Abstract:The gas-liquid cross-flow array (GLCA) system captures particles from industrial tail gas by forming arrays of liquid columns through distribution plates and the particle removal efficiency can be improved by increasing the number of unit rows of liquid columns arrays. However, the system has high operation energy consumption which mainly composed of water recycle. To reduce the energy consumption of GLCA system, non-uniform falling film at windward side which plays a major role in particle capture was utilized to supersede previous liquid columns technology. Large eddy simulation (LES) and discrete phase model (DPM) were employed in the numerical simulation of flow field and particle motion respectively for non-uniform falling film GLCA system with different liquid film angles. The model of liquid falling film angle of 360° was regarded as that of liquid-columns GLCA system and compared with the experiment under the same conditions for verification, which proves a good agreement between simulation result and experiment data. The numerical simulation results of different liquid film angles indicated that particle removal efficiency of one unit row decreases gradually with the reduction of the angles, but the water consumption also decreases. There is an optimal angle of film to minimize water consumption in the system for a specific particle removal task. The removal efficiency of large particles is relatively small, indicating that inertial impact is the main removal mechanism. Using the evaluation criteria of specific power consumption as a baseline, the windward film angle of falling film channel was optimized with the numerical simulation model based on the exhausted gas data of a certain compound fertilizer production by ammonia-acid process. The results showed that the optimal angle with the lowest operation energy consumption of the non-uniform falling film GLCA system is 70°, 634 rows of units required in the system and the corresponding specific power consumption could be as low as 1.83×10^-4 kW·h·m^-3 when the quality dust removal efficiency of exhaust gas reaches 80%. The specific power consumption could be equivalent to Grade 1 comparing to the energy efficiency grades of the electrostatic precipitator in coal-fired power plants.