Specialty Metals Manufacturing Facility

 

Specialty Metals Manufacturing Facility

 

Specialty Metals Manufacturing Facility

 

Contract: $155,000

Design-Build Team Members
Owner: World Resources Company
Engineer: Xerxes/Kelso Company
Contractor: Johnston Construction Company

Key Accomplishments:

• Maintaining production plant operation while constructing the new scrubber system.
• Minimizing down time during the change over from the old scrubber system to the new system.
• Insuring the owner’s plant personnel would work in a safe environment throughout our construction operations.
  

The design-build team included the owner, World Resources Company, an engineer from the major equipment supplier, George Kelso Company, and the general contractor, Johnston Construction Company. The owner selected our team and presented their needs regarding increased fume scrubbing capacity and better particulate removal. We assessed the technical requirements for the process as well as the physical constraints as this manufacturing facility was in full operation. The Engineer selected materials of construction; venturi scrubber and packed tower fume scrubber sizes, packing media configuration and chemical and recycle flow rates. As the general contractor team member, we assembled other supplier and subcontractor team members. We developed a full cost estimate for the owner including design and construction services. JCC was responsible for incorporating the electrical design into the overall project. We also procured all ancillary equipment including recycle pumps, chemical feed systems, pipes, valves, fittings and control systems. A major concern for the owner was keeping the existing process operational during construction and minimizing down time during startup. We accomplished all items successfully. Another hallmark of this project was keeping the owner personnel safe while construction work continued all around and above them as this was a roof mounted system.

A complete, turn-key system including a venturi, cyclone separator and packed tower fume scrubber. All the necessary structural, mechanical, electrical and control functions were furnished and installed. The scrubber fan has a 75 HP motor. A complete chemical feed system was installed with automatic pH monitoring and adjustment. The high temperature process required a stainless steel quench unit to cool the gas prior to being scrubbed. An emergency bypass was installed to automatically divert the hot gas from the FRP equipment should a quench failure occur. This new system was built around an existing scrubber to the maximum extent possible. Then a rapid transition occurred, minimizing the client’s process downtime.