DELOACH BLOG

Fiberglass is a versatile material

Its durability, corrosion resistance, and strength-to-weight ratio make it a popular choice in various industries. These qualities make it a great choice for a variety of applications. These qualities make it an excellent choice for many applications.

At DeLoach Industries Inc., we specialize in fiberglass manufacturing methods, including the hand lay-up contact molding process. In this video, we will discuss this particular process and its application in creating small components for our fiberglass aerator tanks.

The hand lay-up contact molding process is a manual technique. It involves layering fiberglass materials onto a mold.

This creates a desired shape or component. It is a common method used in the production of small to medium-sized fiberglass parts. Let's take a closer look at the steps involved in this process.

Mold Preparation:

To prepare the mold, use a sturdy material such as metal or fiberglass, and clean the surface thoroughly. Apply a mold release agent to prevent the fiberglass from sticking.

Fiberglass Material Selection:

Next, we select the appropriate fiberglass material based on the specific requirements of the component. Fiberglass materials are available in various forms, such as woven fabric, chopped strand mats, or continuous strand roving. The selection depends on factors like strength, flexibility, and the desired finish of the final product.

We apply a fiberglass gel coat to the mold. This creates a smooth and aesthetically pleasing surface finish.

Before creating the component, we apply the gel coat, which is a resin blended with pigment, onto the mold surface. This serves to create a protective layer that enhances the durability and appearance of the final product. The gel coat application is an essential step in the fiberglass manufacturing process.

The gel coat can be applied using two common methods: spraying or brushing. When spraying, a specialized spray gun evenly distributes the gel coat onto the mold, ensuring consistent coverage. This method is efficient for large-scale production or complex shapes where an even application is crucial.

Brushing is a manual process. It involves brushing the gel coat onto the mold surface.

This provides more control over the thickness of the coating. It also ensures that all areas are properly coated. This technique is often preferred for smaller projects or intricate details that require precision.

The gel coat serves multiple purposes. It acts as a protective barrier between the mold and the fiberglass layers. This prevents any potential damage or adhesion issues. Additionally, the gel coat provides an attractive and smooth surface finish for the final component, enhancing its aesthetic appeal.

The gel coat contains a pigment that provides a variety of colors. This allows for customization and ensures the component meets the desired specifications. By selecting the appropriate pigment, the component can be aesthetically pleasing while also meeting any branding or design requirements.

Furthermore, the gel coat plays a vital role in the overall structural integrity of the fiberglass component. It acts as a barrier.

It protects against external elements such as UV radiation, moisture, and chemicals. This safeguards the underlying layers of fiberglass. This helps maintain their strength and longevity.

Overall, the application of the gel coat is a crucial step in the fiberglass manufacturing process. Whether applied through spraying or brushing, it creates a protective layer, enhances the component's appearance, and contributes to its structural integrity. We carefully consider the gel coat and application method to guarantee the final product meets the desired standards. These standards include quality, durability, and visual appeal.

Layering the Fiberglass:

After the gel coat has hardened, we add the fiberglass layers. We soak each layer in resin and carefully place it onto the mold surface to ensure proper bonding. We repeat this process until we achieve the desired thickness and durability of the component. To increase strength in specific areas, we may include additional reinforcements such as fiberglass mats or woven fabric.

We use a catalyzed resin, typically polyester or epoxy, to bind the fibers of each layer of fiberglass together. This creates a solid composite structure.

We call this process resin application and consolidation. We evenly spread the resin using brushes or rollers and remove excess air to ensure proper consolidation. This eliminates any voids.

Curing:

Once we complete the lay-up process, we allow the composite structure to cure. The curing time and temperature depend on the resin system we use. During this stage, the resin undergoes a chemical reaction, transforming from a liquid to a solid state. This bonds the fiberglass layers together.

Once the component has fully hardened, we meticulously remove it from the mold and perform the finishing touches. To achieve the desired dimensions and surface finish, we trim and sand away any excess material or flash.

For a polished finish, we can employ additional techniques such as coating and painting. These techniques serve to meet specific requirements or enhance the component's appearance.

DeLoach Industries Inc. specializes in hand lay-up contact molding. We utilize this method to produce tiny parts for our induced draft aerators. The components are essential for improving the performance and efficiency of our aerators. Our aerators find application in various fields, including water and wastewater treatment systems.

Our experienced professionals possess in-depth knowledge and expertise in fiberglass manufacturing techniques. They follow industry best practices and quality standards carefully. This ensures the production of high-quality fiberglass components. These components meet our customers' specifications and performance requirements.

Are you interested in learning about our fiberglass manufacturing techniques? Or, do you want to know how our induced draft aerators can benefit your specific needs? We're dedicated to providing detailed information, answering any questions you may have, and offering personalized solutions.

Contact DeLoach Industries Inc. at (941) 371-4995 to speak with our experts. We're excited to assist you and provide the top-notch fiberglass solutions you require.

