TESTING CONSULTING 

Report To: Dover Industrial Ch rome, Inc. 

2929 N. CampbdI Avenue 

Chicago IL 606 I 8 

ATTiS: Mr. Arid Schrodt 

I NC . 

Pr-ojcct T ype: S.ack Test Analysis for Chromium Emissions 

IDENTIFICATION OF MATERIAL: 

D~lIlcL J. Bell 

En~ln..-erJl~ S~ .... lcc::l 

3 15S S. Kolin A ~e. 

a.lc~:.o IL 606!l-4l1S9 

Phone: 773_25-1_1406 

F,LX; 77l_Z$.l_6G61 

Repo rt D:lte: 8/28/97 

Pr'ojec t Number: 06-629 

Proj ec t In ception: 71l1 /97 

Seven (7) so.rr:ple bottles, from 306A air testing, identified below: 

PROCE DURE, 

Dover Indusm21 Chrome is a job shop electroplating facility. The facility contains 8 hard 

chromium plating tanks. Tank #4 is no[ operati onal. The test was performed with six of the 

seven tanks in use. The specificoperating conditions are shmvn in Attachment B. The test 

conditions are represe:lt:nive of maximum operating conditions. 

Tests were performed on rh e two stacks that exhaust chromium emissions simultaneously. 

Both stacks had been modified to meet the criteria for an acceptable sampling point. Testing 

waS performed in straight sections of exho.usl duct following the blowers. The sampling 

location on the east stack was 16 inches from the end of the stack and 68 inches from the 

transition to the blower (See Diagram A). The stack has a diamete r of 32 inches. This 

sampling location is therefore 0. 5 duct diameters upstream of the final exit point and 2.1 duct 

diameters downstream from the flow disrurbance of the transition. The sampling location on 

the west stack was 18 inches from the end of the stack and 90 inches from the transition to 

the blower (See Diagram A). The stack is rectangular (30" x 40") and has an equivalent duct 

diameter of 3-1.3 inches. This sampling locarion is therefore 0.53 duct diameters upstream of 

the final exit point and 2.63 duct diameters downstream from the fl ow disturbance of the 

transition. These sampling sites therefore meet the 2.0/0.5 duct diame ter criteria, as specified 

in secrion 2.1 of USEPA Method 1 (40CFR Part 60, Appendix A). There were 12 sampling 

points on two traverses, for a total of 24 sampling points, as per Method 1 section 2.2.1 and 

2.3.1 for the e:lst stack and 25 sampl ing points in a 5 x 5 grid as per sec tion 2.3.2 fo r the 

west stack. The tests were performed on July 11 , 1997 by Mr. Daniel J. Bell, Mr. David 

Caskey, and Mr. Nathan Green of Scientific Control Laboratories. An TEPA official was not 

present. 

All analyses were performed in accordance with the EPAIlEPA approved test procedures as 

specified in 40 CFR, pan 63, Method 306A. 

Note: I: is OUf polky to k:~p ~Op IU of ~p r1 S for six r.\onth,. The daL:l is hpt On m~ for up to thre~ yean.. S.ur.ples (if 3ppli~3blc ) Jf': 

kept for :~re~ .... ed;s. S3rr:pln th3t 3rt b=:dous .... ill be returned to the ~Ii~nt. If Ihls pol i~y poses" dim~ulry. plnn eonl3~t us to m:I);e 

othcr 3=ng~m~~ts . If reproducd. our report. mu~t be n:prot!u~cd completely. Any un3uthor'..l:d ;I.!I~r.ltion of tllis ~port illvJlid31~S lhe 

CO~le~t. 
Pa'!e 2 

Scientific ContTol Labs, Inc., is a certified laboratory for analysis of potable water (IEPA 

Cen. #100183), and a certified laboratory for wastewater analysis (State of Washington Cert. 

#C165 , State of Wisconsin DNR #99809 1930). This means we have a quality control 

program in effect and that this quality comrol progrum is monitored and reviewed annually by 

the certifying agencies. 

RESULTS: 

The s:lmples were analyzed by atomic absorption graphite furnace for the detection of total 

chromium. 

