P.1 

OAR Box 1313 

Prepped by LaTeia Shed 

Document Number: 

78) ll-B-52 

Docket Number: 

A-88-02 

Printed 6/12/2008 9:03:31 AM Sheet 78 of 99 
P.2 

MRI® A-88-02 

MIDWEST RESEARCH INSTITUTE 

X - B-i'pZ Suite 350 

401 Harrison Oaks Boulevard 

Cary. N.C. 27513 

Date: June 13, 1988 

(Finalized August 23, 1988) 

Subject: Revised Model Plant Parameters, Baseline Controls, and 

Regulatory Alternatives for Chromium Electroplating and Chromic 

Acid Anodizing Operations 

Chromium Electroplating NESHAP 

EPA Contract 68-02-3817; ESD Project 85/02a ..-•:-•' \ 

MRI Project 7717-K .,-• •:.• ' 7 

...,.-••"8, •' .."•• • - " i .8 

From: Robin BarkerW 7' ...p \Y\\\ 

To: Andrew M. Smith fr? * ..7\vA', 

ESD/ISB/SSS (MD-13) ••••.•• \ ^*^% ^ -^ 

U. S. Environmental Protection Agency \..-7 .-~-"7" "v ^^3--"" 

Research Triangle Park, N.C. 27711 \-7\ \. '.•5--'" 

I. Introduction 

Preliminary model plant parameters for chromium electroplating and 

chromic acid anodizing facilities were developed in December 1986 (see 

memorandum from Strait, R., MRI, to Vervaert, A., EPA/ISB [December 19, 

1986]). Because Office of Management and Budget approval of the 

Section 114 information collection was not received until June 1987 and 

the Section 114 information request responses were not received until 

December 1987, these preliminary model plants were based on Phase I 

Section 114 information request responses, trip report data, and telephone 

contact surveys. 

In March 1988, the project team reevaluated the preliminary model 

plant parameters using the expanded data base developed from the * 

Section 114 infonnation collection and plant visits conducted to evaluate 

candidate facilities for testing. Tables 1, 2, and 3 present the revised 

model plant parameters developed as a result of this reevaluation.. 

The major model plant parameters that were revised were: (1) plant 

operating hours, (2) percent time electrodes are energized, (3) operating 

current, and (4) production rate in terms of ampere-hours per year. Some 

adjustments were also made to the capacity values of the model plants to 

represent more accurately the data contained in the expanded data base. 

Baseline assumptions have also been revised. Assumptions on control 

techniques applied are based on information obtained from the Section 114 

information collection. Assumptions regarding achievable performance 

associated with each type of control technique applied are based on the 

results of the emission test program. Information on baseline is 

presented in Section V of this memorandum. 

/ 
P.3 

Section VI of this memorandum presents the regulatory alternatives 

under consideration. The level of emission reduction associated with each 

alternative has been revised based on the average performance level of 

each control device. 

II. Section 114 Information Data Base 

Infonnation obtained through the Section 114 information collection 

was compiled into a data base. The.data base is summarized in 

Attachment 1. The data base contains general information for each plant 

(name, location, and contact person); specific information regarding the 

chromium plating or anodizing operation, emission control devices, stack 

parameters; and economic information. This information was obtained for 

120 plants which operate 215 hard chromium plating tanks, 102 decorative 

chromium plating tanks, and 31 chromic acid anodizing tanks. 

The information collected was segregated according to type of 

operation (i.e., hard plating, decorative plating, or anodizing). In 

several instances, an individual facility reported that it performed more 

than one type of operation. In addition, in some cases the same process 

tank was used to perform two different operations. Facilities with two or 

more different operations are treated as if each operation is an 

individual facility. If more than one operation is performed in the same 

tank, that tank is categorized according to the operation for which it is 

used the majority of the time. 

III. Trip Report Data Base 

A trip report data base was developed using information obtained 

from 17 hard chromium plating facilities, 11 decorative chromium plating 

facilities, and 3 chromic acid anodizing facilities. The trip report data 

base contains the following information: (1) type of operation, (2) plant 

operating time, (3) number of process tanks, (4) total tank capacity, and 

(5) operating current and voltage of the process. This data base is 

presented in Attachment 2 and was combined with the Section 114 data base 

for developing model plant parameters. 

IV. Development of Hard and Decorative Chromium Electroplating and 

Chromic Acid Anodizing Model Plants 

Two constraints were assumed in the reevaluation of the model plant 

parameters: (1) the control device configurations would remain the same 

as those developed for the preliminary model plants, and (2) the model 

tank sizes would remain the same. Both the Section 114 and trip report 

information were used to develop the revised model plants. The analysis 

included development of a frequency distribution to establish the model 

plant sizes and an evaluation of the available data on process operating 

conditions to determine typical operating parameters within various plant 

size ranges. 