For more information or to learn more contact the professionals at DeLoach Industries Inc. at (941) 371-4995.

Related Blog: Why Aeration is the Most Cost-Effective Way to Oxidize Iron 

Industrial Odor Control Scrubbers: Making the Right Choice for Your Water Treatment Process

Industrial odor control scrubbers play a crucial role in water treatment processes, ensuring the removal of harmful pollutants and unpleasant odors. When it comes to selecting the right scrubber for your specific needs, it's essential to have a thorough understanding of the requirements of your operation. In this article, we will explore the factors to consider and the key differences between chemical scrubbers and biological scrubbers. By the end, you'll be equipped with the knowledge to make an informed decision for your industrial water treatment system.

Before delving into the specifics of chemical and biological scrubbers, it's important to evaluate your water treatment process thoroughly. Asking the right questions will help you identify the critical factors that will influence your scrubber selection. Consider factors such as the motor system's operation and the loading rate of pollutants. By gaining a comprehensive understanding of your process, you can ensure that your chosen scrubber will effectively meet your water treatment needs.

The design process the most important thing is having a total understanding of the need for the scrubber to ensure you make the right decision. For this reason, always ask the right questions about your process such as how you are going to operate the motor system and what the loading rate is. When selecting an odor control scrubber you must take into consideration all of the variables of the project. 

One example is the decision between Chemical Scrubbers and Biological Scrubbers. If there are a lot of variations and load rates then typically a Chemical Scrubber would be your best choice. A Biological Scrubber would not be the right choice because the biological bed is not able to adjust quickly enough to the increased load rate.

Chemical Scrubbers: A Versatile Solution for Varied Load Rates

Chemical scrubbers are known for their versatility and effectiveness across a wide range of load rates and variations. These scrubbers utilize chemical reactions to neutralize and remove pollutants from the air emissions. When the loading rate of pollutants fluctuates significantly, chemical scrubbers are an ideal choice due to their ability to adjust quickly. By employing various chemical agents and processes, these scrubbers can effectively control odors and remove harmful substances from the air.

Biological Scrubbers: Harnessing the Power of Nature

While chemical scrubbers excel in managing varied load rates, biological scrubbers offer a different approach to industrial odor control in water treatment. Biological scrubbers utilize living microorganisms to break down and eliminate pollutants. This process, known as biofiltration, relies on the natural ability of microorganisms to metabolize and convert pollutants into harmless byproducts. However, it's important to note that biological scrubbers are not suitable for applications with significant variations in load rates. The biological bed in these scrubbers requires time to adjust to increased load rates, making them less adaptable in such scenarios.

DeLoach Industries: Your Trusted Partner for Odor Control Scrubbers

When it comes to finding the right odor control scrubber for your water treatment application, DeLoach Industries is a name you can trust. With a wide range of scrubbers designed for both municipal and industrial markets, DeLoach Industries offers complete package systems tailored to meet your specific needs. Their professional design team can provide expert guidance and support throughout the selection and implementation process, ensuring optimal performance and efficiency.

The water and wastewater industry has a constant need for dependable odor control systems that are reliable and effective. The most popular process types of scrubbers are biological and chemical scrubbers. Each is effective at treating and removing noxious odors that arise from hydrogen sulfide (H2S) and methane.

Chemical injection systems can include biological agents, hydrogen peroxide, or proprietary agents in addition to odor masking agents that do not react but rather cover up odors. Methane odors typically only appear in wastewater applications, but hydrogen sulfide can be present at either water or wastewater treatment facilities.

The common questions for deciding which type to use normally come down to two variables: “What will it cost to install and operate annually?” and “Are the odors caused by corrosive gases which need to be neutralized to prevent equipment damage, instead of just covering up the odorous smell?” In some cases, the remoteness of the location can also dictate the type of process to use. If the location is very remote with infrequent visits then it may make more sense to have a low-maintenance chemical masking or injection system installed. However, if the location does have frequent visits or an operator then the two previous rules normally govern the selection process. Quite often the selection is made improperly because of salesmanship or relationships to suppliers. This should be avoided at all times to prevent safety risks, damage to equipment, or high economical costs. Many times suppliers will offer discounted or even free equipment to secure chemical use contracts for a long-term commitment to chemical sales.

The first step is understanding the chemical analysis of the water you will treat.

Suppose this is an aeration process for iron (Fe) removal. In that case, it is vital to understand the water's concentration, pH, and alkalinity and the amount of calcium carbonate or other minerals present. Once you've determined that the water is suitable for the desired treatment process, you must choose equipment based on the water's volume and flow rate. Remember that water treatment equipment is not one-size-fits-all and is vitally important when selecting equipment to consider your water conditions.

If a tower's internals is damaged due to the weight of random pack media or fouled water and airflow, the pack media will become completely clogged, and water flow will be blocked. This will result in an expensive shutdown and repair. It is advised that routine service cleanings are carried out under a service contract.