SA MPLE 1.0. TEST CONC.I 

TEST TRL-ti. # I 0.057 mgfL 

EAST STACK 

7111197 

TEST TRI.U li2 0.058 mgIL 

EAST STACK 

7/ 11 /97 

TEST TRL"-l. #3 0.165 mgfL 

EAST STACK 

7/1 1/97 

TEST TlUAL ' 1 0.081 mgfL 

WEST STACK 

7/11 /97 

TEST TRIAL #2 0.088 mgfL 

WEST STACK 

7/11 /97 

TEST TRL"-l. "3 0.102 mgfL 

WEST STACK 

7/1 1/97 

BLANK 0.003 mgIL 

Analyzed by SCL 

2 As calcul:ued by SCL (see attached) 

3 Limit for existing small sources 

ACTUAL EM ISSION LIM IT J 

EM ISS ION: 

0.0088 mg/dscm 0.03 mgldscm 

0.0103 mg/dscm 0.03 mgldscm 

0.026 1 mgldscm 0.03 mgldscm 

0.0147 mgfdscm 0.03 mgJdscm 

0.0171 mgldscm 0.03 mgfdscm 

0.0 170 mgfdscm 0.03 mgfdscm 

NA NA 

Leak tests were conducted before and after each test run and found to be less than 0.02 fr/min. 

The presence of cyclonic flow was checked at each sampling location and the average angle of 

misalignment was found to be 2.5 degrees for the east stack and 3.0 degrees for the west stack. 

Since the average angle of misalignment was less than 20 degrees, the amount of cyclonic flow 

is acceptable. 

Not.: It is our polic), to keep copies of ~por:s fo r six months. The d 3t.:1 IS hpt on tile for up to three ),C31"!. Samples (if applit3blc) arc 

hpl for tb~~ ....... ks. Samples tb31 no: bJoZ.:mlous .... i ll be reNmed 10 lhe eli=n!. If !his policy poses a dif1icully. ple3se (OplaC! liS to make 

olh.; lI~ £. .n lS. If r:: produee:!. out r::;:o o r:. :nUS! b. rep rod uced comp!etely. AllY U03uthorUcd a!tO:r.I1ion o f lbis repon illvalid.llcs lb. 

( o nt=lI!. 
~ CL. J. .... c. J.~ •• oc"elf,u Page 3 

CONTRO LABORATORIES, INC. 

Mist suppressant is being used to reduce airborne chromic acid mists. Surface tension is being 

monitored to ensure that the proper concentration of mist suppresant is maintained in the plating 

solution. Surface tension measurements were taken during testing and are shown in Attachment 

B 

SUPPLEMENTAL CALCULATIOr-;S FOR 

DOVER INDUSTRIAL CHROME, INC. 

Equation (taken from Method 306A, FR 1125/95, Pg. 4992): 

Where: 

Cc:r =Concentration in stack gas in mg/dscm 

Mc:r=Amount of Cr in sample from stack sampling in micrograms 

Tm =Dry gas meter temperature, OF 

Y m =Dry gas meter correct.ion factor 

V m =Dry gas meter volume in ff 

Pbar =Barometric pressure in inches of Hg 

Dover Indtlstrial Chrome, Inc. Results East Stack-Trial #1: 

(377 ml in test trial #1 sample) 0.057- 0.003 mgIL = 0.054 mgIL 

Mer = (0.054 mgIL)x(0.377 L) = 0.0204 mg x 1000 micrograms/mg = 20.36 micrograms 

Tm = 93.1 OF 

Y m = 1.03 (see calculation below) 

Vm = (2.319 mJ)(35.3 trIm') = 81.86 tr 

Pbv = 30.35 

Cc:r = (20.36) (93.1 + 460) = 0.0088 mg/dscm 

(499.8)( 1.03)(81.86)(30.35) 

Dover Industrial Chrome, Inc. Results East Stack-Trial #2: 

(433 ml in test trial #2 sample) 0.058-0.003 mgIL = 0.055 mgIL 

Mer = (0.055 mgIL)x(0.433 L) = 0.0238 mg x 1000 micrograms/mg = 23.82 micrograms 

Tm = 94.8 OF 

Y m =1.03 (see calculation below) 

