Industrial Operations Facility

Industrial Operations Facility

Location: Tobyhanna, Pa.

Burns & McDonnell consolidated the existing refinishing areas of the Tobyhanna Army Depot into one efficiently laid-out, state-of-the-art Industrial Operations Facility. The new 91,000-square-foot facility houses three major shop areas: plating, painting and sandblasting, and streamlines the production process for the existing facility.

Burns & McDonnell supplied the commissioning plan and operations and maintenance manuals for the facility. The manuals consisted of 21 volumes, including detailed information and instructions for plating processes, industrial waste/recycle treatment plant, laboratory, safety, mechanical process and support systems. Burns & McDonnell assisted in the startup and commissioning of the facility.

The shop areas encompass the processes of anodizing, cadmium plating, cadmium chromate, blackening, nickel, tin, electroless nickel, metal strip, zincate, precious metals, aluminum cleaning, zinc phosphate, copper, passivation of stainless steel, paint strip, alkaline aqueous clean, aqueous ultrasonic clean, aluminum ion vapor deposition, high-pressure industrial parts washing, and steam cleaning for large parts.

The industrial wastewater recycle/treatment area provides continuous recycling of the wastewater from the cleaning and plating processes, which include chrome, acid, caustic, and oily rinse waters. The recycle system was designed with reverse osmosis technology and two dual bed ion exchange demineralizers to provide an effluent water of proper quality for reuse. The treatment of concentrated wastes includes batch chemical addition designed to break metal chelation, precipitate flourides, and precipitate metals.

The microfiltration is designed to remove suspended solids for subsequent sludge dewatering with a thickener and filter press. The final pH adjustment is designed to adjust the wastewater pH to meet discharge limitations. The metals selective ion exchange system is designed to remove lightly chelated metals. The design included many plating line resource recovery technologies such as microfiltration, diffusion dialysis and atmospheric evaporation.