The Rohde Customized Solution:

• Patent pending undersized pond system to eliminate need for expensive vertical wells
• Combine process cooling loops with geothermal loop to allow beneficial reuse of waste process heat from air compressors, refrigeration compressors and hydraulic systems
• Waste heat utilized with heat pumps for comfort heating, sanitation, and process heating
• Geothermal loop provides cooling for excess heat minimizing the need for cooling towers
• Skid-mounted pump systems pre-piped and pre-wired with controls to reduce cost and time of installation
• Web-based Honeywell Tridium control system to provide graphical user interface over the Allen-Bradley PLC system

Mercury Marine’s Plant 4 needed to add several machining centers to improve productivity while utilizing the same building footprint.

Rohde also included an on-site nitrogen generation system to blanket our die-cast process which saved us money from the start”

~David Hahn, Project Manager, Mercury Marine.

The Rohde Customized Solution:

• Design, fabrication and installation of HVAC in the machine centers area of the plant 17 expansion. 

• Design and installation of on-site nitrogen gas generators for the die-cast facitility. Lowering costs substantially compared to storage, handling and processing of liquid nitrogen.

• Floor sweep HVAC to contribute to higher air quality in the die cast facility as well as machine centers area.

• Variable speed makeup air and exhaust fans added as needed for the expansion.

• Custom PLC for monitoring and control of the HVAC, nitrogen, and process piping.

• Installation of make up air units to supply fresh filtered air back into the facility

Mercury Marine’s Plant 17 aluminum casting facility started a building expansion to accommodate three new large tonnage die cast machines.

Although other systems exist globally, none to our knowledge operate as effectively and efficiently,”

~Stephen Mlinaz, Senior Facilities Engineer, Mercury Marine.

The Rohde Customized Solution: 

• Design, fabrication and installation of die lube over spray and shot fume capture and treatment systems for each die cast machine with retractable hood, multistage filters and fan with return of treated air back into the plant

• Retractable hood allows for die changes using overhead crane

• Four stage filtration system removes die lube/water mist, smoke, oil and particulates allowing return of treated air to the plant significantly reducing the volume of makeup air required

• Variable speed makeup air and exhaust fans added for each die cast machine

• Custom PLC for monitoring and control of the mist collection system provided by Rohde and integrated into Mercury’s central ignition system

• Redesign of the capture hood system and piping systems to accommodate the larger 4500 ton capacity of the third die cast machine. In addition to the larger size, the plant elected to make multiple changes in the methods employed for die preheating and cooling for process quality and efficiency improvement. The new capture system support structure incorporated an equipment platform for new heating and cooling equipment

• Based on the success of the first three mist collection systems, Rohde has installed additional systems in the original plant and a subsequent 2019 addition

• To date, a total of ten mist collection systems have been installed