Vm = (2.329 m3)(35.3 tr/m3) = 82.21 ff 

Pbar = 30.35 

Note: It is our poli~ 10 keep copies of Rpons (or six monlhs. The dal:l is kepi on file for up to three yean. Samples (if appli=le) ~ 

kept for three weeks. Samples thai are hazardous will be returned 10 the clienL If this poli~ poses a difficulty, pleuc contact us to make 

olher anangemenlS. If reproduced. our report. musl be reproduced complelely. Any unauthorized alteration of this report invalidates the 

conleaL 
Cer = (23.82) (94.8 + 460) = 0.0103 mg/dscm 

(499.8)( 1.03)(82.21 )(30.35) 

Dover Industrial Chrome, Inc. Results East Stack-Trial #3: 

(378 rol in test trial #3 sample) 0.165 - 0.003 mgIL = 0.162 mgIL 

Mer = (0.162 mgIL)x(0.378 L) = 0.0612 mg x 1000 micrograms/mg = 61.24 micrograms 

Tm = 94.3 OF 

Y m =1.03 (see calculation below) 

Vm = (2.361 m3)(35.3 fe/m') = 83.34 ft3 

Pilar = 30.35 

Cer = (61.24) (94.3 + 460) = 0.0261 mg/dscm 

(499.8)( 1.03)(83.34)(30.35) 

Dover Industrial Chrome, Inc. Results West Stack-Trial #1: 

(362 rol in test trial #1 sample) 0.081 - 0.003 mgIL = 0.078 mg/L 

Mer = (0.078 mg/L)x(0.362 L) = _ 0.0282 mg x 1000 micrograms/mg = 28.24 micrograms 

Tm = 94.5 OF 

Y m = 0.982 (see calculation below) 

Vm = (2.022 m3)(35.3 ftl/m3

) = 71.38 tr 

Pbar = 30.35 

Cer = (28.24) (94.5 + 460) = 0.0147 mg/dscm 

(499.8)(0.982)(71.38)(30.35) 

Dover Industrial Chrom.e, Inc. Results West Stack-Trial #2: 

(390 ml in test trial #2 sample) 0.088-.003 mg/L = 0.085 mgIL 

Mer = (0.085 mg/L)x(0.390 L) = 0.0332 mg x 1000 micrograms/mg = 33.15 micrograms 

Tm = 97.4 OF 

Y m = 0.982 (see calculation below) 

Vm = (2.051 m3)(35.3 £r/m3

) = 72.40 f~ 

Pilar = 30.35 

Ccr = (33.15) (97.4 + 460) = 0.0171 mg/dscm 

(499.8)(0.982)(72.40)(30.35) 

Note: It is our policy to keep copies of ~pons for six months. The data is kepi 00 file for up to th~e years. Samples (if applicable) ~ 

kept for th~ weeks. Samples that are hazatdous will be feNmed to the cIienL If this policy poses a difficulty, please contact us 10 make 

other arrangements. If reproduced. our ~port. must be n:produced completely. Any unauthorized a1ter:atioD of this report invalidates the 

conleDL 
.~ CI. }, 

~c-. .l.~ dct.en.u 

CONTROU LABORATORIES, INC. 

Dover Industrial Chrome, Inc. Results West Stack-Trial #3: 

(335 ml in test trial #3 sample) 0.102-.003 mg/L = 0.099 mg/L 

Mer = (0.099 mgIL)x(0.335 L) = 0.0332 mg x 1000 micrograms/mg = 33.17 micrograms 

Tm = 97.1 of 

Y m = 0.982 (see calculation below) 

Vm = (2.063 m3)(35.3 tr/m3

) = 72.82 tr 

Pbar = 30.35 

ea = (33,17) (97,1 + 460) = 0.0170 mg/dscm 

(499.8)(0.982)(72.82)(30.35) 

Quality Control Data: 

Sample: 

Duplicate: 

Spike: 

LFB::\ 

LRB: ~ 

~ 

11.41 ppb 

10.51 ppb, relative percent difference = 8.21 % 

15.30 ppb, 97.3% spike recovery 

26,51 ppb, 106% recovery 

2.02 ppb, method detection limit = 2.00 ppb 

Calculation for Post Test Gas Meter Calibration: 

... -

The meters were run for 6 minutes with a critical orifice that allows 0.75 cfm. 

