deep integration of AI and digital twin is its “brain and neural center.” Through real-time data perception, intelligent decision regulation, and virtual simulation optimization, HESA achieves a leap from “passive operation” to “active evolution,” becoming a truly intelligent environmental protection device.

1. Fuzzy-Control Intelligent Regulation: Dynamic Adaptation to Operating Conditions, Achieving Energy Saving and Consumption Reduction

Addressing the pain points of large fluctuations and complex variability in industrial exhaust gas concentrations, HESA is equipped with an advanced fuzzy control system. This system simulates human expert decision logic, accurately identifying imprecise input signals such as “concentration too high” and “sudden airflow change,” and through AI algorithms performs real-time inference and outputs optimal control commands.

It dynamically adjusts key parameters including current intensity of dual-group array electrode plates, channel diversion ratios, atomized water volume, fan frequency, and dual-membrane component cleaning cycles. This “on-demand matching” intelligent operation mode completely eliminates energy waste from “overcapacity operation” and insufficient treatment under “high-concentration overload” in traditional equipment, serving as a paradigmatic intelligent practice of energy conservation and emission reduction concepts.

2. Full-Life-Cycle Digital Twin: From Virtual Reflection to Forward-Looking Management

Each HESA unit is equipped with an exclusive high-fidelity digital twin, realizing real-time data synchronization and bidirectional interaction between “physical equipment and virtual model,” constructing an intelligent management system covering the entire life cycle of the equipment. It precisely maps key parameters such as electrode wear, reaction status, diversion states of dual-group array electrode plates, and wear of dual-membrane components.

Its core value is reflected in two major dimensions:

• Predictive maintenance + zero-risk optimization: Based on real-time operational data and physicochemical models, the digital twin accurately predicts potential failures such as electrode wear of dual-group array electrode plates, pipeline scaling, and dual-membrane pollution saturation, issuing maintenance warnings in advance and reducing the probability of unplanned downtime. Engineers can simulate process parameter adjustments under different operating conditions in a virtual “sandbox” environment, verify the feasibility of synergistic optimization solutions between array electrode plate diversion ratios, electrochemical systems, and dual-membrane components, and then synchronize them to physical equipment, achieving zero-risk technological upgrades.

• ESG data cockpit: The digital twin platform collects and analyzes in real time core data such as pollutant removal volumes, energy consumption reduction values, carbon emission reductions, life cycles of consumables such as multi-layer array electrode plates and dual membranes, and wastewater recycling utilization rates. It automatically generates ESG reports compliant with international standards, with data that are traceable and verifiable, directly interfacing with EU CSRD and domestic ESG disclosure requirements.

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IV. The Ultimate Value of Intelligent Evolution: From Governance Equipment to Green Assets

The innovation of HESA lies not only in breakthroughs of its technical system, but also in reconstructing the value logic of industrial environmental protection. Through graded regulation of dual-group multi-layer array electrode plates, hard-core technical support of physical electrochemistry + dual membranes, and deep empowerment of AI digital twins, HESA transforms environmental protection equipment from a “cost burden” into an appreciable “green asset.”

Its value extension is reflected in three aspects:

1. Data feedback to production: Massive operating-condition data accumulated during equipment operation, optimization parameters of dual-group array electrode plate diversion, and synergistic parameters of dual membranes and electrochemistry can inversely empower enterprise production process improvement, excavating new potential for energy saving and consumption reduction;
2. Enhancement of brand competitiveness: Outstanding environmental performance and transparent ESG data assist enterprises in obtaining green supply chain certifications and expanding high-end markets;
3. Support for circular economy: Without adding oxidants, flocculants, or other chemical agents, with over 95% water resource recycling utilization rate and near-zero secondary waste generation, HESA becomes core infrastructure for industrial ecological transformation.

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Conclusion: Choosing HESA, Embracing the Intelligent Future of Industrial Environmental Protection

When precise five-stage treatment chains, precise regulation of dual-group multi-layer array electrode plates, hybrid electrochemical swirling water technology, and dual-membrane deep purification technology encounter AI and digital twins, industrial exhaust gas governance enters a new intelligent era of “perception – decision – optimization – foresight.”

With a technology system supported by authoritative theories and hard-core strength of multi-technology synergy building a deep purification defense line, and with intelligent technological evolution enhancing value dimensions, HESA not only provides enterprises with compliant, reliable, and economical exhaust gas treatment solutions, but also becomes a core support for enterprises to practice dual-carbon goals and enhance ESG performance.

Choosing HESA is not merely choosing a set of exhaust gas treatment equipment, but choosing a green development model of “intelligent purification and value symbiosis” — allowing industrial production and ecological environment to coexist harmoniously, and allowing environmental protection investment to truly transform into core competitiveness of enterprises.

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