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Solutions for Abrasive Scale/Explosive Lubricant

Abrasive Scale/Explosive Lubricant

PROBLEM: a highly abrasive mill scale combined with an explosive lubricant (sodium stearate) required both heavy duty construction and explosive mitigation features.

SOLUTION: 10000 cfm highly abrasive, explosive dust collection system. The system includes a double access platform, with load off into a truck-loaded containment vessel. It is also is NFPA 2014 compliant. It has a fast acting passive inlet isolation valve per NFPA 69, explosion vents on the sides under the white domes, and a unified hopper with one single rotary valve per NFPA 654.

The customer is still using the first set of cartridges due to a constant volume control unit (vfd) with the same pressure drop as they had when originally installed. The system was installed summer of 2013.

Solutions for Dust Containment

Dust Containment

PROBLEM: As a result of sanding and grinding, steel dust was spread throughout the plant at this steel door manufacturer.

SOLUTION: All sanding operations are contained within a Dust Containment Booth. The booth has acoustic side panels to reduce noise and lighting outside  of the plexiglass enclosure. Notice the space between the left and center dust collectors. As the doors are sanded they move between the two dust collectors to remove any dust remaining on the surface of the door. The doors travel directly to the assembly line. The new system has reduced exposure to below OSHA standards. Additionally, the factory outside of the containment room is cleaner.

Solutions for EPA Visible Emissions

EPA Visible Emissions

PROBLEM:  Activated charcoal  used as a raw material in the production of carbon steel was lost in a black dust cloud at the truck dump bin when it was unloaded.  The result was raw material loss, EPA visible emissions, and employee dust exposure.

SOLUTION: The activated charcoal unloading site (dump bin) was redesigned so that the dust collectors functioned dually as dust collection and raw material recovery, making the system fully redundant. Underneath the dump bin is a huge container for the activated charcoal. Dust from the dust collector drops right back into the bin.  

Because Air Systems Corporation had to guarantee performance, the system was designed with two tandem dust collectors, however each collector is so efficient that the company has only needed to use one at a time.

 

Solutions for Fiberglass Dust

Fiberglass Dust

PROBLEM: Employees were being exposed to fiberglass dust. A system was needed that would enable employees to work anywhere on the boat and not be exposed to the dust.

SOLUTION: A dust containment booth was designed for sanding, cutting, and grinding which protected the employees no matter where they were working on the boat. Additionally the dust collectors were outfitted with noise absorbent blankets for noise protection. The system is so efficient that the company has gone 5 years without changing the filters.

Solutions for Sub-Micron Blue Haze Aerosol Pollutant

Sub-Micron Blue Haze Aerosol Pollutant

PROBLEM: The byproduct of the production process at this foundry was sticky, gooey, sub-micron blue haze aerosol pollutant. This type of particle is the most difficult to capture, similar to tobacco smoke. Not only was there an exposure issue for employees, but the customer is located within downtown city limits and must have exemplary 0 emissions. The existing system was made up of ineffective scrubbers.

SOLUTION: The new system utilizes dense fiber-bed filters by Kimre. The filters run on automatic volume controls with variable frequency drive from Airtech Corporation to save energy. Because the filters start at 5” water column resistance, but end up at 20” of water column the fan must compensate for the difference.

Solutions for Toxic Fumes

Toxic Fumes

PROBLEM: The by-product from stainless steel welding was toxic fumes due to the welding plasma and pyrophoric dust.

SOLUTION: The newly designed system is an HVLV system, that results in extremely high pressure extraction at 200” of water column+ . At the core of the system is an industrial vacuum motivator (fan) which pulls fumes through very small tubing and a double filter for long distances at high pressures. The system features redundant motivators, 6 prong fire reduction systems, and a 55 gallon drum for final disposal.

Solutions for Toxic Metals

Toxic Metals

PROBLEM: Students and Faculty at a Community College were being exposed to toxic metals such as Mercury, Cadmium, Chromium, Cobalt, and Iron (toxic metal dust) in the process of mixing small and large batches of clay and glazes in the pottery studio.

SOLUTION: The newly designed ventilation system is turned on when anyone enters the mixing room to mix clay or glazes. Designed with turnkey units, the system is extraordinarily cost effective. Additionally, the system meets OSHA standards.