Case Studies...

Project Integration, Inc. provides total solutions to the industrial community to meet environmental, energy, safety, and process support needs. The following Case Studies depict some of the solutions implemented.

Power Systems Company

Completed an initial facility environmental gap analysis.  Identified and closed compliance gaps.  Developed an environmental and safety compliance management program and provide on-going environmental compliance management and safety program development and training for the company’s five (5) facilities located in PA, TX, CA, SC, and IL.  The program includes:

• Development and management of facility SWPPP and required recordkeeping and reporting
• Development of and/or management of facility air permits and required recordkeeping and reporting
• Development and management of facility SPCC plans and required recordkeeping
• Completion and management of facility EPCRA reporting (i.e. Tier II, TRI, EHS)
• Development and management of facility waste (solid, hazardous, and universal) management plans and required reporting
• Development of facility safety programs
• Development and facilitation of facility safety training

Specialty Wire Manufacturer – Hazardous Waste Delisting

Completed F006 hazardous waste delisting for a specialty wire manufacturer.  The facility had previously been granted a delisting and had it revoked.  Therefore, regulatory interaction and input was essential.  The major phases of the project included:

• Developing the delisting strategy
• Meeting with the state and EPA regulators to outline the strategy and obtain input
• Develop Sampling and Analysis Plan (SAP)
• Develop Quality Assurance Project Plan (QAPP)
• Review Meetings with state and EPA
• Develop Draft Delisting Petition
• Submit Final Delisting Petition
• Provide comments on draft delisting from state

Flat Glass Facility Air Emissions Control System

Designed, built, and installed an emission control system for a coating system to control halogenated hydrocarbon emissions and recover valuable by-products. The system included:

• High Temperature Oxidation Chamber
• Burner System with Custom  Designed Vent Gas Injector
• Combustion Gas Cooler System
• Product Recovery Baghouse System
• Reagent Injection System
• Dry Scrubber System
• Adiabatic Quench System
• Packed Tower Scrubber System
• Selective Catalytic Reduction System
• Integrated Control and Data Collection System

Secondary Aluminum Facility

Provide environmental compliance and process safety management support for the integrated aluminum facility.  The compliance areas of assistance include:

• Development of facility Title V application and draft Title V permit
• Title V Permit Negotiation
• Development of EPCRA Reports (Tier II, Toxic Release Inventory (TRI))
• Facility Expansion PSD Avoidance Construction Permit Application
• Development of Underground Injection Control (UIC) Permit
• Annual Air Emission Inventory
• Secondary Aluminum MACT Semi-Annual Reports
• Development of Secondary Aluminum MACT Notice of Compliance (NOC) Status Report, Operation, Maintenance & Monitoring (OM&M) Plan and Start-Up, Shutdown, and Malfunction (SSM) Plans
• Development of facility Process Safety Management (PSM) Program
• Facilitation of Process Hazard Analysis (PHA)
• MACT Compliance Stack Testing Management
• Development of facility SPCC plan

Tier 1 Automotive Supplier – Hazardous Waste Delisting

Completed F006 hazardous waste delisting for a Tier 1 automotive supplier.  The major phases of the project included:

• Developing the delisting strategy
• Meeting with the state regulators to outline the strategy and obtain input
• Develop Sampling and Analysis Plan (SAP)
• Develop Quality Assurance Project Plan (QAPP)
• Develop Delisting Petition

Chemical Manufacturing Facility -

Provided the environmental permitting, mechanical, piping, and utility design and construction oversight for a chemical manufacturing facility in North Carolina. Have since provided on-going environmental compliance support.  The programs, systems and equipment developed, designed and specified included:

• Developed and Submitted Air Permit Application
• Developed facility SWPPP and SPCC plans
• Ice Bank Process Chilled Water System
• Process Water Tempering System
• Air Pollution Control System for tank and reactor vents
• Interconnecting Piping for reactors/tanks and utilities
• Facility Expansion Construction Permit Application
• Tier II Reporting
• Annual Air Permit Reporting
• Annual Air Emission Inventory

Secondary Aluminum Facility - Chlorine Injection System

Provided the design and construction oversight for a chlorine gas injection system in the cast house of a major aluminum supplier. The system was designed to deliver, control, and inject chlorine gas into aluminum furnaces for removal of impurities. The key elements of the project included:

• Design and specification of piping, valves, instrumentation, and controls
• Computation Fluid Dynamic (CFD) Modeling to simulate the consequences of potential chlorine gas leaks to satisfy OSHA compliance requirements
• Development and implementation of the Process Safety Management Program for the use of chlorine gas in the process