Performance Augmentation and Cost Minimization of Pollution Control Device by Value Engineering Techniques

Wet scrubbers are highly effective devices for controlling air pollution, primarily utilized in industrial exhaust streams. The operation of a wet scrubber involves spraying the contaminated gas stream with a scrubbing liquid, typically water. This research article presents a case study that employs value analysis techniques to reduce costs and enhance the performance of wet scrubbers. The functions of individual components of the wet scrubber are analyzed, and the critical component contributing to performance loss is identified using the Function-Cost-Worth-Analysis (FCWA) matrix. The spray nozzle is identified as the critical component with a high-value index. The issue is determined to be the inadequacy in the spray area of the scrubbing liquid, which allows flue gases to escape, thereby reducing the scrubber's performance. The proposed solution involves increasing the spray area by changing the nozzle type and redesigning the nozzle positions. Although this solution results in a higher cost compared to the old design, cost reduction is achieved by altering the nozzle material. The proposed solution is validated using Computational Fluid Dynamics (CFD) and structural Finite Element Analysis (FEA). The validation results indicate an 11.5% increase in performance and a 2.52% reduction in the cost of the wet scrubber.