Ammonia Fume Extraction and Scrubbing

CPS was approached by a multinational metal recycling company to assist in controlling ammonia gas emissions resulting from their recycling process. A by-product of this process is a powder with high ammonia content, stored in a dedicated building measuring 18m x 40m x 10m high.

To address the emissions, CPS designed and installed a 50,000 m³/hr HDPE fume scrubbing system. The system includes:

· Duty and standby base tanks for continuous operation

· 1400mm diameter HDPE inlet ductwork extracting fumes directly from the storage building

· A turbulent contact fume scrubber, selected for its efficiency in handling high dust and fume loads

Sulphuric acid is used as the scrubbing solution, reacting with ammonia to produce ammonium sulphate. This solution is allowed to concentrate in the duty tank before the system automatically switches to the standby tank.

The collected ammonium sulphate is then pumped to a nearby mixing facility, where urea is added to produce a saleable fertiliser product transforming a waste stream into a valuable resource.

This solution not only reduced harmful emissions but also supported the client’s sustainability goals through waste-to-value recovery.

Case Studies

With many years experience providing Storage and Process Tanks, Fume Extraction and Scrubbing Systems, Projects, Pipework and Bespoke Fabrications and Thermoplastic Heat Exchangers, CPS can provide thermoplastic products and turnkey solutions throughout the UK and Europe.

Acid and NOX Scrubbing System

CPS was awarded a contract by a leading electronics manufacturer in Ireland to design, manufacture, and commission advanced fume extraction and scrubbing systems for...

CPS was awarded a contract by a leading electronics manufacturer in Ireland to design, manufacture, and commission advanced fume extraction and scrubbing systems for their new production facility.

The installation included two key systems:

· An 88,500 m³/hr Acid Fume Scrubber, measuring 3.5 metres in diameter and 9.5 metres in height

· An 8,000 m³/hr twin NOX Fume Scrubbing System

All the scrubbers were fabricated from HDPE for chemical resistance and long-term durability.

Each system was equipped with duty and standby recirculation pumps, fitted with PFA-lined vortex flow meters for accurate flow monitoring. These meters were fully integrated with the facility’s Building Management System to provide real-time data and alerts.

To ensure optimal scrubbing efficiency,...

Acid Etch Facility

Having installed similar systems at various sites for the same customer, CPS were asked to design and install an acid etch plant for surface...

Having installed similar systems at various sites for the same customer, CPS were asked to design and install an acid etch plant for surface treatment of Super Alloys.

The new facility included a heavy gauge polypropylene etch tank measuring 7m long which is extracted through an 18,000m3/hr HDPE fume scrubber and ductwork.

Supply chemicals are housed in chemical resistant HDPE IBC stores with automated transfer and dosing pumps to ensure the correct acid concentration is used for the different customer products.

A recipe based PLC system is installed to ensure consistency of the various acid mixes used in the process and to eliminate operator error.

The acid waste from the process is stored...

Automated Mixing System for Cleaning Product Manufacturer

CPS was engaged by a leading cleaning product manufacturer to improve their manual mixing process, which involved mixing 1,000 litre batches and long settling...

CPS was engaged by a leading cleaning product manufacturer to improve their manual mixing process, which involved mixing 1,000 litre batches and long settling times creating a bottleneck as demand grew.

CPS designed a semi-automated mixing system with a 5,000-litre HDPE vessel, integral static mixer, and recirculation pump, all mounted on a GRP platform with load cells. A dedicated chemical docking station enabled automated ingredient transfer from IBCs.

Using a HMI interface, operators select a pre-programmed recipe, triggering automatic dosing, mixing, and transfer to either an automated bottling line or IBCs. An automated washdown cycle was programmed to run between batches.

Following the success of the initial trial unit, the client ordered...

Ultra Pure Chemical Dispense Modules

CPS was contracted to design, fabricate, install and commission Ultra Pure Chemical Dispense modules for a major new Electronics facility in Germany. Seven units...

CPS was contracted to design, fabricate, install and commission Ultra Pure Chemical Dispense modules for a major new Electronics facility in Germany.

Seven units were designed and installed to handle a range of Acids, Alkali’s and Solvents from 200 Litre drums to the tools in the cleanroom.

The units were manufactured in White Polypropylene with Stainless Steel and PFA pumps and pipework. Each system holds two 200 litre chemical drums with continuous level measurement and auto changeover of drums.

The units are fitted with an ultra pure filtration system to recirculate and polish the chemicals prior to automatic transfer to the tools.

‘Keyed’ drum connection heads are utilised on each CDM to ensure...

Bulk Storage Installation

CPS was awarded the contract to supply new spiral wound HDPE bulk storage vessels for a large pigments manufacturer. The contract involved the supply,...

CPS was awarded the contract to supply new spiral wound HDPE bulk storage vessels for a large pigments manufacturer.

The contract involved the supply, fabrication and installation of new 34m³ Sodium Hydrogen sulphide and 30m³ sodium hydroxide storage tanks.

Each tank was supplied with integral spiral wound HDPE Bund and rainskirt complete with actuated discharge valves, heaters and level sensors.

The vessels were delivered and installed on site complete with new stainless steel tanker fill pipework.

On completion of the project CPS were awarded a second contract to supply and install a new 25m³ bulk 96% sulphuric acid tank and integral bund. The project included the construction of a new concrete bund and...

Rutherford Appleton Laboratories

The new research complex at Harwell Oxford is a multi-disciplinary laboratory providing world leading facilities for new and cutting edge research in both life...

The new research complex at Harwell Oxford is a multi-disciplinary laboratory providing world leading facilities for new and cutting edge research in both life and physical sciences and the interface between them.

Environmental issues were at the forefront of the building design with all energy use carefully monitored. An innovative earth tube has been buried along side the building to utilise the relatively stable below ground temperature, heating the building’s incoming air in the winter and cooling during the summer.

CPS were contracted to design and manufacture six thermoplastic heat exchangers complete with spray cleaning systems as part of the building’s heat recovery system.

The units are designed for extraction flow rates...

GRP Tank Failure

CPS was contacted by a large waste treatment company after the catastrophic failure of a grp tank had caused major damage and halted production...

CPS was contacted by a large waste treatment company after the catastrophic failure of a grp tank had caused major damage and halted production at the plant. The initial tank failure led to the failure of a second grp tank and compromised the integrity of the existing civils bund.

Initial work involved the installation of new polypropylene pipework on site to enable the plant to operate.

On completion of the work CPS was awarded the contract to construct a new concrete bund complete with chemical resistant screed and supply and install new 40m3 spiral wound HDPE process vessels, complete with polypropylene transfer pipework and pumps.

As principle contractor on the project CPS...

New Inspection Facility

CPS was awarded the contract to design and build a new inspection facility for a specialist alloy manufacturer. The contract included the design and...

CPS was awarded the contract to design and build a new inspection facility for a specialist alloy manufacturer.

The contract included the design and construction of a new production building, electrics and processing equipment.

The building works included the design and construction of a new building complete with 6 hoist overhead crane, production office and bunding with chemical resistant epoxy screed.

The new test facility included the installation of 12 polypropylene process tanks complete with heating, temperature control and agitation. Access to the vessels is via a GRP walkway ensuring that all production areas are fully chemical resistant. Chemical delivery and waste transfer pumps and pipework were installed to minimise manual handling...