A metal foundry in Oman began experiencing a steady decline in the effectiveness of their existing fume control system. Over time, the plant observed:

1. Low Flow and Poor Efficiency
   Furnace exhaust gases were not being adequately captured or treated. Emission readings surpassed local regulatory thresholds and threatened worker safety.
2. Frequent Maintenance Headaches
   Corrosion, overheating, and buildup of contaminants in the old system led to unplanned downtime and spiraling maintenance costs.
3. Urgent Need for an Effective, Long-Term Solution
   The foundry required a robust, 24/7 system to manage the high-temperature fumes generated during metal melting and pouring operations—critical to maintaining productivity and regulatory compliance.

Reason for Choosing a Dry Scrubber

While the original equipment had been a wet or hybrid type, SAZ ENVIRO recommended transitioning to a dry scrubber system for these core reasons:

1. Better Suited for High-Temperature Furnace Gases
   Dry scrubbing relies on solid sorbents (e.g., lime or sodium bicarbonate) injected into the gas stream to neutralize acidic and noxious gases, making it ideal for the hot off-gases from melting furnaces.
2. Reduced Water Usage and Corrosion Issues
   By eliminating the constant handling of water and harsh chemicals, a dry scrubber avoids many of the corrosion and bacterial buildup problems that plagued the foundry’s previous wet system.
3. Lower Maintenance Over Time
   Dry systems often have fewer pumps, pipes, and liquid-handling components. This simplification can translate to decreased maintenance costs and downtime.
4. Improved Particulate Removal
   When combined with a properly configured baghouse or cartridge collector, dry scrubbers offer excellent capture of fine particulate and fumes.

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Solution: 30,000 CFM SAZ ENVIRO Dry Scrubber System

Working closely with the foundry, SAZ ENVIRO designed and installed a 30,000 CFM dry scrubbing system that encompassed several critical upgrades:

1. High-Efficiency Sorbent Injection
   • Sorbent Feeder and Injection Lances: Precisely meters a powdered reagent (e.g., hydrated lime) into the hot fume stream.
   • Optimized Residence Time: Ensures sufficient contact between the reagent and the contaminants for effective neutralization.
2. Baghouse or Cartridge Collector
   • A robust filtration module with high-temperature filter media traps the spent sorbent and particulate matter.
   • Differential pressure monitoring (via a Magnehelic or Capsuhelic gauge) allows operators to schedule filter replacements/cleaning precisely when needed.
3. Suction Hoods and Ducting
   • Custom Engineered Suction Hoods at the furnace exhaust points, carefully sized to capture the high-temperature fumes.
   • Heavy-Duty Ducting (~200 feet of ductwork) designed for both high temperature and corrosive gases. Proper insulation and expansion joints accommodate thermal growth.
4. ID and FD Blowers: Capacity and Specifications
   • ID (Induced Draft) Blowers: Two blowers, each rated at 15,000 CFM (total 30,000 CFM) at 8–10 in. w.g. static pressure. These fans pull furnace fumes through the ducting and into the dry scrubber, maintaining slight negative pressure at the capture points.
   • FD (Forced Draft) Blowers: Smaller blowers (~5,000 CFM each, if required) supply or circulate additional airflow for ventilation or maintaining stable furnace conditions.
   • Energy-Efficient Motors: Each blower is equipped with a high-efficiency (IE3 or IE4) motor, reducing overall power consumption and operational costs.
5. Advanced Control System
   • PLC-Based Controls: Automated control of sorbent feed rate, pressure setpoints, and baghouse cleaning cycles.
   • Real-Time Sensors: Temperature probes, static pressure transmitters, and differential pressure gauges constantly monitor system performance.
   • Fail-Safe Alarms: Alerts operators to any anomalies, ensuring rapid response and preventing equipment damage.
6. Additional Accessibility and Maintenance Features
   • Inspection Doors added at strategic locations on the scrubber housing and ducting to facilitate routine cleaning and future upgrades.
   • Corrosion-Resistant Construction using specially coated steel or alloys, reducing the likelihood of structural damage from residual acidic fumes.

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Installation and Rebuild Process

1. Assessment and Demolition of Old Equipment
   • SAZ ENVIRO’s service team inspected the failing competitor scrubber and recommended partial demolition of severely corroded sections to make room for the new dry scrubber.
2. Turnkey Installation
   • New Ductwork replaced leaking or undersized metal pipes.
   • Sorption and Filtration Modules positioned to streamline operator access and maintenance.
   • Fan/Blower Alignment: Proper alignment and balancing to achieve the designed negative pressure throughout the fume path.
3. Downtime Minimization
   • The rebuild and installation teams completed the key aspects of the upgrade in under five days on-site, drastically reducing production downtime.
4. Testing and Commissioning
   • Startup Tests verified airflow, temperature, differential pressures, and sorbent consumption.
   • Operator Training provided hands-on learning for the foundry team, covering everything from filter inspection to adjusting the sorbent feed rate.

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Results and Ongoing Benefits

1. Improved Fume Capture and Control
   The 30,000 CFM dry scrubber system now consistently handles the foundry’s furnace off-gases, maintaining regulatory compliance and a safer working environment.
2. High Operational Efficiency
   Steady airflow ensures contaminants are continuously drawn away from the furnace area, limiting worker exposure and reducing particulate accumulation.
3. Reduced Corrosion and Downtime
   By eliminating water-based processes, the foundry has drastically lowered instances of pipe and component corrosion, leading to less frequent repairs.
4. Long-Term Reliability
   With a robust mechanical design and simplified maintenance routine, the new dry scrubber system demonstrates excellent performance and reliability since its commissioning.
5. Partnership for Future Rebuilds and Maintenance
   Impressed by the system’s efficiency and short installation timeframe, the foundry’s management engaged SAZ ENVIRO to assess additional pollution control units at the plant, aiming to standardize on proven dry scrubbing technology.

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Conclusion

The SAZ ENVIRO 30,000 CFM Dry Scrubber System has revitalized fume control at this major metal foundry in Oman, delivering a reliable, cost-effective, and low-maintenance solution for high-temperature furnace exhaust. By choosing dry scrubbing technology, the foundry has overcome the persistent corrosion and performance issues of its prior system, ensuring that melting and pouring operations remain safe, compliant, and efficient for years to come.

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