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Fume extraction System

Shivas offers customized solutions for fume extraction in the form of tower scrubbers, complete with FRP ducts and dedicated FRP blowers. All the components of the plants are made from corrosion-resistant Thermoplastic material. The system uses FRP Scrubbers to exhaust the air, preventing release of aggressive and harmful vapors into the environment. This process is designed to extract smoke, fumes and gases directly from source, before the contamination spreads in the premises.

The fume Extraction plants from Shivas reduces the overall dimensions and allows a full personalization of the units depending on the pollutant and on the system demands. Different for fume extraction system includes Acid Proof Fume Extraction Plant, Plastic Tanks Acid Plant, Plastic Plant for Galvanizing, etc.

We supply Maximum Achievable Control Technology (MACT) in compliance to emission regulatory agency requirements.

Shivas has developed an innovative line of fume extraction plant for encapsulated pre-treatment and lateral suction channels. The lateral suction channels extracts smoke, fumes and harmful emission right at source on pickling tanks. Performance of Fume Extraction Plants is as per emission regulations.

We specialize in providing turnkey solutions for extraction of corrosive fumes and gases across diverse industries. These plants enable the manufacturers to meet the environmental protection norms laid down by the regulatory bodies. Some of the features of our extraction plants include the following :

Fume Extraction Plant
Fume Extractor

The Process
The fume extraction plants work by scrubbing the exhaust air, preventing the release of aggressive and harmful vapors into the environment. Vapours and gases are absorbed in the scrubbing liquid and returned to the circuit. The most important basis for calculations are the determination of the exhaust air volume and the dependence of the pre-treatment plant. All the calculations are performed by program modules developed by Shivas.

Effective scrubbing and guaranteed compliance with emission limits can only be achieved through an individually designed fume extraction plant optimized on the particular application.

The Fume Extraction Plants are designed for the toughest working environments in different industries across the globe. Every component is made of acid proof and plastic materials. Followings are the type of industries uses fume extraction system.
Shivas' fume extractor plants are specifically designed for improvement working condition and environment in industries. These system provides a significant advantages of less wear and tear of the machines and much lower cleaning costs. Some of the other advantages include:
Fume Extraction system comprises of following equipments

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Wet Scrubber

Gas Scrubbing

Gas scrubbing consists of solubising a gaseous pollutant in a liquid. This liquid can be either water or water with a reagent or a solvent. There are different types of gas scrubbers i.e. random packed scrubbers, spray gas scrubbers and venturi scrubbers. The choice of which type/model to be used depends on the characteristics of the gas to be removed. Extraction of vapors from the surface treatment baths and treatment to legislation.

Shivas will be your partner in helping 'you' choose the most appropriate solution for the design of the fume capture and extraction systems, chemical and mechanical engineering of the fume scrubbing unit for your needs and assist with the installation and commissioning of the plant to an agreed discharge concentration. In the metal process industry extract and treat the vapors produced by the metal sheets and wires during the pickling process such as hydrochloric acid pickling. Through extraction and treatment, we ensure the well being of the people working with the machines as well as compliance with all the know standards.

Shivas offers a complete range of fume scrubbing units backed by a comprehensive design, manufacturing and installation service.

Design & Manufacture
2D & 3D mechanical design. Product design using parametric solid modeling and photo realistic rendering. Injection moulding, plastic extrusion, vacuum forming and rapid prototyping and vacuum casting.

Scrubbers & Degasers

Packed Bed Types
Packed Bed Type Scrubbers and Degasers are used for removal of gas, vapors, chemical mist etc. These scrubbers are cylindrical towers and are packed with plastic tower packing or any-other suitable packing material for particular application. The scrubbers are provided with a water spraying arrangement, which can be supplied in various sizes with gas velocities ranging from 0.5m/sec. to 2m/sec and pressure drop between 50mmwg and 750 mmwg. Fumes / Gaseous contaminants travel vertically upwards while caustic liquid / water is sprayed from the top, over the tower packing. The liquid is recirculated with pump. Additionally, packed bed scrubbers offered, mostly counter current scrubbers, which can collect efficiently particulates up to a size of 4 - 5 micron.

