How to Design and Set Up an Efficient Acid Fume Extraction System

Acid fume extraction systems are a vital part of any pickling or galvanizing plant. Whether you’re working with hydrochloric acid, sulfuric acid, or other corrosive chemicals, the fumes generated during surface treatment processes pose serious risks to worker safety, equipment life, plant infrastructure, and regulatory compliance. 

But simply installing a fume extraction system isn’t enough. If the system isn’t properly designed, it can lead to inefficient capture, poor airflow balance, excessive corrosion, and even higher maintenance costs. That’s why optimizing the system from the design stage is essential. 

This practical guide is designed to help plant owners, engineers, and consultants understand what goes into a truly effective acid fume extraction setup. From airflow calculations to material selection and system layout, we’ll break down the key design considerations that ensure your extraction system works efficiently, safely, and sustainably. 

At Arvind Anticor, we don’t just build equipment we engineer smart, customized solutions using high-quality thermoplastics, DVS welding techniques, and advanced design software like RITA 6.0. This guide reflects the insights we’ve gained from delivering high-performance systems across India and abroad. 

Key Design Factors in Acid Fume Extraction Systems 

Designing an effective acid fume extraction system requires more than just selecting a hood and connecting a blower. It involves a detailed understanding of the chemical process, plant layout, and operational parameters. Here are the critical design elements that influence system performance and long-term reliability: 

1. Type and Concentration of Acid Fumes 

Different acids such as hydrochloric, sulfuric, nitric, or phosphoric generate fumes with varying levels of corrosiveness and toxicity. The design must factor in: 

• The chemical reactivity of the fumes 

• Expected fume volume and temperature 

• Specific health and environmental risks 

This helps determine the right neutralization method, material selection, and system capacity. 

2. Process Layout and Source Proximity 

An efficient extraction system is designed around the physical location of tanks, kettles, and reaction zones. Poorly placed extraction hoods can lead to dead zones where fumes escape into the workplace. 
At Arvind Anticor, we assess: 

• Open surface areas of tanks or kettles 

• Equipment height and spacing 

• Accessibility for ducting and maintenance 

• Plant ventilation flow patterns 

3. Airflow and Suction Velocity 

The system must provide sufficient airflow to capture fumes before they disperse. Undersized blowers or miscalculated duct lengths lead to poor suction. Proper design involves: 

• Calculating air changes per hour (ACH) 

• Selecting optimal suction velocities (typically 0.3–0.5 m/s for open tanks) 

• Minimizing pressure loss through smooth duct routing 

We use RITA 6.0 software to model these parameters and simulate real-world performance before fabrication. 

4. Ducting and Hood Configuration 

The design and material of the ducting play a major role in preventing backflow, corrosion, and fume leakage. Considerations include: 

• Hood design: lip type, canopy, or slot type depending on process 

• Duct length and bends: minimizing elbows and friction losses 

• Diameter sizing for optimal airflow balance 

• Material selection: PP, FRP, HDPE, or dual laminate options based on chemical compatibility 

5. Material Selection for System Durability 

The entire system including hoods, ducts, and scrubbers must be built from materials that resist corrosion and deformation over time. We offer: 

• Polypropylene (PP) for most acid fumes 

• HDPE for low-temperature, less aggressive chemicals 

• FRP for added structural strength and UV resistance 

• Hybrid constructions for demanding environments 

Material selection directly impacts lifespan, safety, and maintenance costs. 

System Sizing and Capacity Planning 

One of the most overlooked aspects of acid fume extraction system design is proper sizing. An incorrectly sized system whether too small or excessively large can lead to serious performance and cost issues. 

Why Sizing Matters 

A system that’s too small may: 

• Fail to capture fumes effectively 

• Lead to acid condensation inside ducts 

• Accelerate corrosion and require frequent maintenance 

A system that’s too large may: 

• Consume excessive energy 

• Create turbulence that affects process stability 

• Increase capital costs unnecessarily 

The goal is to achieve optimal airflow, consistent extraction, and balanced energy usage based on your plant’s specific requirements. 

