Composite Stacks Save Taxpayers Money
December, 2010 : Collierville, TN
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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.
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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 for corrosive exhausts. President, Jeff Jones pointed out how all-composite stacks could do the job better for less.
“We explained how composite can be engineered to be freestanding and to withstand the same forces that the steel stacks were designed for" said Jones. "In addition, the solid composite ensures superior corrosion resistance and 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.
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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.”
120,000 CFM System
Suggesting the all-composite stacks drew upon Engineering Composite Systems’ reputation for offering superior solutions with high value. “Like everyone else today, municipal authorities are looking for ways to trim costs," saide Jones. "We offer a variety of odor control systems to help meet performance requirements in the most cost-effective way.”
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The stacks were a natural extension of an odor control system designed to move 120,000 cubic feet (3,400 cubic meters) per minute of air. The system’s 100-inch (254-centimeter) diameter, filament wound composite ducting and open-molded composite covers and dampers were also made with in the ECS facility with Vipel K022 vinyl ester.
Vipel K022 resin resists the highly acidic internal operating environment of the anti-odor system where pH levels can get as low as 2. Furthermore, with minimal synergist addition, the resin meets ASTM E84 Class 1 flame spread and smoke requirements. or go to www.ecs-frp.com. \About AOC
AOC is a leading global supplier of resins, gel coats, colorants, additives and synergist systems for composites and cast polymers. Offering a wide range of Vipel resin technologies, AOC is the leading producer of corrosion-resistant resins in North America. AOC knows technology, lives quality and delivers service better than any other supplier. For more information, e-mail Ben Bogner, P.E., C. Eng., at BBogner@aoc-resins.com, phone him at (630) 665-2675, or go to www.corrosionresins.com.
About Engineered Composite Systems
Headquartered in Central Texas, Engineered Composite Systems specializes in the design, manufacture, sales and service of equipment for the municipal, chemical and power industries. ECS / BPI is the largest odor control system supplier in North America. Product offerings include a full line of odor control systems, such as carbon adsorbers, chemical scrubbers, several different biological systems, ductwork, dampers, chemical storage tanks and odor control covers. For more information, e-mail jeff.jones@ecs-frp.com