Design Optimization of Packed Bed Scrubber for HCl Gas Removal from Chemical Manufacturing Exhaust

Abstract

Hydrochloric acid (HCl) gas emissions from chemical manufacturing processes pose significant environmental and occupational health risks due to their corrosive and toxic nature. This study investigates the design optimization of a packed bed scrubber for efficient HCl gas removal from chemical manufacturing exhaust streams. The proposed optimization framework integrates mass transfer analysis, fluid dynamics evaluation, and process simulation techniques to improve gas absorption efficiency, operational reliability, and energy performance under varying industrial operating conditions. A comprehensive experimental and numerical investigation was conducted to evaluate the influence of packing material characteristics, liquid-to-gas ratio, gas flow rate, scrubber height, packing density, and absorbent concentration on HCl removal efficiency and pressure drop behavior. The packed bed scrubber system was designed to maximize gas-liquid contact area and enhance mass transfer performance while minimizing operational energy requirements and equipment corrosion. Results demonstrated that optimized packing configurations and controlled operating parameters significantly improve HCl absorption efficiency and reduce pollutant discharge levels compared to conventional scrubber designs. The study further revealed that appropriate selection of packing material and hydraulic loading conditions contributes to enhanced flow uniformity, reduced channeling effects, and improved scrubber stability during continuous operation. Comparative analysis indicated substantial improvements in pollutant removal efficiency, pressure drop reduction, and process sustainability under optimized design conditions. Additionally, computational modeling enabled accurate prediction of flow distribution and absorption performance, supporting effective scrubber design and operational management.