BASF USA Modernizes SDA Units with Burgess Manning Silencers via MEDAS
BASF USA replaced legacy Spray Dryer Absorber (SDA) silencers with next-generation Burgess Manning SDA silencers, supplied and engineered via MEDAS and executed together with the Burgess Manning New York team. The project used 100% U.S.-sourced materials and fabrication to deliver lower noise, reduced pressure drop (ΔP), higher reliability, and faster lead times—all within planned outage windows.
Why upgrade aging SDA silencers?
Noise creep & compliance risk: Degraded media and loosened baffles erode attenuation.
Rising ΔP & energy use: Fouling and collapsed internals increase fan load and cap throughput.
Fatigue & corrosion: Thermal cycling and condensate drive panel/weld failures.
Unplanned maintenance: Emergency repairs inflate OPEX and EHS exposure.
Outcome focus: Quieter operation, energy savings, stability across turnarounds, and measurable lifecycle cost reduction.
What’s improved in Burgess Manning SDA silencers
Tuned reactive-absorptive cores targeting tonal peaks from ID/FD fans.
Low-ΔP, high-open-area geometry to preserve airflow and reduce fan power.
Material options (e.g., 304/316L, duplex, coated carbon steel) matched to SDA chemistry.
Modular cartridges for rapid drop-in replacement and easy inspection.
Thermal & structural resilience for high-temperature excursions and vibration.
Executed with Burgess Manning New York — 100% U.S. sourcing
Single integrated team: MEDAS engineering + Burgess Manning New York application and fabrication support streamlined design decisions and QA.
Domestic supply chain: All major components, assemblies, and fasteners were sourced and manufactured in the U.S., enabling shorter lead times, simplified logistics, and consistent quality documentation.
Procurement advantages: Easier vendor audits, material traceability (MTRs), weld procedure records (WPS/PQR), and coating DFT reports consolidated under U.S. suppliers.
On-site efficiency: New York team supported lift plans, install supervision, leak checks, and commissioning SPL/ΔP baselining—keeping the outage critical path tight.
Result: A faster, predictable retrofit with robust U.S. quality standards and ready availability of spares.
MEDAS retrofit approach at BASF USA
On-site survey & baseline – duct geometry, fan curves, SPLs by band, ΔP, materials, and failure modes.
Acoustic & flow modeling – predicted attenuation (octave/⅓-octave), velocity profiles, and ΔP checks.
Design finalization – material/coating selection, flanges and supports matched to existing interfaces.
U.S. fabrication & QA – dimensional checks, MTRs, WPS/PQR, coating DFT, trial fits.
Planned-outage installation – modular swaps, bolting & gasketing, leak tests.
Commissioning & handover – post-install SPL/ΔP, as-built docs, spare cartridge plan.
Measurable gains
3–10 dB(A) typical overall noise reduction (site-specific).
5–20% lower ΔP than degraded internals → fan energy savings and airflow headroom.
Reliability ↑ via corrosion-resistant materials and rigidized modules.
Maintenance ↓ with cartridge inspections and predictable spares.
Note: Results vary by baseline condition, spectrum, and site constraints.
EHS & Compliance
Upgraded silencers support plant noise policies and community standards. Documented pre/post SPL and ΔP results create audit-ready evidence for internal EHS and stakeholder reporting.
Scope, schedule, and services
Scope: Supply of Burgess Manning SDA silencers, adapters, supports, gaskets/bolting; install supervision; commissioning support.
Schedule: Works aligned to BASF shutdown windows; modularization shortens the critical path.
Aftermarket: U.S. cartridge spares strategy, inspection templates, and training.
