Client Overview
Our client is a leading provider of waste management and environmental services across the UK. As part of their operational processes, acid plant facilities are used to treat calcified components, requiring effective Local Exhaust Ventilation (LEV) systems to control hazardous vapours and maintain safe working environments. We were appointed to design, install, and commission a range of systems to control acid vapours generated by process operations across two Energy Recovery Facility (ERF) sites.
The Challenge
As an approved supplier and contractor, responsible for the mechanical servicing of various pneumatic and separation systems across numerous facilities, we were approached by the Head of Maintenance to design a suitable ventilation solution. This followed previous difficulties in securing a supplier with the specialist expertise required for the project. The systems needed to deliver the specified air changes and extraction rates to effectively control hydrochloric acid fumes below the WEL (Workplace Exposure Limit), and in accordance with industry best practice, COSHH regulations & HSG 258- Controlling Airborne Contaminants at Work.
Basingstoke
At the Basingstoke site, we designed, supplied and mechanically installed a complete replacement general ventilation system for the acid processing facility. The system was engineered to achieve approximately 20 air changes per hour and provide a total extraction capacity of 8,000 m³/hr.
Key features included:
- Corrosion-resistant PVC extraction ductwork
- Eight 400mm x 400mm extraction plenums with lockable balancing dampers
- 5kW forward curved centrifugal fan
- Stainless steel support brackets and fixings within the acid room
- Redesigned discharge ductwork to suit the site’s operational requirements
Portsmouth
At the Portsmouth site, we designed, supplied and mechanically installed a modified general ventilation system alongside a bespoke Local Exhaust Ventilation (LEV) solution for the acid dipping process. The new system was designed to achieve approximately 10 air changes per hour with a total extraction capacity of 13,000 m³/hr.
Key features included:
- New PVC ductwork integrated with the existing ventilation header
- Replacement room extraction inlets with balancing dampers
- 11kW forward curved centrifugal fan with silenced exhaust stack
- Bespoke PVC extraction plenums designed in accordance with ACGIH VS-70-01 guidance
- Integrated tank extraction connected into the general ventilation system
- Stainless steel support brackets and fixings for improved corrosion resistance
Our Solution
We provided complete turnkey ventilation solutions at both sites, from system design through to mechanical installation, balancing and commissioning. Each system was engineered to deliver the required extraction performance while using corrosion-resistant materials suitable for the demanding acid plant environment. Following installation, each system was commissioned to verify airflow performance and confirm it met the required design criteria. Operator training and supporting documentation were also provided.
The Results
Both sites now benefit from modern, corrosion-resistant ventilation systems designed specifically for their acid plant processes; to provide effective control of hazardous acid vapours while achieving the required airflow performance. With documented commissioning and LEV records in place, the client has confidence the systems are operating as intended and are prepared for ongoing COSHH compliance and statutory Thorough Examination and Test (TExT) inspections.