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TESTING - CONSUL.TING July 2, 1997 Daniel J. BeD Enginearing Service. 3158 South Kolin Avenuo Chlcallo IL 60623-4888 Phone: 773·254-2406 FAX: 773-254-6661 

### STft·iE OF ILLINOIS**'1-:":'~Eh"iAL** 

### PROTECTION AGEN Illinois Environmental Protection Agency Division of Air Pollution Control Eisenhower Tower 

### ) i:CEIVE tf'i .t. Li1. 

### .JUL 

# 14 1997 BUREAU OF 

### AIR 1701 First Avenue Maywood 

## n.. 60153 Dear Sir or Madam: 

### ;IV OF 

### AIR POLLUTION C('''T"nl 

### FIELD 

### OPERATIONS**SECTi~::** Please find enclosed a chromium emission stack test report prepared for our client: Gravure Process 4179 West Belmont Avenue Chicago IL 60641 I.D. No.: 031600GBT**::..-...-~-** 

## .- ..... The stack test was performed June II, 1997. If there should be any questions, please do not hesitate to call.

db:DB CN06083b Respectfully Submitted,

# ~/4j/ SCIENTIFIC CONTROL LABORATORIES, INC.

### •

TESTING - CONSULTING 

### Report To: Gravure Process 4179 W. Belmont. Chicago IL 60641 A1TN: Mr. Dave ParsiIl Project Type: Stack Test Analysis for Chromium Emissions IDENTIFICATION OF MATERIA L: DanIel J. BeD Enclneerlna Semca 3158 

### s. Kob Aye. OJaao IL 606l3-48119 PlulDe: 7'7J.254-2406 FAX: 773-254-66&1 

### Report Date: 06130/97 

### Project Number: 06-083 Project Inception:06/11197

Four (4) sample bottles, from 306A air testing, identified below: PROCEDURE: 

### Gravure Process manufactures printing rolls. Part of this process involves electroplating of hard chromium. The facility has two hard chromium electroplating tanks, a large tank 

### of 600 gallons identified as L and a smaller tank of 350 gallons identified as M. It is rare that both of these tanks are operated at the same time. However, in order to demonstrate compliance under maximum operating conditions, both tanks were electroplating throughout testing. The biggest rolls available at the job shop were chromium plated in these two 

### tanks. Tank M contained a roll wi'th a surface area of approximately 18,600 square inches. This roll was being electroplated throughout the entire day of testing at 900 amps. The rectifier for this tank has a m3ximum capacity of 2500 amps. Tank L contained several rolls throughout the testing, with surface areas ranging from 39,340 in. 2 

### and 49,860 in. 2• 

### The rectifier to this tank 

### was operated at 1700-2000 amps. The rectifier for this tank has a maximum capacity of 3000 amps. This workload represents the maximum operating conditions and therefore the emission results should be representative of maximum conditions. An 

### attachment shows the specific tank and rectifier operating parameters that were recorded during the performance test. The test was performed on June 11, 1997 by Mr. Daniel J. Bell, Mr. David Caskey, and Ms. Joelie Hill of Scientific Control Laboratories. An 

### IEPA official was not present. All analyses were performed in accordance with the EPAlIEPA approved test procedures as specified in 40 CPR, 

### part 63, Method 306A. Scientific Control Labs, Inc., is a certified laboratory for analysis of potable water (IEPA Cert. #100183), and a certified laboratory for wastewater analysis (State of Washington Cert. #CI65, State of Wisconsin DNR #998091930). This means we have a quality control program in effect and that this quality control program is monitored and reviewed annually by the certifying agencies.

Nole: It is our policy 10 keep copiea of n:polU for six mGDIhs. Tbe clara i, kept OD file for up tD tbree yean. Samples Cd' IPPlicable) arc kept for three 

### weeo. Samples thai arc hazardoul witt be mumed tD the c:lieDL If this policy 

## po., • difJic:ulty. plcuc coDlKt 111 10 make other arraDBCmeDts. IfftProduc:ed. our n:port. must be reproduc:ed c:ompletely. ADY uuuthorized aliemtiOD of this ftpGrl UaYalidalea the c:oatcDL

# t1'~

# ~/". 

# ''k'' dCLULU

CONT RO LA.ORATO'UI:S, I NC. R ESULTS: Page Two

The samples were analyzed by graphite furnace atomic absorption for detection of total chromium.