< ^ 
P.4 

A. Determination of Model Plant Sizes 

Frequency distributions were prepared using data on total tank 

volumes per plant in the hard and decorative chromium data bases. These 

frequency distributions are shown in Figures 1 and 2 and were used to 

determine model plant sizes. Three model plant sizes, representative of 

small, medium, and large facilities, were selected for both the hard and 

decorative chromium categories. The tank volume cutoff values selected 

for hard chromium electroplating shops are less than 15,100 liters (a) 

(4,000 gallon [gal]) for a small-size plant, between 15,100 a and 37,850 a 

(4,000 and 10,000 gal) for a medium-size plant, and greater than 37,850 a 

(10,000 gal) for a large-size plant. The cutoff values for decorative 

chromium electroplating plants are less than 7,570 a (2,000 gal) for a 

small-size plant, between 7,570 a and 30,280 a (2,000 and 8,000 gallons) 

for a medium-size plant, and greater than 30,280 a (8,000 gal) for a 

large-size plant. 

A frequency distribution was not used to determine model plant sizes 

for chromic acid anodizing operations because it was evident that all but 

one of the operations could be divided into two, distinct size ranges. 

The total tank volume at small operations ranged from 378 to 7,570 a (100 

to 2,000 gallons), and at large operations was over 37,870 a 

(10,000 gal). One operation reported a tank volume of 2,730 a (7,200 

gal). Only small and large model plants were defined for anodizing 

operations. 

B. Process Parameters 

The first set of process parameters that was evaluated for the 

purpose of revising the model plant parameters included (1) number of 

tanks, (2) total tank capacity, (3) operating time per year, and 

(4) percent time electrodes are energized. The information in the data 

bases was grouped according to the model plant size, and average values 

were calculated for each of these parameters. These average values were 

then used as the bases for revising the preliminary model plant 

parameters. Other process parameters such as chromic acid concentration, 

sulfate ratio, and temperature of the plating solution were revised as 

needed based on a general review of the information provided by all 

plants. 

The operating current and production rate values, expressed in terms 

of ampere-hours per year, for each hard and decorative chromium model 

plant were revised based on the modified individual tank parameters and 

tank capacity information collected during the emissions test program. 

Attachment 3 presents the derivation of these values for each hard and 

decorative chromium plating model plant. 

C. Capture System, Control Device, and Stack Parameters 

Parameters for capture systems, control devices, and stacks were 

revised, as appropriate, based on modifications to the control device 

configurations for each model plant and technical data and cost quotations 
P.5 

supplied by vendors for each of the applicable control techniques. The 

control device configurations for each model plant are shown in Figures 3 

through 7. 

V. Baseline Control Levels and Emissions 

Baseline control levels for each type of operation were revised 

based on data in the Section 114 information data base. Information on 

control techniques applied was obtained from 44 hard chromium plating 

facilities, 63 decorative chromium plating facilities, and 25 chromic acid 

anodizing facilities. A summary of these data is presented in Table 4. 

The revised baseline level of control for each type of operation is 

also presented in Table 4. For operations that use two different control 

devices in series, the operation was considered to operate with only the 

more efficient control device. The average performance level for each 

type of control device was determined from the emissions test program, 

(see Table 5). 

Uncontrolled emission data for eight hard chromium plating 

operations and two decorative chromium plating operations are presented in 

Table 6. An uncontrolled hexavalent chromium emission factor of 

10 milligrams per ampere-hour (mg/A»h) (0.15 grains per ampere-hour 

[gr/A»h]) is considered to be representative of uncontrolled emissions 

from a hard chromium electroplating operation. An uncontrolled hexavalent 

chromium emission factor of 2.0 mg/A-h (0.030 gr/A-h) is considered to be 

representative of a decorative chromium electroplating operation. 

Uncontrolled emission data for chromic acid anodizing were not 

obtained through source testing of an anodizing facility. Instead, a mass 

balance determination was conducted on a scrubber used to control 

emissions from a chromic anodizing operation. The results of this mass 

balance indicate that an uncontrolled hexavalent chromium emission factor 

of 0.6 mg per hour per square meter (mg/h/m ) (0.009 grains per hour per 

square foot) of tank surface^rea is appropriate to characterize emissions 

from this type of operation. 

VI. Regulatory Alternatives 

The regulatory alternatives under consideration for each type of 

operation are presented in Table 7. These regulatory alternatives will be 

evaluated to determine the environmental, cost, and economic impacts of 

various levels of chromium emission reduction. 

