New Unit Construction

When your facility needs new pollution control equipment, whether driven by a new air permit requirement, an expansion project, a regulatory rule change, or replacement of equipment that has reached end of life, Falcon Environmental Solutions manages the entire project from concept through commissioning. New unit construction is the most complex service we provide, involving process engineering, mechanical design, structural design, fabrication, site preparation, installation, controls integration, and startup. Our turnkey approach puts a single point of responsibility over the entire project scope, eliminating the coordination gaps that occur when multiple independent contractors divide the work.

Thermal oxidizer construction covers the full range of oxidizer technologies used in pollution control. Direct-fired thermal oxidizers are the simplest configuration, using a burner to heat the process gas stream to the required destruction temperature (typically 1,400 to 1,800 degrees Fahrenheit) in a refractory-lined combustion chamber with sufficient residence time (typically 0.5 to 2.0 seconds) to destroy VOCs and HAPs to the required efficiency. Recuperative thermal oxidizers add a primary heat exchanger that preheats the incoming process gas with energy from the hot exhaust, reducing fuel consumption by 40-70% compared to direct-fired units. We design and construct both types for applications ranging from small process vents to large industrial exhaust streams.

Regenerative thermal oxidizer (RTO) construction addresses the most energy-efficient oxidizer technology available for high-volume, low-concentration VOC streams. RTOs use ceramic heat exchange media to capture and recycle up to 95% of the combustion energy, achieving thermal efficiencies that reduce supplemental fuel consumption to a fraction of what direct-fired or recuperative units require. We construct two-bed, three-bed, and rotary valve RTO configurations depending on the application requirements. Two-bed RTOs are the most common and cost-effective for many applications. Three-bed RTOs provide more consistent outlet concentrations by adding a purge cycle that sweeps residual VOCs from the media before the exhaust stroke. Rotary valve RTOs use a continuously rotating valve to cycle between media beds, providing smooth, pulsation-free operation.

Catalytic oxidizer construction provides a lower-temperature alternative to thermal oxidation for applications where the process stream is compatible with catalyst technology. Catalytic oxidizers destroy VOCs at temperatures of 400 to 700 degrees Fahrenheit by passing the process gas through a precious metal (platinum, palladium) or base metal catalyst bed. The lower operating temperature reduces fuel consumption and NOx formation. Falcon Environmental Solutions designs and constructs catalytic oxidizer systems with proper catalyst selection for the specific VOC species and process conditions, preheat burner sizing, and catalyst bed configuration. We work with catalyst manufacturers to select the optimal catalyst formulation and loading for each application.

Scrubber system construction addresses particulate, acid gas, and odor control applications where thermal or catalytic oxidation is not the appropriate control technology. We construct wet scrubbers (spray towers, venturi scrubbers, and packed bed absorbers), dry scrubbers (spray dryer absorbers and circulating dry scrubbers), and combination systems that address multiple pollutants in a single treatment train. Wet packed bed scrubbers are our most commonly constructed scrubber type, used for acid gas absorption (HCl, SO2, H2S, HF), ammonia scrubbing, and odor control. We design the packing type and depth, recirculation rate, chemical reagent feed system, mist elimination, and effluent treatment for each specific application.

Flare system construction provides the final layer of emissions control for process upset conditions, emergency releases, and routine waste gas disposal. We construct elevated flares, ground flares (enclosed and open), and combination systems. Elevated flares handle large emergency relief volumes and are sized per API 521 for the maximum credible relief scenario. Ground flares provide smokeless, quiet waste gas combustion for routine and semi-routine streams. Every flare system includes a properly designed pilot system with reliable ignition, flame detection, and monitoring per 40 CFR 60.18 and 40 CFR 63.11 requirements. Flare tip selection considers the waste gas composition, flow rate range, noise constraints, and radiation limits at the property boundary.

Structural fabrication and pressure vessel construction for new pollution control equipment is performed by our industry partner Millennium Welding Services. Millennium operates a fully equipped fabrication facility capable of producing the structural steel, vessels, tanks, stacks, and large-diameter ductwork required for pollution control equipment construction. Their ASME-certified welders fabricate pressure vessels per Section VIII of the ASME Boiler and Pressure Vessel Code. Structural steel is fabricated per AWS D1.1 Structural Welding Code. This partnership allows Falcon Environmental Solutions to deliver complete fabricated equipment without maintaining a separate fabrication facility, keeping our overhead costs lower and our pricing competitive while maintaining full quality control over the finished product.

Site preparation and foundation work establishes the physical infrastructure that supports the new equipment. Pollution control equipment can be heavy and subject to significant wind, seismic, and thermal loads. Foundation design must account for equipment dead weight, operating weight (including media, liquid holdup, and refractory), wind loads per ASCE 7, seismic loads per the applicable building code, and thermal expansion forces. We coordinate foundation design with a licensed structural engineer and manage the civil construction through qualified concrete contractors. Equipment is set by crane with rigging plans developed for the specific lift requirements.

Controls integration connects the new pollution control equipment to the facility's control system and, when appropriate, to our FalconWatch remote monitoring platform. Controls work for new unit construction projects is coordinated through our industry partners Creekmist Controls and MAK Solutions, who provide PLC programming, HMI development, and safety system integration for the new equipment. The control system typically includes a burner management system (BMS) per NFPA 86, process temperature control, airflow control, safety interlock logic, and alarm management. Falcon manages the overall project and coordinates between the controls partners and the mechanical installation team to ensure seamless integration.

Commissioning and startup is the final phase of every new unit construction project. Our commissioning process follows a structured sequence: mechanical completion verification, control system checkout, safety interlock testing, cold startup (airflow verification without combustion), warm startup (burner lightoff and temperature ramp), performance testing at design conditions, and operator training. We do not consider the project complete until the equipment is operating at its design performance, all safety systems are verified functional, the operators are trained and comfortable, and the system is ready for the initial compliance source test.