三方機械工業股份有限公司

—A Proven Multifunctional Exhaust Treatment System Combining Physical Scrubbing and Electrochemical Reactions—

Abstract

This study reports the structural design and performance evaluation of a hybrid air purification device capable of treating complex multi-component industrial exhaust. The system integrates a spiral-flow wet scrubber and a multi-layer electrode-based electrochemical unit to simultaneously remove dust particles, VOCs, oils, odors, and heavy metals with high efficiency.

Through optimization of the flow path design, significant reductions in pressure loss and power consumption were achieved. The use of pulse-controlled electrochemical reactions enables rapid treatment within short residence times. The system operates without chemical reagents and achieves zero wastewater discharge, presenting both environmental and economic benefits. Experimental results on removal efficiency, reaction speed, and operational stability are discussed, confirming its industrial feasibility.

1. Introduction

Modern industrial exhaust contains increasingly complex pollutants. Traditional single-function devices struggle to handle mixed pollutants such as dust, VOCs, oils, odors, and heavy metals. This study introduces a novel hybrid system combining physical scrubbing and electrochemical treatment to address such challenges.

2. System Configuration and Technical Outline

2.1 Components

(1) Inlet air stabilization chamber
(2) Spiral-flow wet scrubber section
(3) Multi-electrode electrochemical reactor
(4) Gas-liquid and solid-liquid separator

2.2 Scrubbing Unit

Helical fluid design enhances gas-liquid contact area to efficiently capture particulates and aerosols, while optimized flow speed reduces overall pressure loss.

2.3 Electrochemical Treatment

Electrochemical reactions include:

• Anodic oxidation to release metal ions
• Cathodic generation of OH⁻ for heavy metal precipitation
• Pulse current triggering fast redox reactions for rapid pollutant decomposition

3. Experimental Methodology

3.1 Test Parameters

• Airflow capacity: 500 m³/h
• Electrode configuration: graphite/stainless steel multilayers
• Spiral flow speed: 5–12 m/s (adjustable)
• Voltage: 0–24 V (with pulse mode)
• Test pollutants: carbon dust, n-hexane, ammonia gas, Cu²⁺ solution

3.2 Evaluation Metrics

• Dust removal efficiency (μ and nano scale)
• VOC degradation rate (GC/MS)
• Heavy metal removal (ICP-OES)
• Pressure drop (Pa), energy consumption (kWh)

4. Results and Discussion

4.1 Removal Performance

Pollutant	Removal Efficiency	Notes
PM2.5	98.9%	Effective for fine particles
VOC	94.5%	Decomposed within 5 seconds
Cu²⁺	96.8%	Hydroxide precipitation successful

4.2 Pressure and Energy

Total pressure loss reduced by ~42% compared to conventional systems. Daily energy consumption averaged 0.247821 kWh/day.

4.3 Zero-Waste and Chemical-Free Operation

Closed-loop water reuse and chemical-free design achieved zero liquid discharge and minimized maintenance, leading to significantly lower operational costs.

5. Conclusion

The proposed system demonstrates high performance and environmental compatibility for treating complex exhaust streams. With modular design and intelligent control, the device shows promise for further development including AI-based optimization, self-diagnosis, and diversified pollutant treatment.