Custom Gas Scrubbers: Engineering, Installation, and Service
A reliable gas scrubber is more than just a column in which air and scrubbing liquid come into contact. Its performance is determined by the entire system: from vapor collection and air transport to material selection, process control, chemical dosing, and maintenance.
CGK Group guides you through the entire process. We analyze your process , design and manufacture the system, handle the installation, and remain your point of contact even after commissioning.
One partner for the entire gas scrubbing system
In a gas scrubber, various technical components must be properly coordinated. An air duct that is too small, an unsuitable fan, or improper liquid distribution can affect the operation of the entire system.
CGK Group can therefore handle the entire gas scrubbing system, including:
- analysis of the gas or vapor flow
- selection of the appropriate gas scrubbing technology
- process and mechanical engineering
- plastic structures
- exhaust hoods and collectors
- air ducts and fans
- tanks, pumps, and piping
- chemical dosing
- measurement and control technology
- Electrical control and automation
- Installation and commissioning
- inspection, maintenance, and optimization
You don’t have to coordinate different suppliers separately. You’ll have a single point of contact for the entire system.
From initial analysis to a fully operational installation
1. Assessment of your process
Every project begins with a thorough analysis. We map out your process, emission source, flow rates, available space, and objectives . If key information is missing, we determine which measurements or further analyses are needed.
2. Concept and technology selection
Based on the process data, we compare the possible solutions. We determine whether a passive, active, recirculating, multi-stage, or combined system is required.
3. Engineering
Our engineers fully develop the process and the design. In doing so, we take into account:
- the operation of the gas scrubbing process
- material compatibility
- pressure drop
- pumps and fans
- piping
- instrumentation
- accessibility
- maintenance
- safety and relevant regulations
4. Production and Pre-assembly
As many plastic parts and installation components as possible are manufactured and pre-assembled in our workshop. This enhances quality control and reduces installation time at your location.
5. Transportation, Installation, and Connection
CGK Group handles the entire installation process .
This includes, among other things:
- transport
- hoisting
- mechanical installation
- piping connections
- air duct connections
- installation of pumps and fans
- Electrical connections
- integration with existing tanks or processes
- Interface with a PLC or central control system
6. Commissioning
After installation, we check the operation of the entire system. Among other things, we examine:
- direction of rotation and operation of pumps and fans
- fluid distribution across the packing
- measuring instruments
- dosing functions
- alarms
- Process settings
7. Commissioning and User Training
After commissioning , your team will receive an explanation of:
- how the gas scrubber works
- how to operate it
- inspections
- alarms
- safe use of the system
Automation and Process Monitoring
Proper process control ensures reliable operation and minimizes water and chemical consumption.
Depending on the system, CGK Group can equip the gas scrubber with measurement, control, and safety systems.
Measurements and Control
We measure key process parameters such as pH, redox, conductivity, flow rates, pressure, level, and temperature. Based on these measurements, we automatically control water and chemical dosing, blowdown, and level control.
Monitoring and Safety
The system can be equipped with pump and fan monitoring, dry-run and level protection, leak and pressure monitoring, and alarm notifications.
Integration with Control Systems
The gas scrubber can be integrated with a PLC, control panel, or building management system, allowing you to monitor all process data and alarms centrally.
The automation is always tailored to your application and desired level of complexity.
Service Throughout the Entire Lifecycle
Even after commissioning, CGK Group remains your point of contact.
Among other things, we can provide:
- inspection and preventive maintenance;
- inspection of the most important system components;
- repairs and replacement of parts ;
- modifications to existing systems;
- supply of spare parts;
- optimization of operation and energy consumption.
Thanks to our in-house expertise in plastic fabrication, we can also repair, modify, or remanufacture parts.
Optimization of Existing Gas Scrubbers
Has your process changed, or does the gas scrubber no longer meet your current needs? In that case, we’ll assess the existing system and recommend targeted improvements. This allows you to extend the service life of your system and avoid a complete replacement whenever possible.
Why choose CGK Group?
One partner for the entire installation
We combine gas treatment with expertise in plastic construction, chemical storage, pumps, dosing, piping, and process installations.
Custom Engineering
No off-the-shelf solution without a process analysis. The system is tailored to the actual substances, flow rates, conditions, and operational requirements.
In-House Manufacturing
Many components are manufactured in our own plastics workshop. This allows us to maintain control over execution, dimensions, materials, and scheduling.
Focus on safety
We consider not only emissions, but also safe storage, tank pressure, chemical compatibility, maintenance access, leak control, and the safety of your employees.
Practical Implementation
Our engineers and technicians take into account the day-to-day realities at your site: limited space, existing piping, production schedules, accessibility, and minimal downtime.
Local service
CGK Group supports industrial customers in Belgium and the Netherlands and also carries out projects in northern France and Luxembourg.
Post-Commissioning Support
Even after commissioning, you can count on us for inspections, maintenance, repairs, spare parts, and optimization.
Discuss your gas flow with our engineers
Are you experiencing issues with acidic vapors, ammonia, odor nuisance, or other harmful emissions? Or are you unsure whether your current gas scrubber still meets process and emission requirements?
If possible, please provide us with the following information: the type of process or emission source, the substances that need to be removed, the concentrations present, the normal and maximum gas flow rates, the temperature, the desired emission limit, and details about the existing system.