SAMPLE lO. TE ST CONe,] TEST TRlAL # 1 0.0 19 mgIL 6/1 1197 TEST TRlAL #2 0.032 mgIL 611 1 /97 TE ST TRlAL #3 0.038 mgIL 6/ 11 197

. BLANK 0.003 mgIL

Analyu d by SCL 2 As calculated by SCL (see attached) ) As calculated by SCL (see attached) ACTUAL EM I SS IO N L IM1T' [JItHSSJON 1 0 . 0029 mgldscm 0.03 mglds cm 0 .0054 m g/dscm 0.03 mg/dscm 0 .0065 mgldscm 0.03 mg/dscm NA NA

The sampling ports were already in stalled in the slack. These sampling test perts were located in a duct after the blower with diameter of 16 inche s. The length of thi s straight duc t section is 66 i nches. The ports are located 54 in ches (3.4 duct diameters) downstream from a minor flow disturban ce (a change from a rec tangul ar to a circular duct immediately followiu g th e blower) and 12 in ch es (0.75 duct diameters) from th e top of th is duc t. This sampling locati on does meet the minimum criteria of 2.0/0.5 duct diam ete rs for an acceptab le samp lin g point as spec ified in sec ti on 2.1 of US EPA Method I (40CFR Part 60, Appendix A). See the attached di agram f or a description of th e samp lin g loc ation and the specific samp lin g poin ts. The presence of cyclonic flow was checked at each sampling locati on and the average an gle of misalignment was found to be 9.2"' . Since the average angle of misalignment i s less than 20 degree s, the amount of cyclonic flow is acceptable. The pressure drop across th e p ollution control devive was 2. 1 in. of wate r co lumn pressure throughout the day of te stin g. Leak tes ts were conducted before and aftc:r each test run and found to be le ss than 0.2 Umin. Th e vacuum pressure of the sampl ing pump was 22" of mercury.

Note: It iI ou r polity to keep eopin o (**~poru** (or six mooths. The cbu is kept 00 file tor up to thRe yean.. Sampks (if sppliwle) a.re kept tor throe
.... eeks. Samples that IR hazardous will be Rtumed to the clieoL I(this polity poses I dimtulty. pl cuc cOllucl us to make other Imngcmellu. If Rproduccd. our ",port. mus! be ", produced completely
. All)' u nluthorized ahen.Lioll o f lbi.**~porl** iovalidalu the cootcol.

# ~ V7'J

# ~=.k.QRATQRII:.' INC. Page Three


### SUPPLEMENTAL CALCULATIONS FOR GRAVURE PROCESS Equation (taken from Method 306A, FR 

### 1125/95, Pg. 4992):



### Where: CeI' =Concentration in stack gas in mg/dscm MeI'=Amount of Cr in sample from stack sampling in micrograms 

### Tm 

### =Dry gas meter temperature, 

### OP 

### Y

ID 

### =Dry gas meter correction factor 

### Vm 

### =Dry gas meter volume in 

### it' Pilar =Barometric pressure in inches of Hg

Gravure Process Results Trial ##1: 

### (360 ml 

### in test trial #1 sample) 0.019-0.003 mgIL = 0.016 mgIL Mel' = (0.016 mgIL)x(0.360 L) 

## = 0.0058 mg x 1000 micrograms/mg 

## = 5.76 micrograms 

### Tm 

## = 95.6 

### OP YID 

### =1.009 (see calculation below) v 

### Vm =(1.985 m ' )(35.3 ftl/ml)**~** 

### 70.07 

### ft3 Pilar = 

### 30.72
-- .. - Cer = 

### (5.76) (95,6 

### + 460) = 0.0029 mg/dscm .,/ (499.8)( 1.009)(70.07)(30.72) Gravure Process Trial 

### #2: (370 ml 

### in test trial #2 sample) 0.032-0.003 mgIL = 

### 0.029 mg/L Mer 

## = (0.029 mgIL)x(O.370 L) = 

### 0.0107 mg x 1000 microgramslmg = 

### 10.73 micrograms Tm 

### = 84.9 

### OF YID 

### =1.009 (see calculation below) V ID 

### =(1.992 m' )(35.3 ft'/ml) =:_70.32 

### ft3.. .", Pilar = 

### 30.72
-- Nolo: It i. our policy to keep copies oC rcpons Cor six monthL The data p kept on file Cor up to three yean. Samples 

## rd' applicable) are kept for three 

### _au Samples that are hazanlous will be relUroed to the clienL If this policy poses a difficulty. please contact us to make other arraDgements. Ifreproduced. our report. must be reproduced completely. Any unauthorized aheration ofthis report invalidatct tile c:onlenL

# ~(c-**~J ~~,**  

## -udi,1-
..**Ca';!'TRa~~.aRATaRIED.** INC. 

### Page Four
Cer = 

### (10.73) (84.9 

### + 460) = 

### 0.0054 mg/dscm v 

### (499.8)( 1.009)(70.32)(30.42) Gravure Process Results Trial ##3: (368 ml in test trial #3 sample) 0.038-0.003 mgIL = 0.035 mgIL Mer = (0.035 mgIL)x(0.368 L) = 0.0129 mg x 1000 micrograms/mg =" 

### 12.88 micrograms 

### Tm = 71.2 

### of 

### y m 

### =1.009 (see calculation below).

- ___ Vm 

### =(1.917 m')(35.3 ft'/m') =;,,67.67 ff).**~** 

### Pilar =30.65
--- Cer = 

### 02.88) (71.2 

### + 460) = 

### 0.0065 mg/dscm v 

### (499.8)(1.009)(67.67)(30.65) Quality Control Data: Sample: Duplicate: Spike: LFB: 

### LRB: 19.63 ppb 20.44 ppb = relative percent difference = 4.13 % 39.74 ppb = 101.0% spike recovery 9.49 ppb = 

### 94.9% recovery <1.0 ppb 

## = < minimum detection limit Calculation for Post Test Gas Meter Calibration: The meter was run for 6 minutes with a critical orifice that allows 0.75 cfm. The meter recorded a volume of 4.7703 