Packed towers are used as contacting equipment for gas-liquid and liquid-liquid systems. It presents a cross-section of a typical unit. The shell is usually cylindrical, although square wooden, light metal, or .reinforced plastic towers are used. The basic unit consists of:
  • Shell
  • Packing (one or more sections)
  • Packing support(s)
  • Liquid distributor (s)
  • Intermediate supports and redistributors
  • Gas and liquid entrance and exit nozzles
Many of the mechanical aspects of tower construction and assembly have an influence upon the design and interpretation of tower performance. Every effort should be made to increase the effectiveness of contact between the process streams and to reduce losses by entrainment or wall effects at a minimum expenditure of pressure drop. At the same time the design must be consistent with the economics dictated by the process and type of construction.

The shell may be of metal (steel, alloy, or non-ferrous). plastic, wood or some combination which may require the addition of liners or inner layers of rubber, plastic or brick. The mechanical problems of attaching inner nozzles, supports and brick require considerable attention that is not an integral part of sizing the equipment.A shows a typical large steel brick-lined-membrane fined tower with corbeled brick support locations. In these towers, temperature and/or corrosive conditions usually dictate the internal lining, and the selection of the proper acid-(or alkali-) proof cements.

Ceramic, plastic and other non-metal tower shells are used quite often. It is important to consider in ceramic construction that the main inlet or outlet nozzles or any other large connections should be oriented 90° to each other to reduce the possibility of cracking the walls, as most cracks go one-half diameter. Preferably there should only be one nozzle at any one horizontal plane. The nozzles should never carry any piping or other stress load.

The bell and spigot type tower, is satisfactory for 2 to 2.5 psi in 12-inches diameter. to 30-inches diameter. towers when the joints are packed with asbestos and caulking compound. For operating pressures of 5 psi in 18-inches through 48-inches diameter., use asbestos and silicate cement?- Special hold-down packing gland-type rings will allow operation at slightly higher pressure. The porcelain towers should be used for the higher pressures rather than the weaker stoneware.

The rate of heating or cooling a stoneware or porcelain tower should not exceed 15° F. per minute.

The packing is the heart of the performance of this equipment. Its proper selection entails an understanding of packing operational characteristics and the effect on performance of the points of significant physical difference between the various types.. The evaluation of these materials for various conditions of service is given later.

Packed Bed Scrubbers
Packed Bed Scrubbers
Packed Bed Types

Plate Scrubber
This high-efficiency Plate Scrubber is designed for absorption and removal of soluble harmful gases such as Sulfurous Acid Gas (SOx) and Hydrogen Chloride (Hcl), which are contained in exhaust gas, and simultaneously remove dust from the exhaust gas. Our range of plate scrubber is provided with a perforation plate and a baffle plate such that the gas to contact the water efficiently. The plate finds application for incinerating and roasting plants as well as for deodorizing and washing purpose. In order to improve the efficiency of gas absorption and dust collection, the plate scrubber has a mechanism to enable an efficient contact of gases with the washing water. The venturi enables an easy mixing of the ash contact in the washing water.
Plate Scrubber
Plate Scrubber

The known fractionating plate columns which are utilized for liquid-gas contacting may be divided into two classifications:
  • cross-flow plate, and
  • counter-flow plate.
The cross-flow tray requires a liquid downcomer and is more generally used than counter-flow tray because of transfer-efficiency advantages and greater operating range. The flow pattern of the liquid on a cross-flow tray can be controlled by varying the placement of downcomers in order to increase stability of operation or improve mass-transfer efficiency.

Where the liquid loading on a column is less than 60-80 gal./min-ft. of weir, a normal cross-flow pattern with segmental outlet weir is generally used. In the event the liquid loading exceeds 60-80 gal./min.-ft. of weir, in a column having sufficient vapor capacity, split-flow and sometimes radial flow are used.

The fraction of column cross-sectional area available for gas-dispersion components, such as caps or perforations, is significantly lower in split-flow design than in cross-flow design. Thus, for the same vapor capacity, split-flow design generally requires a larger column diameter than normal cross-flow.

Elements used in plate towers for the purpose of gas dispersion are bubble caps, sieve perforations, or modifications thereof.

The tray construction, wherein the liquid is maintained on the tray surface by the kinetic energy of the vapor, is called the sieve tray. The openings in the tray may take the form of circles or slits formed by mechanical punching of the metal tray.

