COMPOSITE STACKS SAVE TAXPAYERS' MONEY

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RESIN

Vipel® K022 fire-retardant bisphenol A epoxy vinyl ester

COMPOSITE APPLIcATIONS:

Exhaust stacks, ducting, covers,dampers for odor control system

MANUFACTURING PROCESS

Filament winding Hand lay-up

Stack Height:

72 feet (22m)

Stack Diameter:

96 inches (152cm)

System Capacity

120,000 cubic feet (3,400 cubic meters) per minute

Installed

2010

Location

Camden, New Jersey, USA

In early 2010 ECS received a contract to install (2) 72-foot tall stacks in Camden, New Jersey. Each stack was designed to meet air velocity requirements.

An alternative specification for two new towering exhaust stacks not only significantly reduced initial costs for the Camden County Municipal Authority. The durability and superior corrosion resistance of the stacks’ all-composite design will essentially eliminate maintenance costs at a Camden, New Jersey, wastewater facility for years to come.

The 96-inch diameter by 72-feet tall stacks were designed and manufactured by Composite and odor control specialists Engineered Composite Systems. ECS made the stacks and odor control system components with corrosion-resistant and fire-retardant Vipel K022 bisphenol A epoxy vinyl ester from AOC.

To meet the specification for freestanding stacks without guy lines, the Authority initially selected stacks made of steel. A thin inner liner of fiber-reinforced polymer (FRP) composite was to be added to protect the metal from corrosive exhausts. President Jeff Jones pointed out how all composite stacks could do the job better for less.

“We explained how with a bit of creativity, composites could be used to build stacks which would withstand the same forces that the steel stacks were designed for. In addition, the solid composite construction ensures superior corrosion resistance while providing a Class 1 fire rating throughout the entire structure – inside and out.

The stacks were manufactured by the filament winding process in which continuous fiberglass roving is encapsulated in the Vipel® resin. One design parameter that helped each composite stack meet the freestanding requirement was to manufacture the cylinder wall to be well over 1-inch (25.4- centimeter) thick.

Building a composite that thick can compromise laminate integrity because of excess exotherm, the heat generated when a composite resin cures into a structural solid. “Controlled exotherm was another benefit of using the AOC material, Jones pointed out. AOC’s Eric Stuck worked with us to develop a resin formulation that keeps exotherm down until the resin was fully cured.”








CASE STUDIES

SERVICE SOLUTIONS

Media Exchange and Sales

ECS stocks a range of carbon and specialty media in our Texas warehouse. We offer aftermarket sales and full exchange service solutions.

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Odor and Media Testing Service

Trained technical personnel can conduct on-site odor testing. ECS can also conduct media testing to determine disposal requirements.

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Trouble-Shooting

Expertise to optimize an existing odor control system or equipment.

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Equipment Repair

Repair and/or replace broken components to get your system up and running properly.

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Equipment Services

ECS has a variety of temporary odor control systems available.

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PRODUCT SOLUTIONS

Control Options

ECS offers a full range of odor control options; selection is typically based on the following criteria:

  • Odor compounds
  • Flow rate
  • Available space
  • Client experience /preference
  • Lifecycle and capital costs

Odor Control Systems

Odor control technology offerings include:

  • Activated Carbon
  • Chemical Scrubbers
  • ECS Ex-Pac Degasifiers
  • Biological Solutions

Odor Control Accessories

ECS Environmental Solutions offers a full range of accessories to complement our Odor Control Systems. Each of these components has been designed by ECS engineering staff and is manufactured in our Texas facility.

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