GAS METER USED ON EAST STACK 

The gas meter used on the .east stack recorded a volume of 4.6643 ftl. The average 

temperature was 93.0 and the barometric pressure was 30.35 in. of mercury. To correct tostandard conditions: 

where: 

Vm(SId) = (K1)(VJ k+ (~HI13,6) from EPA Method 5 

Tm 

Kl = 17.64 

V m = volume of gas recorded from post test in ff 

Pb2r = barometric pressure in inches of mercury 

Note: It is our policy to keep copies of reports for six monlhs. The dau is kepI on file for up 10 th~c yean. Samples (if applicable) arc 

kept for thR:C weeks. Samples thai a~ hazardous will be ~lUmed to the clienL If this polic;y poses Ii difficulty, please contact us to make 

other arr.lngements. If reproduced, our report. must be R:produced completely, Any unauthorized llIteratioD of this report iovalidates the 

conlenL 
·~ .:£ 

CL J 

"'C. J..~ oct.el£u Page 6 

CONTROU LABORATORIES, INC. 

ill ~ average pressure differential across the orifice in inches of water provided on orifice 

calibration sheet 

T m = temperature in degrees R 

Vm(std) = C17.64)(4.6643)( 30.35 + (1.8/13.6)] 

93.0+ 460 

_ . V m(sld) = 4.5353 ff 

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

V CI($Id) = K' 

.[Tamb 

where: 

K' = factor from orifice calibration sheet provided with critical orifice by manufacturer 

Pilat = barometric pressure in inches of mercury 

e = time in minutes 

T:amb = temperature in degrees R 

0.5933 (30.1)(6) 

.[547.25 

V Cl(Sld) = 4.5803 ff 

the Y value for the post test is then: 

Y m (after laI) = ~$Id) 

V m(Sld) 

Y m(after test) = 4.5803 

4.5353 

Ym(manu) 

Y m(after laI) 

= 1.039· 

1.010 

= 1.029 

• As provided on the meter calibration sheet provided with the meter by the manufacturer 

Note: It is our policy 10 keep copies of repons for six months. The data is kept on file for up 10 three years. Samples (if app1i~le) arc 

kept Cor three weeks. Samples that ale hazardous will be returned to tbe clienl. If this policy poses a difficulty, please CODlaet us 10 make 

other amlDgemenlS. If reproduced. our report, must be reproduced completely. Any unauthorized a\lenltion oC this report invalidates the 

contenl. 
®< CI. 1 .... C. .l.~ dC'~l£u Page 7 

CCNTRCLl I..ABCRATCRIES. INC. 

Si~ce the Y value is between 0.95 and 1.05, the gas meter is acceptable. 

GAS METER USED ON WEST STACK 

The gas meter used on the west stack recorded a volume of 4.7703 fr. The average 

temperature was 95.8 and the barometric pressure was 30.35 in. of mercury. To correct to 

standard conditions: 

Vm(Sld) = (17.64)(4.7703)[ 30.35 + n.8113.6)] 

95.8+ 460 

V m(std) = 4.6150 re 

the Y value for the post test is then: 

Y m (:after \eSt) = YatSld) 

V m(Sld) 

Y m(:after lese) = 4.5803 

4.6150 

Y m(aftcr ICSI) = 0.992 

= 0.974· 

0.992 

= 0.982 

·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: 

The tests were conducted to demonstrate compliance with the National Emissions Standard for 

Hazardous Air pollutants (NESHAP),. The results of these perfonnance tests indicate that 

Dover Industrial Chrome meets the small source emission limit of 0.030 mg/dscm. Ongoing 

compliance will be demonstrated by recording the surface tension of the chromium plating 

solutions. Dover Industrial Chrome will be considered to be in compliance as long as the 

surface tension remains below those values recorc.ted during the performance tests. 

Note: It is our policy to keep copies of repons for six. months. The data is kept on file for up to three yeIUS. Samples (if applicable) are 

kept for three wee""'- Samples that are bazanlous will be returned to the clienL If this policy poses a difficulty. please CODtact us to make 

otber arrangements. If reproduced, our report. must be reproduced completely. Any unauthorized alteration of this report invalidates the 

content. 
· .' 

~ CL. } 

... c . .s.~ •• oC£tn.u Pa~e 8 

CONTRO L.A80RATCRIEB, INC. 