For heavy fouling conditions, a slat tray media selection can save you both downtime and costs. Slat trays provide an anti-fouling benefit based upon the design intended to “shed” particulate as it is formed. They still need to be cleaned in heavy conditions, but far less often, and cleaning is more manageable. The tower process application requires high removal efficiency, then loose fill media may be the only choice unless a pretreatment tower with slat trays is installed in front of the process. Each application must be evaluated on its merits and reviewed for potential fouling and anticipated operating cost.

If fouled completely, loose fill, random pack media will block water flow and air and can, in some circumstances, become so heavy that the weight can damage the internals of a tower. This will cause a shutdown and more expenses to remove and repair. Routine service cleanings under a service contract are highly recommended.

Industrial water treatment systems play a crucial role in maintaining the quality and sustainability of water used in various industrial processes. One of the key challenges faced by industries is the presence of dissolved gases, particularly carbon dioxide (CO2), and corrosive gases like hydrogen sulfide (H2S) in the water. These gases can have detrimental effects on equipment, cause pH imbalances, and even compromise the overall efficiency of industrial processes.

When operating a forced or induced draft water treatment tower system it is important to properly maintain your distribution system.

The distribution system is a fundamental component for any type of unit: an Aerator, Degasifier, Scrubber, or Air Stripper. It must be designed and constructed with precision and accuracy. This will ensure its optimal performance throughout its lifetime.

It is essential that the distribution system undergo regular and thorough maintenance. This will ensure it can do its job effectively.

Maintenance should include cleaning and inspecting pipes and connections. Additionally, worn or damaged parts should be replaced or repaired. Lastly, test the entire system to ensure proper functioning.

Regular maintenance is essential. It helps to prevent costly breakdowns or failures. Additionally, it minimizes disruptions to the distribution system.

Regular maintenance helps the distribution system run efficiently. This leads to better, more reliable service for customers.

The key role of the distribution system is to properly distribute the water flow over the media bed. If the distribution system is designed incorrectly then water will not be properly distributed which can cause multiple problems.

The distributor can be damaged or fouled. When this happens, the water pattern is changed. This affects the flow rate across the media bed. This can lead to low or high hydraulic flood conditions in the media bed.It is important to inspect the distribution system within 30 days of the initial startup of a system. Then decide, based upon application, if the future inspections can be extended to 90 or 180 days.

Iron oxidation and H2S require more frequent cleaning of the distribution system than a degasifier used for CO2 removal. This is because they are more corrosive.

"Oxidation" refers to electron loss from a reducing agent. It is common to say that "the process has been oxidized."

]Electrons carry negative charges, and the oxidation process leads to an increase in positive valence.

During oxidation, the number of electrons orbiting an element decreases, causing the element to form bonds with oxygen when oxygen is present. Oxygen is naturally attracted to electrons.

Iron can exist in various forms in water, with the most prevalent being ferrous bicarbonate (C2H4FeO6), which is soluble.

Ferrous iron possesses a positive two valence. As ferrous iron undergoes oxidation, the number of electrons decreases, resulting in the development of a positive three valence known as ferric hydroxide: Fe(OH)3.

The most cost-effective method of oxidizing iron in water is thorough aeration using an "aeration tower." The aerator is very similar to a degasification tower or air stripper as it utilizes either forced draft or induced draft air movement to create the enriched oxygen environment needed.

Select the best type of odor control, fume, or air emission scrubber.

Industrial and municipal operations often face the challenges of capturing and treating air emissions from their process operations.  Off-gases, fumes, and odor emissions can be generated from the downstream process or material handling, such as those in the municipal wastewater industry.  However, industrial operations often generate fumes and off-gas air emissions from either the production of chemicals or the use and application of chemicals like acids and a wide range of other chemicals. These types of air emissions share a common need to be safely captured, contained, and treated to make the air steam safe before its release.  Some types of air streams create an odor that becomes a nuisance, as is typical with municipal waste that often releases Hydrogen Sulfide (H2S) and or Mercaptans (R-SH) gas during decomposition.  

Many variables should be considered

when beginning to choose the best type of air emission treatment process.  Within the industry, there are wet chemical scrubbers, dry absorbent scrubbers, biological scrubbers, and destructive type scrubbers such as catalytic and thermal oxidizers and flare technology that utilize heat to destroy and consume and oxidize certain types of off-gases. 

Each type of air emission process has its own parameters where it will perform optimally, and each type of scrubber has different levels of operating challenges and associated operating costs.  So how does one select the best process for each application?

At DeLoach Industries, we like to help customers with this evaluation process by completing a checklist guide, which helps guide the customer to the most economical and safe solution. Going through this process can help eliminate costly mistakes that may otherwise be overlooked.  Solutions are often selected by looking at the contamination only or by familiarity with the process.