The American Airline plating facility located in Tulsa, OK operated two hard chrome plating lines with 65,000 amp rectifier capacity that could not meet the new EPA emissions standard. The two 30,000 CFM ventilation systems were only six years old and in excellent condition, but test results showed chrome emissions in excess of 0.070 mg/dscm each.
Every ventilation vendor encountered the same problems as the quotes were prepared for bidding on this project:
- The existing systems were located in the basement of the plating facility
- Possible modifications to the building itself may be necessary
- Replacing the system would require extensive down time - time for demolition removal and relocation of the existing system had been estimated at 10 to 14 days for each unit by other vendors, and the time quoted for installation of the new systems was an additional 14 to 21 days
- A new system would require assembly onsite because spatial constraints of the facility would not allow for movement of a completed separator into place
After thorough inspection of the existing systems, Tom O'Connor knew the equipment could meet ScrubAir's criteria to qualify for modifications:
- It was economically feasible to retrofit versus replace
- The fan capabilities to pull the additional static pressure requirements of a composite mesh pad system were adequate
- The design CFM capabilities were in compliance with OSHA requirements of required ventilation per the combined tank sizes
- The units had structural integrity to facilitate proper installation of grid supports for the pads
- The scrubber length was adequate to install at least two (2) stages of composite mesh pads, spray headers and nozzles
After reviewing quotes from other ventilation vendors, the airline chose ScrubAir for the project - based largely on ScrubAir's commitment to fully guarantee the entire retrofit. Tom engineered comprehensive drawings for the airline's approval, then arrived onsite with the ScrubAir Installation Crews to proceed with demolition and installation of new equipment.
How long did the entire process take?
Three Days!
Was the production line shut down during this installation of the retrofit?
The process was in operation during the retrofit installation by utilizing a crossover pipe between the two scrubbers - allowing ventilation through one scrubber while the other scrubber was being modified!
An independent environmental testing company tested the exhaust air and the results showed chrome emissions under 0.005 mg/dscm - far surpassing the EPA requirements! The system continues to operate efficiently and practically maintenance-free. The plating supervisor of this airline facility presented a paper to the 1997 AESF Aerospace Conference detailing the success of this project.
The American Airline plating facility located in Tulsa, OK operated two hard chrome plating lines with 65,000 amp rectifier capacity that could not meet the new EPA emissions standard. The two 30,000 CFM ventilation systems were only six years old and in excellent condition, but test results showed chrome emissions in excess of 0.070 mg/dscm each.