Oil Mist/Weld Smoke Collection.
Engineered solutions, no matter the system size
Problem
A Midwest scrap yard handles the physically demanding process of cutting down large chunks of metal into manageable pieces so it can easily be remelted and recycled. The torch cutting process is very volatile, generating a significant amount of heat & smoke in the process.
This created multiple challenges both operationally and environmentally.
This high level of smoke often falls into trouble with environmental regulations, as the cutting happens mostly in open air environments. Agencies such as the EPA, OSHA & MI EGLE have strict regulations for air pollution that can result in penalties and shutdowns if the emission standards are not met. Scrapyards therefore are forced to take action to mitigate their harmful particulate and smoke to ensure compliance with regulation standards.
The Challenge
There are several challenges for designing a system of this sheer size and scale. The scrap metal pieces could easily be several feet in length, and the scrapyard frequently has 2 workers cutting at the same time. This not only affects the size of the collection hood; it also significantly increases the required airflow to capture all of the smoke across the hood. An overhead hood would not work because of the use of overhead cranes to pick up and move the scrap material. A permanent building with collection pickups built in would be the best solution for this problem. The issue is that it would be too expensive and take too long to build for the client to satisfy OSHA’s timeline.
The Client needed an effective solution immediately.
The Solution
IAS contacted ACT for their engineering expertise for dust collectors on this mammoth scale. After a thorough site visit and working with the client to achieve their goals of minimal downtime and to hit all of MI OSHA’ emission limits. The final design required 48,000 cfm; an ACT 5-120 cartridge collector was the perfect selection. Matching hoods were constructed to accommodate both of the cutting stations; these hoods draw smoke in from there the smoke goes through a 92” spark trap before it reaches the ACT cartridge collector. Finally, the 150hp Design-95 fan from Chicago Blower engineered to deliver massive volumes of air discharges the clean air to the atmosphere.
From final drawing approval to start up, the process took 3.5 months.
Results
The results were immediate and effective. The system reduced emissions below MI OSHA’ emission levels, allowing the client to avoid fines, shutdowns, and lawsuits. All of the visible smoke that floated into the atmosphere is now pulled into the collector and discharged as clean air. The fumes no longer are in the workers’ faces and are pulled into the collection hoods, thus increasing worker health and safety.
IAS & ACT’s solution put the scrap yard into OSHA compliance and increased worker safety without impacting productivity.
Project Success Points
Our approach wasn’t just about providing a product. IAS & ACT partnered with the client to fully understand their operation, spending hours in person refining the design. This included everything from formal presentations and CAD drawings to hands-on modeling, to visualize the solution. The result was a custom solution that fit both the operational needs and regulatory demands of the client. With a rapid turnkey solution delivered in 3 months, we solved the customers’ needs quickly. The ACT cartridge collector was effective from day one, that paired with Chicago Blowers Design 95 fan exceeded the customers’ vision for this system.
Companies Involved
- ACT
- Chicago Blower
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