Project Synopsis

Process engineering assistance in purchasing new air pollution control systems to control nitrogen oxides (NOX) emissions for a new catalyst manufacturing facility.

Project Summary


The client was installing a brand new (greenfield) facility that manufactures catalytic inserts for automotive and industrial emission control applications.  The production lines include batch reactors, a drying oven, and calcining ovens.  The client contracted with Process Engineering Associates, LLC (PROCESS) to provide process engineering assistance in support of the purchase of the new air pollution control system for the facility to control nitrogen oxides (NOx) emissions from the calcining ovens.  Specific project tasks and deliverables included the following:

  • Assisted client with the preparation of scrubber equipment specification.  The specification was submitted to five vendors to solicit bids for the system.
  • Performed a detailed vendor review to assist the client in vendor selection.  The review involved interfacing with each vendor to detail the scope of their supply, summarizing the expected system performance, and developing detailed operating cost estimates for each system (chemical usage, fresh water usage, and wastewater disposal rates).
  • Provided the client with guidance on good engineering practice (GEP) stack height requirements for three (3) facility exhaust stacks.  This included performing screen air dispersion modeling (EPA SCREEN3) of the emissions control stack to define the maximum on-site and off-site impacts.  This information was used in discussions with the state air permitting agency to solicit their approval on the stack height design.

Industry Type

  • Catalyst Manufacturing

Utilized Skills

  • Process equipment selection
  • Regulatory compliance engineering support

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