# OAR Box 1313

Prepped by LaTeia Shed



### Document

Number: 

# 34 ) ll-B- 8

Docket Number: 

# A-88-0 2

Printed 6/12/20089:03:28AM Sheet 34 of 99 P. 1P. 2

$ 

# FINA L A-88-0 2 n-e>- 8 MIDWES T RESEARC H INSTITUT E

450 5 Creedmoo rRoa

d Raleigh , N.C

. 2761 2 JTglephon e (919) 781-575 0



### Date : Jul y

16 , 198 6 (Finalize dSeptembe r 2 , 1986 ) Subject : Sit e Visit—Consolidate d Engraver s

Chromiu m Electroplatin g NESHA P EPA Contrac t 68-02-3817 ; ESE D Projec t 85/02 a MR I Projec t 7717- K
From : To : Randy

Strai t Jl\~

Al Vervaer t ESED/ISB/SS S (MD-13 ) U . S . Environmenta l Protectio nAgenc y Researc hTriangl e Park , N.C . 2771 1
I . Purpos e Th e purpos e o f thi s sit e visi t wa s t o gathe r backgroun dinformatio n abou t th e chromiu

m electroplatin g operatio na t thi s plan t an d t o determin e th e suitabilit y

o f thi s plan t fo r chromiu m emission s testing . II . Plac e an

d Dat e Consolidate dEngraver s Corporatio n Pos t Offic e Bo x3366 9 Charlotte , Nort hCarolin a 2823 3 Ma y 2 , 198 6 (704 ) 333-036 5
III . Attendee s Consolidate dEngraver s Richar dSteele , Vic e Presiden t
Buz z King , Electroplatin g Superviso r U . S . Environmenta l Protectio nAgenc y Al Vervaert , IS B Midwes t Researc hInstitut e Randy Strai t Bet hFriedma n

/P. 3

IV . Discussio n
W e arrive d a t th e plan t a t 9:3 0 a.m . Th e visi t consiste do f a tou r o f th e platin g sho p an d a discussio nabou t th e har dchromiu m electro platin g operation s an d chromiu

m emission s captur e an dcontro l equipment . A . Genera l Consolidate d Engraver s ha s fou r plant s i nth e U.S . Th e Charlotte , Nort hCarolina , an

dChester , Sout hCarolina , plant s ar e captiv e shop s tha t perform chromiu

m platin g o f industria l roll s fo r th e packagin g an dtextil e industries . Har d chromiu m plat e i s applie da s th e final , finishin g stage . Th e chromiu

m platin g tank s ar e operate don e shif t pe r day . B . Proces s Informatio n Ther e ar e thre e hard chromiu m platin g operation s use da t thi s plant , whic har e referre dt o a s Operation s A , B , an dC i nth e followin g discussion . Operatio nA consist s o f thre e har dchromiu m platin g tanks , arrange d a s show

ni nFigur e 1 . Tan k 2 wa s no t i noperatio ndurin g th e visi t bu t i s expecte dt o be brough t o nlin e b y th e en do f May . Th e thre e tank s ar e use d t o chromiu m plat e engravin g roll s fo r th e packin g industry . Afte r bein g plated , th e roll s ar e lifte dfro m th e platin g solutio nan

drinse dwit hwate r directl y ove r th e platin g tank s t o reduc e drag-ou t o f chromi c acid . Operatio nB consist s o f tw o tanks . Th e tank s ar e use dt o chromiu m plat e hollow

textil e rolls , an

d two roll s ar e plate dsimultaneousl y i n eac htank . Operatio nC consist s o f on e tan k an di s use dt o chromiu m plat e gravur e rolls . On e rol l i s plate d a t a time . Th e rol l i s rotate di nth e platin g bat hs o tha t n o mor e tha non § hal f o f th e surfac e are a i s submerge d durin g plating . C . Emission s Contro l Th e emissio ncontro l system fo r Operatio nA

i s show

ni nFigur e 1 . Tank s 1 an

d 3 ar e equippe dwit hone-side ddraf t hoods , an dTan k 2 i s equippe dwit ha double-side ddraf t hood . Al l thre e tank s ar e vente dt o a chevron-blad e mis t eliminato r (Seria l No . 1054 ) locate do nth e roo f o f th e plant . Th e desig nga s flow rat e o f th e mis t eliminato r i s 8,00 0 actua l cubi c fee t pe r minut e (acfm) . Th e captur e an dcontro l syste

m wa s manufacture d an

dinstalle d b

y Dual l Industries , Inc. , inFebruar y 1986 . A moistur e extracto r i s installe d i nth e stac k downstream o f th e mis t eliminato r i nth e even t tha t chromiu m emission s ar e draw

nthroug hth e mis t eliminator . Th e moistur e extracto r consist s o f a stationar y se t o f blade s tha t centrifugall y force s aci d mis t o r droplet s entraine di n exhaus t ga s t o imping e agains t th e side s o f th e extracto r wall . Th e droplet s drai ndow

nth e side s o f th e extracto r int o collectio narea s an d the nar e flushe d ou t o f th e unit .

o £P. 4

Figur e 1 . Schemati c o f har dchromiu m platin g Operatio nA a t Consolidate dEngravers .