I certify that the above results are, to the best of my knowledge, true and accurate. 

If you have any questions please call me. 

SCIENTIFI.s.-CONTROL LABORATORIES, INC. 

By ~,~//~ /. ,. 

Daniel 1. Bell 

CERTIFICATION: 

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

this ' 

DB:db 

CN06629A 

TWENTY EIGHTH day of AUGUST, 1997. 

Notary Public 

~rX~ 

"OFFICIAL SEAL" 

LAURA L. CAIRO 

Notary Public, State of Illinois 

My Commission Expires 3/612001 

,Note: It is our polit;)' to keep copies of reports for six months. The data is kept on file for up to three years. Samples (if applicable) :ate 

kept for three weeks. Samples that are hazardous will be returned to the clienL If this policy poses a difficulty, please conlact us to m:ake 

other amngemenlS. If reproduced. our repOTt. must be reproduced completely. Any unauthorized altel'Btion of Ibis report invalidates tbc 

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Ff .. r:tE i'LI. : 77347SQ008 Jul. 19 1997 03:29=1'1 Pl 

DOVER INDUSTRIAL CHROME. INC. 

2929 N. Campbell Ave. 

Chicago, JL 60618 

July 18, 1997 

Scientific Control Laboratories. Inc. 

3158 South Kolin Ave. 

Chicago.IL 60623-4889 

Attn: Dan Bell 

A ........ r/c ;.;jw :::'"/' --- TS -II .. - ~J 7" 

Re: Data relating to July 11. 1997 chromium emission testing. 

Six of seven chrome plating tanks were in operation on July 11. We alternately 

use either #5 tank or #7 tank, depending upon the work size, but we never use 

both at once. We pump solution from one to the other as needed and connect 

one rectifier the the particular tank selected. (Note that at this time we do not 

have a #4 tank in operation). 

Tank # Volume Surface Tension Ampere Hours 

1 

2 

3 

4 

5 

6 

7 

8 

before 

7529 27.9 

838g 22.4 

1.5989 27.S 

not installed 

not operational 

712 9 27.0 

1,036g 28.8 

373g 24.8 

after 

29.3 

22.0 

28.3 

27.2 

30.3 

25.2 

during testing 

. 36.850 

19,292 

9,600 

2,050 

32.300 

3.500 

103,592 total 

If there is any further information required, please let me know. 

Sincerely yours, 

~~£,/,,--- Ariel G. Schrodt. Ph .. D. 

President 

Phone: 773-478-2022 

Fax: 773-478-0008 

e-mail: tvjdover@mcs.com 
3158 S. KOLIN AVENUE 

CHICAGO, IL 60623-400n 

TEL (312) 254-2t106 

FAX (312) 254-66fJ 1 

CHAIN OF CUSTODY RECORD () . ~q ProJcd "0 (}~edUam8 

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Federal Register / Vol. so. No. 16 / Wednesday. Tanuary 25. 1995 I Rules anc: Regulat:ons 4989 

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Federal Register / Vol. 60. No. 16 I Wednesday. J.Jnuary 25. 1995 I Rules and Reguiations 

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Federal R~ter / Vol. 60. :-ro. 15 .' Wecr:esciay, January 1995 / Rules and Reg'!.Iiaticns 4989 

Plant..' _..;...- . r~ '.~'. ________ ~ ~ ____ _ 

~r~p~_______ 1iQe~ ________ _ 

Cjrcle one: 

Befon: BUll 1 

T12venc 

p,oint 

.N~mber 

Befo~ Run '; 

- . 

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Sellec-.atie of Points . 

gefo~ Bun,. 6 fte:- '!tun No. 

Decimal . Whole 

./A cxS min Part of MiCutes+ 

( .;E:Pr. "9' Minute I SceoZlds sa 

II ilumeric!:.l :::t 60 =- Sacple Minuces SccoZlds TIme 

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Federal Register / Vol. 60. Nc. 16 I Wednesday, january 25. 1995 / Ruies and Reg'J.iaticns 

Pllllt~~' _________ .....;:. ____ _ 

~r~e~ ______ _ TIm.c.e ______ _ l.oc:l::,,~t:. ______________ _ 

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