Scrubber & Air Pollution Control
PLC programming, HMI/SCADA, sequencing, alarms, and facility-defined operating-data integration for wet scrubbers and air pollution control equipment. Final CAM plans, permit requirements, environmental compliance, and validation remain the facility owner’s responsibility.
What We Do for Scrubber & APC Systems
Scrubbers and air pollution control equipment combine pumps, fans, valves, chemical feed, pH, pressure, level, flow, alarms, and upstream or downstream process interlocks. VIR Automation supports the controls-side integration while the facility and its qualified parties retain process design, environmental, permit, calibration, and performance responsibility.
PLC Logic for Scrubber Sequencing & Interlock Control
Pump sequencing, valve interlock logic, recirculation control, blowdown timing, and process interlocks — all built on Allen-Bradley platforms for reliable, repeatable scrubber operation.
HMI/SCADA for Scrubber Performance Monitoring
Operator interfaces with real-time process graphics, differential pressure trends, liquid level visualization, alarm management, and remote monitoring dashboards for scrubber and APC systems.
CAM Data Logging and Reporting Support & CEMS Integration
Integrate facility-selected operating parameters, CEMS interfaces, alarm events, and historian tags around the approved CAM plan and reporting workflow.
Pressure Differential & Liquid Level Monitoring
Instrumentation integration for pressure drop across packing beds, liquid sump levels, flow rate tracking, and automated alerts when parameters drift outside operating limits.
Scrubber Startup/Shutdown Sequence Logic
Automated startup permissive checks, staged pump and fan sequencing, controlled shutdown procedures, and interlock verification to protect equipment during transitions.
Fault Diagnosis & Troubleshooting for APC Systems
Review PLC logic, I/O status, alarms, trends, and sensor signals to identify whether controls or instrumentation warrant further investigation; field calibration and process-performance work remain with qualified parties.
Equipment We Support
We work across the full range of scrubber and air pollution control equipment found in chemical processing, manufacturing, and waste treatment environments:
Wet Scrubbers
Venturi scrubbers, packed-bed towers, and spray tower configurations — recirculation pump control, pH management, reagent dosing, and blowdown sequencing for acid gas and particulate removal.
RTOs with Scrubber Pre-Treatment
Regenerative thermal oxidizer systems with upstream scrubber stages — coordinated control logic for scrubber conditioning before oxidizer inlet, including interlock sequencing between APC stages.
Thermal Oxidizers with Scrubber Stacks
Direct-fired and catalytic oxidizer systems with downstream scrubber quench and polishing stages — temperature control, scrubber liquor management, and integrated compliance monitoring.
Acid Gas Absorbers
Packed-column and tray-tower acid gas absorber systems — caustic feed control, pH regulation, liquid distribution management, and effluent neutralization sequencing.
Mist Eliminators with Instrumentation
Mesh pad and chevron-style mist eliminators — differential pressure monitoring, wash cycle sequencing, drain management, and performance trending to maintain capture efficiency.
Combined APC Systems
Multi-stage air pollution control trains combining scrubbers, oxidizers, filters, and mist eliminators — coordinated PLC logic, unified HMI, and centralized compliance data across all stages.
Scrubber Controls Project Experience
All project references are anonymized to protect client confidentiality.
Chemical Plant — Wet Scrubber PLC Upgrade
Programmed Allen-Bradley PLC logic for a packed-bed wet scrubber system at a chemical processing facility. Scope included pump sequencing, interlock design, and HMI development for real-time scrubber performance monitoring.
Industrial Manufacturer — APC Data Logging and Reporting Support
Designed and deployed data systems supporting CAM workflows for an industrial manufacturer’s scrubber equipment. Integrated CEMS data with PLC-based parameter monitoring and automated deviation tracking to support Title V permit requirements.
Waste Treatment Facility — Scrubber Controls Integration
Delivered full controls integration for a scrubber system at a waste treatment operation. Work included startup/shutdown sequence logic, pressure differential monitoring, liquid level control, and operator training on the new HMI interface.
Scrubber Controls FAQ
What PLC platforms do you use for scrubber control systems?
We primarily program on Allen-Bradley ControlLogix and CompactLogix platforms, which are the most common in scrubber and APC applications. We also work with Siemens S7-1500 and TIA Portal. Platform selection is driven by your plant standards and existing infrastructure.
Can you integrate scrubber controls with our existing CEMS or compliance system?
Yes. We design data systems supporting CAM workflows that integrate directly with continuous emissions monitoring systems (CEMS). This includes automated parameter logging, deviation tracking, and reporting outputs designed to support Title V permit requirements.
Do you provide on-site commissioning and startup support?
Yes. Our scope typically includes on-site commissioning, loop checkout, sequence verification, and operator training. We support initial operation within the authorized commissioning scope and document results, open holds, and handoff responsibilities.
Can you troubleshoot an existing scrubber control system you didn’t originally build?
Yes. We regularly diagnose and resolve issues on scrubber and APC control systems originally built by other integrators or OEMs. Our troubleshooting process includes PLC program review, I/O verification, sensor calibration checks, and alarm history analysis to identify root causes.
Related Services
Our scrubber and APC controls work connects directly to these core capabilities: