Engineering and Permitting - Roswell
Shot Blast & Coating Facility Development
Kloeckner metals corp, roswell, georgia
GSE provided engineering and permitting services to develop and build a metal shot blast and coating operation.
This project consisted of:
- Pre-construction Review and Consulting, which included:
- Reviewing the system design to identify the feasibility of certifying the spray booth and oven as permanent total enclosures (PTE) using US EPA Method 204. Making enclosure design suggestions that would meet the requirements of a PTE.
- Assisting in sizing the regenerative thermal oxidizer (RTO) to control exhaust emissions from the paint spray operation and drying oven.
- Assisting in specifying paint booth and filter performance criteria.
- Evaluating the feasibility of returning heat from the RTO to the oven and or the preheater.
- Evaluating energy recovery options.
- Assisting in specifying enclosure and dust collector options for the shot blast process.
- Reviewing the overall process design and providing input as needed.
- Attending meetings as requested (both on-site and by video).
- Attending site visits to review vendor designs and equipment.
- Reviewing vendor proposals and specifications for selecting final equipment.
- Acting as the owner’s representative in evaluating options.
- Construction, which included:
- Review of system design details from selected vendors and provided comments and input.
- Attending/participating in milestone meetings.
- Conducting an air pollution rule applicability determination, specific to the project and location.
- Evaluating fuels, paints, thinners and cleanup solvents.
- Preparing potential and actual air emission calculations.
- Attending pre-construction permitting meetings in Houston with the Texas Commission on Environmental Quality (TCEQ).
- Preparing an air pollution permit application to allow the construction of the proposed metal finishing line.
- Working with the permitting staff at TCEQ to complete the permitting process.
- Reviewing the air permit draft while providing comments.
- Negotiating the specific permit conditions with TCEQ.
- Start up, Commissioning and Compliance Testing, which consisted of:
- Assisting in preparing a written operation and maintenance plan, and a startup-shutdown and malfunction plan as required by the permit.
- Preparing record keeping spreadsheets for maintaining daily, monthly and annual paint usage and air pollution emission records as stipulated in the air permit.
- Preparing a test protocol to demonstrate initial compliance with the air permit testing requirements and submitting it to TCEQ for approval.
- Conducting an initial destruction efficiency test on the inlet and outlet of the RTO using US EPA Method 25A.
- Preparing a formal report and submitting it to TCEQ.
- Preparing an application for an air operating permit and submitting it to TCEQ.
- Assisting with ongoing compliance and maintenance of the final air permit as requested.