Case Study Details

Client Name

National Bronze & Metals, Inc.

Application

Metal Processing Fumes

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Challenge

The completed solution for National Bronze & Metals, Inc. meeting strict EPA lead limits.

National Bronze & Metals, Inc. is the leading manufacturer and master distributor of brass, bronze and copper alloys in the United States. Houston, Texas is the home of the National Bronze & Metals, Inc. corporate office but this particular installation is at their foundry in Lorain, Ohio which has been in business since 1997.

The National Bronze & Metals, Inc. foundry had been using a 196-10TR Camfil Ramtube Baghouse. In November 2009, the foundry expanded their manufacturing and warehouse facility by over 200,000 sq. ft. That expansion came with new challenges and a need for a bigger dust collector. With the new facility, the owners emphasized that the Gold Series equipment should be selected since effectiveness takes priority over cost factors. The system needed to capture all fumes due to the hazardous lead levels generated in their foundry and longevity and reliability were essential. The Gold Series equipment needed to meet all EPA emission standards according to current published guidelines.

Solution

In 2006, Leonard “JR” Iacco, Jr. of Rolin & Associates started working with the customer on their new effective Tandem GS96 dust collection system to capture the harmful and hazardous fumes and dust in their new facility. After reviewing the old system airflows and materials collected and verifying the process temperatures, they were able to recommend the following system design.

The model GS96 Gold Series® industrial dust collector is rated at 90,000 CFM with 16” of static pressure with 192 cartridges total. It has a Camfil APC custom integrated drop out box and EPA driven explosion venting. JR said, “The big decision was whether or not to use cartridges or bags. Everyone quoted bags, and only Camfil APC knew that they were capable of using a cartridge collector that offered higher efficiencies and filtration life and exceeded the stringent EPA emissions regulations.”

The cartridges were selected to provide an optimal air-to-media ratio and efficiency rather than using bag filters which offered a ratio of 1.8 to 1. Camfil APC was able to make the system operate on a variable frequency drive, keeping airflow constant with their 250 horsepower fan, and include EPA driven explosion venting. JR continued, “When the sale was made, National Bronze & Metals responded that after reviewing and receiving quotes from as many as six manufacturers/competitors over a two-year period and reviewing all products, ‘I know I made the right decision.'"

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