I’m not an expert in chemistry or physics but this is what I have figured out about scrubber efficiency. With some crude simplifications.
The most important factor to scrubber efficiency is temperature!!! Many chemical reaction rates double for every 10℃ temperature rise.
The chemical reaction of scrubbing CO2 out of the gas is an exothermic reaction. Meaning it produces heat.
Heat can be lost by three different means: convection, conduction and radiation
Convection:
At depth the gas is denser. The specific heat (energy needed to heat the gas, kJ/(kg*K)) increases with the density. The denser gas at depth takes away more heat from the reaction (by convection) and therefore decrease the reaction temperature and scrubber efficiency.
Nitrogen N2 got a specific heat of 1.04 kJ/(kg*K). Helium He got 5.19 kJ/(kg*K). So is nitrox better than trimix?
No. You have to take density into account. N2 got a density of 1.165kg/m^3. He got a much lower density of 0.1664 kg/m^3. So if specific heat is converted to 1 atm cubic meters instead of kilograms the values turn around. N2 got about 1.2 kJ/(m^3*K) and He got 0.86 kJ/(m^3*K). Helium transfers 29% less energy from the reaction than N2.
As a less dense gas He also lowers the work of breathing (WOB).
Conduction:
Heat loss by conduction comes from the temperature gradient between the inside and outside of the scrubber. Heat is conducted from the warmer material to the colder material. An aluminum tube filled with soda lime is much worse than a plastic scrubber cartridge inside a scrubber canister. Thermal conductivity of aluminum is 205 W/(m*K) and of hard PVC-U plastic is only 0.16 W/(m*K).
An air gap between the cartridge and the canister insulates the soda lime better from the surrounding cold water. Thermal conductivity of air is as low as 0.0262 W/(m*K) at 1 atm. It gets higher with increasing depth/density. The best option is a radial in-to-out scrubber or a co-axial scrubber where the warm inhale gas flows between the canister and the cartridge.
Radiation:
All materials radiate thermal energy based on their temperature. The hotter an object, the more it will radiate.
The middle of the scrubber gets more thermal radiation from surrounding material than a position closer to the edge. This phenomenon is one more reason why the middle of the scrubber is warmer.
One interesting and easy thing to try is covering the inside of the scrubber canister or cartridge with
heat reflective sheet with one sided adhesive (check for off-gassing!). I planned to test this with my next DIY unit. This could potentially even out the thermal profile though the scrubber from middle to the edge.
Scrubber breakthrough
One way to increase the scrubber efficiency is to increase the size. Tests show size versus time to breakthrough is not linear. A half size scrubber last for less than half the time. Doubling the size more than doubles the time. This may be caused by the long cone shaped reaction front. With a flat and short reaction front the size to time ratio would be more linear.
Average dwell time does not depend on geometry. Only on scrubber volume. Scrubber geometry and counterlung design affect the gas flow speed in the scrubber.
Scrubber breakthrough happens when the reaction front reaches the end of the scrubber. Time to breakthrough can be expanded by making the reaction front shorter and less cone shaped.
Gas flow speed and scrubber temperature affect the length of the reaction zone. Lower gas flow speed and hotter temperature makes the reaction front shorter and therefore increase the efficiency. More soda lime is used before breakthrough
The scrubber is hotter in the middle because of thermal conductivity and radiation. This makes the reaction front cone shaped in a round axial scrubber. Longer at the sides and short in the middle of the scrubber. The cone shape can be reduced by evening out the thermal differences with good thermal insulation and maybe with the heat reflective sheet.
The length of the reaction front caused by gas flow speed can be changed with scrubber geometry and counterlung design. A long and narrow scrubber tube has a higher gas flow speed because of smaller cross section area. The Mk15/16 rebreather got a donut shape axial scrubber design. The length (L) to surface area (A) ratio L/A is very low. The KISS rebreather got a long and narrow scrubber tube with high L/A ratio. The L/A ratio affect the gas flow speed and WOB.
To make things more complicated the cross section area also affect the temperature. With a larger cross section the heat is spread over a larger reaction front making it cooler. There is a usable range of L/A ratios and you have to make compromises between WOB, gas flow and temperature.
Counterlung design affect the flow speed. Average flow speed stays the same but peak flow speed is half with a dual counterlung design. With a single counterlung you push gas through the scrubber for half the time of your breathing cycle followed with an equal length pause. Gas moves through the scrubber at inhale or exhale cycle only. With dual counterlungs gas flows the scrubber at both inhale and exhale cycles with half the peak flow speed.
With a single counterlung you have an exhale counterlung if the rebreather is front mounted. You have an inhale counterlung for back mounted units. This is because you can use the hydrostatic imbalance (pressure difference caused by the water column height between the lung centroid and the air fill level in the counterlung) to your advantage to reduce WOB. The pressure differen assists the gas though the scrubber.
To make things more complicated gas can drastically cool down in the counterlung. A single inhale counterlung may be better in some design because the warm exhale breath goes directly into the scrubber. The dual counterlung may cool the gas so much in the exhale counterlung it makes the scrubber less efficient. One good example is the Sentinel rebreather. It is known for good scrubber efficiency.
That old “Here on Zord…” explanation is BS. It’s a kindergarten type explanation with no scientific basis. The extra N2 or He diluent molecules do not work as an chemical inhibitor. The increase in gas molecule collisions under higher pressure works both ways and cancel each out. A CO2 molecule can collision and change path from or to soda lime. Extra N2 or He molecules do not interfere with the scrubbing chemical reaction or the reaction in O2 sensors other than by thermal transfer.
Check for interesting WOB & scrubber docs at
Theory&Docs | DIY Rebreathers
If I missed any good documents please let me know.
Sorry for the long post
I left out some minor stuff.