## W. The average temperature was 85.5 and the barometric pressure was 30.42 in. of mercury. To correct to standard conditions:

where: VIII(IId) = (KI)(VaaJ 

## k + (&HIl3.6from EPA Method 5 

### Tm

Note: It i. our policy 10 keep copies of rqM)N for lilt moathL The data i. kept oa file for up 10 thRO yean. Sample. (illppIiClble) an kept for three weeks. Sample. that arc hazardous will be retumed to the cliell1. If lhiJ policy poses. difficulty. plcuc co","t us 10 make other amJIsements. If reproduced. our report, must be reproduced completely. Any unauthorized alteration ofthi. rcpon invalidates the conicaL

# ~ D" 

### 1

## :£;'udi.l·~ Page Five**CaNTRaJ)~.aRATaRIES,** INC.

K\ = 17.64 Vm = volume of gas recorded from post test in fe Pbv = barometric pressure in inches of mercury 

### ili = average pressure differential across the orifice in inches of water provided on orifice calibration sheet T m 

## = temperature in degrees R Vm(Itd) = (17.64)(4.7703)[ 30,42 

### + (1.8113,6)1 85.5 

### + 460 Vm(Itd) = 4.7130 

### rf

To calculate the standard volume of air passed through the critical orifice: 

### V Q{1td) = 

### K' where: K' = factor from orifice calibration sheet provided with critical orifice by manufacturer Pilat = barometric pressure in inches of mercury, from orifice calibration sheet provided with critical orifice by manufacturer 

### e 

## = time in minutes, from orifice calibration sheet provided with critical orifice by manufacturer T amb = temperature in degrees R, from orifice calibration sheet provided with critical orifice by manufacturer


### 0.5933 (29.72)(6) .[541 VQ{Sld) 

## = 4.5486**f~**
Note: II is our policy ta keep copies of reports for six months. The d4ta is kepI on file for up ta three yean. Samples (If applicable) IR kepI for three weeks. Samples that arc baurdous will be rel1lrDed ta the clienL If this policy poses a difficulty, please CODlaCl us ta make other atraDgelnCnts. If reproduced. our repon. must be repraduced complelely. Any unauthorized alteration of this report iDvaJidates the conlenL

# .~~-**CaNTRa;J)~aAATC"IE** •• INC.
the Y value for the post test is then: Page Six

Y at (after tea) =**~IId)** Vm(IId)

Ym(aftcrfal) 

## =_ 4,5486 4.7130
Y_(after Ia') 

### = 0.9651**~.** 0.965 

## = 1.009

• As provided on the meter calibration sheet provided with the meter by the manufacturer Since the Y value is between 0.95 and 1.05, the gas meter is acceptable.


### CONCLUSION: This report was prepared to demonstrate compliance with the National Emissions Standard for Hazardous Air Pollutants (NESHAP). The results of this performance test indicate that Gravure Process meets the emission limit of 

### 0.03 mgldscm. Ongoing compliance will be demonstrated by recording the pressure drop across the composite mesh pad system. Gravure Process will be considered to be in compliance as long as the pressure drop remains within 

### :1.0 inch of water pressure of the value recorded during the performance testing (Le., 2.1 in.). These measurements will be recorded daily.

Note: II is our policy to keep copiCi of repons for six moaths. The data is kept oa file for up to three 

### ycazs. Sample. 

### car applicable) 1ft kepi for three wccb. Sample. lhallft Iaazardou. wiD be mumed to the clieaL If this policy polCl • difficulty. plcuc coatact Ulto IIIIb other amDgemcats. IfrepRlduccd, our repol1, must be reprudu=d completely, ADy uaauthorizcd alteratioa of this report iDvaIidISca the coDleaL

# ~/ .

# ~**7'~;'uJL1·i" CONTRO~~.OAATCUllE.,**  INC. 

### Page Seven

I cenify that the above results are, to the best of my 

### knowledge, true and accurate.

Daniel 

### 1. Bell CERTIFICATION: 

### The above statements and report were subscribed and sworn to before 

## me' this

DB:db 

### CN05519a

Note: It is our policy to keep copies or RP0rts ror six montbs. The data is kept 00 file ror up to three yean. Samples (ir applieable) are kept ror three weeks. Samples that are bazardous will be RlUmed to the clieoL Ir this policy poses a difficulty. please CODtact us to make other arDIIsemeDts. Ir Rprodllced. our Rport. mull be reproduced completely. ADY uDauthorized alteratioD or this report invalidates the CODteDLFederal Kqister I Val. 60. No. 16 I**Wednesda~·.** January 25. 1995 I Rules and Reguiatians 4989 Piau 

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GRAVURE PROCESS 4179 W
. BELMONT AVENUE CllICACO IL 60641 1.0
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### CI nCAGO. Il 60623-4889 

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