Introduction: Sulfur dioxide (SO2) is a major air pollutant with severe health and environmental impacts. Spray towers are widely used in flue gas desulfurization (FGD) systems; therefore, optimizing their operational parameters is crucial for enhancing SO2 removal efficiency.
Methods: This study investigated the effects of liquid flow rate (4–6 L/min), gas flow rate (105– 158 ft³/min), inlet SO2 concentration (60–120 ppm), nozzle type, and the number of nozzles on the removal efficiency of sulfur dioxide gas using a spray tower (1.38 m in height, 0.25 m in diameter). The experiments were designed using Response Surface Methodology (RSM) through Design-Expert software.
Results: The highest removal efficiency (96%) was achieved with the SS80 Berto nozzle, liquid flow rate of 6 L/min, gas flow rate of 105 ft³/min, three nozzles, and an inlet SO2 concentration of 60 ppm. Gas flow rate and inlet concentration negatively impacted efficiency, while liquid flow rate and the number of nozzles had a positive effect (P < 0.001).
Conclusion: Optimizing operational parameters, particularly nozzle type and liquid flow rate, significantly improves spray tower performance for SO2 removal.