Many facilities need to be in compliance yesterday to keep from incurring fines and penalties. Just how soon can a new system be up and running and pass EPA tests?
A large anodizing facility in Phoenix attempted to eliminate the yellow NOx plume exiting their stack by installing a 2-Stage NOx reduction system costing in excess of $1,000,000.00.
For much of the time, this system could control the yellow plume, but the high concentrations of NOx could not consistently be controlled through the system. The anodizer was under threat of penalties and fines from the city unless his system met the opacity mandate for NO visible yellow plume. Upon recommendation from a leading manufacturer of NOx systems, the anodizer purchased the vendor's proposed 3rd Stage for approximately $500,000.00.
When the new system was turned on for the first time, a large quantity of water rained down from the stack, causing corrosive damage to the roof and surrounding equipment. The vendor could not prevent the mist caused from the high liquid loading, so he installed a large rain cap above the fan with a drain to collect the mist.
Another serious problem for the anodizer was the annual cost of the sodium hydrosulfide to reduce the NOx = $100,000.00+
The anodizing facility contacted ScrubAir and several other NOx ventilation vendors in hopes of finding a better solution to improve the efficiency of the system, eliminate the excessive costs to operate the 3-Stage system and make repairs to the numerous leaks in the existing system. Tom O'Connor flew from ScrubAir to Phoenix to inspect the problem first hand. Observing large loads which produced high PPM of NOx, it was obvious the system still was not eliminating the yellow NOx plume. Tom realized that only repairing the leaks and replacing the dump pack, as suggested by other vendors, would not solve the problem.
Tom proposed removing the first two stages completely, as well as the top portion of the third column, then rebuilding it into a single stage reduction scrubber designed and guaranteed to drastically reduce the chemical additions required to control the pH and ORP of the existing three systems, yet still completely reducing ANY visible yellow plumes and mist from the existing stack.
By this time, the anodizer had already invested a significant amount of money and time on this 3-Stage Scrubbing system, and he needed to be certain that this retrofit would really work. He began contacting other facilities where Tom had designed and installed NOx systems. He received very positive responses from other ScrubAir clients, and he secured a letter of guarantee that this system would reduce the NOx to non-visible emissions. He issued a purchase order to ScrubAir with a four week deadline for completion.
The ScrubAir production shop began fabricating the new sections for the NOx column, duct and fittings and shipped the finished equipment to Phoenix via flatbed delivery. Four of the ScrubAir installers arrived at the anodizing facility and started the demolition by removing the 3 large scrubbers and rain cap, and then installing the new ScrubAir scrubber, duct and controls.
How long did the installation take?
Three days!
Did it pass the opacity test?
Yes!
The customer is very pleased with the new ScrubAir NOx system - he likes the appearance of the unit, and appreciates all the additional space available to him once the large units had been removed. The costs to operate the system have been substantially reduced! The reduction agent (sodium hydrosulfide) was reduced by 80% and the maintenance time is minimal.
ScrubAir Systems, Inc.
1250 Rose Road
Lake Zurich, IL 60047
Ph: (847) 550-8061
Fx: (847) 550-8062
A large anodizing facility in Phoenix attempted to eliminate the yellow NOx plume exiting their stack by installing a 2-Stage NOx reduction system costing in excess of $1,000,000.00.
When the new system was turned on for the first time, a large quantity of water rained down from the stack, causing corrosive damage to the roof and surrounding equipment. The vendor could not prevent the mist caused from the high liquid loading, so he installed a large rain cap above the fan with a drain to collect the mist.
Tom O'Connor flew from ScrubAir to Phoenix to inspect the problem first hand. Observing large loads which produced high PPM of NOx, it was obvious the system still was not eliminating the yellow NOx plume. Tom realized that only repairing the leaks and replacing the dump pack, as suggested by other vendors, would not solve the problem.
By this time, the anodizer had already invested a significant amount of money and time on this 3-Stage Scrubbing system, and he needed to be certain that this retrofit would really work. He began contacting other facilities where Tom had designed and installed NOx systems. He received very positive responses from other ScrubAir clients, and he secured a letter of guarantee that this system would reduce the NOx to non-visible emissions. He issued a purchase order to ScrubAir with a four week deadline for completion.
The customer is very pleased with the new ScrubAir NOx system - he likes the appearance of the unit, and appreciates all the additional space available to him once the large units had been removed. The costs to operate the system have been substantially reduced! The reduction agent (sodium hydrosulfide) was reduced by 80% and the maintenance time is minimal.