• 

, .-

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 EP AlIEP A 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 (IEP A 

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. If ftProduc:ed. our n:port. must be reproduc:ed c:ompletely. ADY uuuthorized aliemtiOD of this ftpGrl UaYalidalea the 

c:oatcDL 
t1'~ 

~/". dCLULU ''k'' 

CONTRO LA.ORATO'UI:S, INC. 

RESULTS: 

Page Two 

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

chromium. 

SAMPLE lO. TEST CONe,] 

TEST TRlAL # 1 0.0 19 mgIL 

6/1 1197 

TEST TRlAL #2 0.032 mgIL 

611 1/97 

TEST TRlAL #3 0.038 mgIL 

6/11197 

. BLANK 0.003 mgIL 

Analyud by SCL 

2 As calculated by SCL (see attached) 

) As calculated by SCL (see attached) 

ACTUAL EMISSION LIM1T' 

[JItHSSJON 1 

0.0029 mgldscm 0.03 mgldscm 

0.0054 mg/dscm 0.03 mg/dscm 

0.0065 mgldscm 0.03 mg/dscm 

NA NA 

The sampling ports were already installed in the slack. These sampling test perts were located 

in a duct after the blower with diameter of 16 inches. The length of this straight duct section 

is 66 inches. The ports are located 54 inches (3.4 duct diameters) downstream from a minor flow 

disturbance (a change from a rectangular to a circular duct immediately followiug the blower) 

and 12 inches (0.75 duct diameters) from the top of this duct. This sampling location does meet 

the minimum criteria of 2.0/0.5 duct diameters for an acceptable sampling point as specified in 

section 2.1 of US EPA Method I (40CFR Part 60, Appendix A). See the attached di agram for 

a description of the sampling location and the specific sampling points. 

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

misalignment was found to be 9.2"'. Since the average angle of misalignment is less than 20 

degrees, the amount of cyclonic flow is acceptable. The pressure drop across the pollution 

control devive was 2. 1 in. of water column pressure throughout the day of testing. 

Leak tests were conducted before and aftc:r each test run and found to be less than 0.2 Umin. 

The vacuum pressure of the sampling pump was 22" of mercury. 

Note: It iI our 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. plcuc cOllucl us to make 

other Imngcmellu. If Rproduccd. our ",port. mus! be ",produced completely. All)' unluthorized ahen.Lioll of 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 

T m =Dry gas meter temperature, OP 

Y ID =Dry gas meter correction factor 

V m =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 

Y ID =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 

Y ID =1.009 (see calculation below) 

VID =(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. If reproduced. our report. must be reproduced completely. Any unauthorized aheration of this 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 

V m = 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 

V Q{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 

Yat (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. If repRlduccd, 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 

CODteDL 
Federal Kqister I Val. 60. No. 16 I Wednesda~·. January 25. 1995 I Rules and Reguiatians 4989 

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CROSS SECTIONAL vir. or SAMPUNC POINTS 

GRAVURE PROCESS 

4179 W. BELMONT AVENUE 

CllICACO IL 60641 

1.0. NO: 031600CBT 
~ ;1"'11 

1".4,.,":' '"1, ... t/ 'I. '" ~ (!,,(..- 'Z. p.".p> ,. .OJ ~J"(' 

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• 
I 

tMPANY GIUJNVt,C P~c.~ r 

MPUNG ADDRESS 

4=(1, W 

~il!".fi:l·c CDNTRDJ)~ABORAl DRIES. INC. 

n S .. NG. EN I) INII R!!!lJ __ ~"D CO H S Ul" N CJ 

.. 3158 S. KOLIN I\VENUE 

CI nCAGO. Il 60623-4889 

'f EL (312) 254-240() 

FAX (312) 254-6661 

CHAIN OF CUSTODY RECORD 

d". C:od~l~j/.~ ~.~~-~~:.--~---'-----''--or-

'LER'SIGl~~ --~ "~ J ..:. - -.-- talnp-rs 

lI. station DATE TIME S C pH stallon locallon rl~ 0 ~ ii G 

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CONTAINER 

(I) 2 oz. 

(2) 4 oz. 

(3) 1/2 r." 

cot) ".,. (5) QURr' 

(6( 1/2 Gal. 

(7) Ganon 

(8) VOC Vials 

(9) Vials 

(10) Olher 

PRESERVATIVE 

1\ - None 

O-flN03 

C-112S0" 

(). NaOll 

E -I\scorblc 

F - Na2S20J 

G· Oilier 

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