What We Consider During Sizing 

At Arvind Anticor, we take a data driven approach to sizing each system based on: 

• Number and size of process tanks or kettles 

• Open surface area exposed to acids 

• Process duration and batch frequency 

• Ceiling height and room volume 

• Fume generation rate (based on temperature and concentration) 

• Required air changes per hour (ACH) for the specific work zone 

We model these parameters using RITA 6.0 software, which allows us to simulate system performance under real-world load conditions minimizing trial and error and ensuring efficient extraction from day one. 

Capacity Planning for Growth 

Another key consideration is future scalability. Many plants expand operations over time, and a short-sighted system design may limit your ability to add new tanks or increase throughput. 

We help clients plan for: 

• Modular expansion 

• Reserve blower capacity 

• Flexible duct routing and spare ports 

This future ready mindset ensures long-term value and reduced upgrade costs. 

Scrubber Integration and Neutralization Strategy 

Capturing acidic fumes is only half the job,what happens to those fumes after extraction is just as important. An effective fume extraction system must include a wet scrubber that neutralizes harmful acid vapors before releasing treated air into the atmosphere. 

Why Scrubbers Matter 

Without a proper scrubber, extracted fumes containing hydrochloric acid, sulfuric acid, or zinc oxide particles can: 

• Corrode ductwork and exhaust stacks 

• Contribute to air pollution 

• Fall short of environmental compliance standards (like CPCB or OSHA) 

Scrubbers not only reduce emissions but also protect your entire fume handling system from long-term chemical damage. 

How Arvind Anticor Designs Scrubber Integration 

We offer a range of thermoplastic wet scrubber systems designed specifically for pickling and galvanizing applications. Each system is: 

• Chemically engineered for acid neutralization efficiency 

• Designed with a zero discharge philosophy, minimizing environmental impact 

• Built using corrosion resistant PP or FRP materials 

• Seamlessly connected to the extraction system for optimized flow control 

Depending on your chemical process, we help you choose the right scrubber type packed bed, venturi, or crossflow with appropriate neutralizing media. 

🔗 Learn More: 

For an in-depth understanding of scrubber working principles, components, and types, check out our blog: 
👉 How Wet Scrubbers Work in Industrial Fume Extraction 

Why Choose Arvind Anticor 

Choosing the right partner for your acid fume extraction system is crucial to ensuring performance, reliability, and compliance. At Arvind Anticor, we deliver more than just equipment we provide complete, engineered solutions tailored to the specific needs of pickling and galvanizing plants. 

Custom Engineered for Your Operations 

We take a consultative approach to every project. Our team evaluates your plant layout, process parameters, chemical usage, and airflow requirements to design systems that integrate seamlessly into your production environment. 

Corrosion Resistant Material Expertise 

All components are manufactured using industrial grade thermoplastics such as polypropylene (PP), high-density polyethylene (HDPE), and fiber reinforced plastic (FRP). Material selection is based on your chemical environment, ensuring long term durability and reduced maintenance costs. 

DVS-Certified Welding Standards 

Our fabrication processes follow DVS welding standards for thermoplastics, ensuring leak proof joints and robust mechanical strength. This results in higher system reliability and safety under continuous operation. 

Precision Design with RITA 6.0 

We utilize RITA 6.0 software for accurate airflow modeling, pressure drop calculation, and system performance simulation. This ensures the final system is properly sized, balanced, and optimized before fabrication begins. 

Industry Experience and Reach 

With decades of experience in supplying turnkey solutions for galvanizing and pickling plants, Arvind Anticor has built a strong presence across India and international markets. Our systems are trusted by manufacturers who prioritize safety, compliance, and operational efficiency. 

Conclusion 

Optimizing an acid fume extraction system requires more than selecting off the shelf components. It demands a thoughtful design approach that considers your plant’s chemical processes, layout, airflow requirements, and long-term operational goals. 

From suction hood placement to duct routing, scrubber integration, and system automation every detail influences performance, safety, and compliance. With the right engineering and materials, a well-designed fume extraction system not only protects workers and equipment but also reduces maintenance costs and improves environmental outcomes.