JPS Industries was consulted on the replacement of a failed comeditor’s baffle system at a chemical plant. JPS manufactured and installed 19,950 linear feet of heavy-duty reinforced industrial baffle. The baffle system was installed to increase retention time to promote cooling.

Field conditions and lead time.

1. The site had a massive lagoon that experienced high winds and significant flow rates.

2. The logistics of manufacturing almost 4 miles of baffle within the time frame needed by the customer.

• Reduced available water volume for processing
• Clogging and inefficiency within the clarifier system
• Slower throughput and increased operational strain
• Risk of production slowdowns

The client needs a durable baffle system installed, capable of withstanding their unique conditions to provide cooling with no disruption to their processing.

JPS designed, manufactured and installed a heavy-duty reinforced industrial baffle system.

Key elements of the approach included:

• Baffle design included additional tension members
• Baffle system included additional weights to anchor the baffle to withstand wind and hydraulic loading
• Modified factory floor to run additional production lines
• Shipped and installed in 4 phases to keep installation within the allotted lead time
• Adapted installation techniques to meet unique safety parameters specific to the site

Upon completion of JPS baffle system installation, the customer not only reached but exceeded cooling requirements. The cooling was so effective it eliminated the need for a cooling tower project, which was expected to be implemented in conjunction with the baffle system to reach cooling requirements. This was a huge savings for the plant. Installation was achieved with no downtime to the plant.

Outcomes included:

• Increased water volume within the clarifier
• Improved processing efficiency and flow-through
• Reduced risk of clogging and system disruption
• Minimal downtime and rapid return to full operation

Cooling was an integral component of the water recycling for the plant. Without cooling, water could not be recycled and increase the efficiency of the plant’s manufacturing system. This project demonstrates how baffle systems can meet goals by enhancing the efficiency of existing lagoon infrastructure, saving time and money.