A more effective method of insuring contact between the vapor and the reflux of a fractionating column is the use of bubble caps on the trays. Each plate in the column has a plurality of openings and each of the openings is provided with a short nipple. Each nipple is surmounted with a bell-shaped cap which is secured in place by means of a spider and a bolt. The lower edge of the cap may be serrated or provided with slots. As the vapor rises through a nipple from the plate below, it is diverted downward by the cap and bubbles out under the serrations or through the slots. A layer of liquid is maintained on the plate and the depth of the liquid is such that the caps are submerged. The downpipe from the plate above is sealed by liquid on the plate below, so that vapor cannot enter the downpipe. Ordinarily, the liquid is delivered at one end of the tray by a downpipe from the plate above, flows across the tray, and is discharged by a downpipe onto the lower tray. Baffles can be placed between the caps to divert the liquid and cause uniform flow across the tray.

Packed Bed Types

The shortcomings of the known trays are severalfold: the construction costs are high; there is a considerable loss in pressure as the vapor traverses from the boiler to the top of the column; and the undesirable transfer of entrained liquid particles through the openings in the trays to the liquid on that tray detrimentally interferes with the concentration differential of the liquid and the vapor.

It is an object of this invention to provide an improved gas-dispersing assembly.
It is another object to provide a simple device which can be manufactured at a reduced cost.
It is another object to provide a device which would reduce the escape of entrained liquid to the upper trays.
It is still another object to provide a gas-dispersing assembly having a greater mass-transfer efficiency between liquid and vapor.

Spray Column
A Spray Column find applications for removal of sulfur dioxide (SO2) from flue gas and other chemical process industries owing to its various advantages like low-pressure drop and simplicity. Our range of spray columns have various advantageous as they are easy to use and require less maintenance. Manufactured from quality raw material, these columns offer a durable and hassle-free usage. Robust in design and construct, our range of columns are known for their high yielding performance.
Spray Column
Spray Column

Gas Absorption Plants

Optimizing on our new-generation product development facility, we manufacture and supply gas absorption plants for emission control of any toxic gas like NH3, HCl, HF, NOx, SO2, Cl2, Hbr, Br2, H2S, HCN, HCHO etc. These pollution control systems are manufactured in according to set industrial pollution control parameters. Their compliance with requisite standards have made them reliable in the industry. All our products are quality tested & we ensure to deliver certified air pollution control system.

Gas Absorption Plants
Wetted Wall Column

Fume Extraction System For Pickling Plants

Steel pickling plants are mainly of two types viz.
(1) Continuous pickling lines of the closed type for strips and wires
(2) Batch pickling lines of the open type for wire coils, straight tube bundles, automobile bodies (surface pretreatment prior to painting) etc. Induced draft type fume extraction systems are adopted for the former and push-pull type systems are used for the latter. The surface treatment solutions could be hydrochloric acid, sulfuric acid, hydrofluoric acid, nitric acid, chromic acid or any other at various concentrations and temperatures. The design of the system is aimed at protection of the operating personnel on the one side and protection of the environment by controlling emissions. Temperature, concentration and toxicity and partial pressures of the vapors are considerations in system design. Our service covers from conceptualization to design, selection of appropriate materials of construction, manufacture, specification and procurement of purchased items such as pumps, motors, instrumentation and control etc., supply, erection, commissioning and handing over with guarantees for quality and integrity of the supplies and performance of the system conforming to specified parameters.

Fume Extraction System For Pharmaceutical Plants

Bulk drug manufacturing plants typically comprise several reactors. Several toxic chemicals are used in their manufacture. Also they generate several highly toxic gases such as NH3, HCl, HF, NOx, SO2, Cl2, HBr, Br2, H2S, HCN, HCHO and other organic and inorganic gases. Personnel, who feed the raw materials into the reactors and operate the plant, have to be protected from the poisonous vapors and gases. The emissions from the plant have also to be controlled. As the gases generated are of different types the solutions to be used for absorbing them will also be different. As it would be expensive to use many absorption systems, the reactors are grouped into two or more groups for the purpose of providing fume extraction systems. The systems cover everything from retractable fume hoods near reactors to protect personnel to final absorbers and stacks. We also undertake trouble-shooting in existing fume extraction systems supplied by others.

Fume Extraction System For Pesticide and Petrochemical Plants

As in the case of pharmaceutical plants we also undertake turnkey contracts for plants for the extraction and absorption of toxic gases in the case of any chemical industry, pesticide and petrochemical industry.

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Fumeless Pickling Electro Pickling for Steel Wire Rod FRP Duct Work FRP Pipes (F.W.) FRP & FRP (FW) Storage Tank
Reaction Vessels / Tanks in Platics Pickling Tank Pickling for Pipe / Structure
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