^P. 5

Th e mis t eliminato r an dmoistur e extracto r ar e rinse dapproximatel y onc e pe r wee k wit h2 0 gallon s (gal ) o f water . Th e rins e wate r drain s throug ha 2-inc h(in. ) pip e int o a holdin g tank locate dinsid e th e platin g shop . Thi s rins e wate r i s use da s platin g bat hmakeup . Rinsin g frequenc y ma y b e increase d whe nTank 2 i s brough t o nlin e an dplatin g personne l hav e mor e experienc e wit hth e system . Accordin g t o plan t personnel , th e critica l facto r i nth e rins e schedul e i s th e nee dfo r platin g bat hmakeu p solution . However , th e efficienc y o f th e mis t eliminato r woul dno t b e impaire d b

y les s frequen t rinsin g unde r norma l conditions . Plan t personne l state d tha t the y ar e please d wit hth e performanc e o f th e emission s contro l syste m t o date . Tank s 1 an

d2 o f Operatio nB ar e equippe d wit hdouble-side ddraf t hoods , an

dchromiu

m emission s fro

m eac htank ar e vente dt o separat e mis t eliminator s fo r whic hth e manufacture r an dag e ar e unknown . Th e har d chromiu m platin g tank fo r Operatio nC als o i s equippe dwit ha double-side d draf t hood , an

dth e surfac e o f th e tank i s covere dwit ha panel . Emission s fro

m thi s tan k ar e vente dt o a mis t eliminato r fo r whic hth e manufacture r an

d ag e ar e unknown . 0 . Conclusion s Th e mis t eliminato r use d t o contro l chromiu m emission s fro

m Operatio nA

i s a goodcandidat e fo r emissio ntestin g fo r th e followin g reasons : (1 ) operatin g parameter s o f th e platin g tank s ar e withi nth e range s typica l o f hard chromiu m platin g tanks , (2 ) th e typ e an damoun t o f wor k plate d woul d generat e adequat e emission s loadin g fo r testing , an d (3 ) th e chevron-blad e mis t eliminato r i s typica l o f impingement-typ e mis t eliminator s i nus e a t othe r har dchromiu m platin g facilities . Th e majo r drawbac k i s tha t th e straigh t sectio no f duc t a t th e inle t locatio ni s onl y 2 8 in . i nlengt han d2 1 in . i ndiameter , whic hi s equivalen t t o onl y 1.3 3 duc t diameter s downstream o f th e neares t elbow . Minimu m condition s woul drequir e a t leas t 2 duc t diameter s downstream an d0. 5 duc t diameter s upstream o f th e neares t flow disturbance . Consolidate dEngraver s personne l wer e cooperativ e durin g th e visit , an dth e informatio nprovide d wil l b e mos t usefu l t o th e chromiu m study . E . Additiona l Informatio nObtaine d fo r th e Chromiu m Platin g Operatio na t th e Chester , Sout hCarolina , Plan t
W e als o me t briefl y

wit hMr . Ji m

Steel e fro

m th e Chester , Sout h Carolina , plant . Th e plan t ha s on e har d chromiu m platin g tank . Th e tan k i s vente d t o a Dual l chevron-blad e mis t eliminato r an da moistur e extracto r installe d i nth e stac k downstream o f th e mis t eliminator . Th e desig nga s flow

rat e o f th e mis t eliminato r i s 3,20 0 acfm . However , th e operatin g ga s flow

rat e currentl y

i s les s tha nth e desig nga s flow rat e becaus e th e mis t eliminato r wa s designe dt o contro l emission s fro m a secondtank tha t ha s bee nremove dfro m service . Th e mis t eliminato r an d moistur e extracto r ar e washe d dow nonc e pe r day , an

dth e rins e wate r drain s directl y

int o th e platin g tank . Th e plan t ha s significantl y reduce dit s chromi c aci d consumptio nan d th e contro l system ha s pai dfo r itsel f throug hrecover y credits .



# YP. 6



### Th e mis t eliminato r an dmoistur e extracto r hav e bee nteste db y a consultan t t o provid e dat a fo r a Sout hCarolin a permi t application . Mr . Steel e agree dt o provid e a copy o f th e tes t repor t i nrespons e t o a writte nreques t fro

m EPA .



## S