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; Duct Coaponent 

! Specification 

!Gas flow rate, cfa 

'Duct diameter, in. 

:Duct length, ft. 

!No. of 30 degree entries 

!No. of one step tapers 

!No. of 90 degree elbows 

Duct Section Location : 

fl 

2,625 

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Id 

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Figure 3. Plan view and ductwork specifications of the small 

and medium decorative chromium plating, small chromic 

acid anodizing and small hard chromium plating model tanks. 

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Duct Coaponent I Duc t Sectio n 

Specification ! * 

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Loca t io n 

H 

Bas flow rate, cfs 

Duct diaaeter, in. 

Duct length, ft. 

No. of 30 degree entries 

No. of one step tapers 

No. of 90 degree elbow 

2,000 5,000 8,000 11,000 14,000 2,344 4,688 7,032 9,376 18,752 32,752 

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11 

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Figure 4. Plan view and ductwork specifications of the medium and large hard 

chromium plating model plant. 

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!6as flow rate, cfn 

IDuct diaaeter, in. 

IDuct length, ft. 

•'No. of 30 degree entries 

!No. of one step tapers 

!No. of 90 degree elbows 

Duct Section Location 

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Figure 5. Plan view and ductwork specifications of two 12-foot 

tanks for the large decorative chromium plating model plant. 

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IGas flow rate, cfa 

IDuct diaaeter, in. 

IDuct length, ft. 

!No. of 30 degree entries 

INo. of one step tapers 

INo. of 90 degree elbows 

Duct 

Locat 

fl 

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16 

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0 

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12-foot of the large decorative chromium plating model plant. 

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Bas flow rate, cfa 

Duct diaaeter, in. 

Duct length, ft. 

No. of 30 degree entries 

No. of one step tapers 

No. of 90 degree elbows 

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Figure 7. Plan view and ductwork specifications of the large chromic acid 

anodizing model plant. 

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TABLE 1. MODEL PLANT PARAMETERS FOR HARD CHROMIUM ELECTROPLATING OPERATIONS3 

Plant size 

Parameters Smal 1 

5.0x106 

70 

1,130 (2,500) 

8 

5 

50 

2,000 

1 

3.6, 1.1, 1.8 

(12.0, 3.5, 6.0) 

6,550 (1,730) 

4.0 (42) 

250 (33) 

Sulfuric acid 

2.5 (0.33) 

49-65 (120-150) 

6-9 

3,625 

2,800 (260) 

Double-sided 

lateral 

300 (10,500) 

1 

340 (12,000) 

Med 1um 

42x106 

70 

5,670 (12,500) 

14 

5 

50 

3,500 

4 

1.2, 1.2, 3.0 

(4.0, 4.0, 10.0) 

2 § 3.6, 1.2, 1.8 

(12.0, 4.0, 6.0) 

7.6, 0.9, 1.8 

(25.0, 3.0, 6.0) 

30,930 (8.170) 

17 ift87) 

250 (33) 

Sulfuric acid 

2.5 (0.33) 

49-65 (120-150) 

6-9 

2,330, 2 6 4,145, 

6,475 

2,800 (260) 

Push-pul1, 

double-sided 

lateral 

870 (30,750) 

1 

990 (35,000) 

Large 

160xl06 

80 

14,700 (32,500) 

24 

5 

50 

6,000 

8 

2 6 1.2, 1.2, 3.0 

(4.0, 4.0, 10.0) 

4 6 3.6, 1.2, 1.8 

(12.0, 4.0, 6.0) 

2 fi 7.6, 0.9, 1.8 

(25.0, 3.0, 6.0) 

61,850 (16,340) 

35 (374) 

250 (33) 

Sulfuric acid 

2.5 (0.33) 

49-65 (120-150) 

6-9 

2 6 2,330, 4 § 4,145, 

2 S 6,475 

2,800 (260) 

Push-pul1, 

double-sided 

lateral 

2 6 870 (30,750) 

2 

2 § 990 (35,000) 

A. Production rate 

Total ampere-hours per year 

Time electrodes are energized, % 

Chromic acid usage, kg/yr (lb/yr) 

B. Operating time 

Hours/day 

Days/week 

Weeks/year 

Hours/year 

C. Process 

Number of tanks 

Tank dimensions, (I, w, d) , m (ft) 

Total tank capacity, 4, (ga4)D

 9 

Total tank surface area, nr (ft ) 

Chromic acid concentration, g/S, (oz/gal) 

Catalyst 

Catalyst concentration, g/fl, (oz/gal) 

Temperature of plating solution, *C ("F) 

Tank operating voltage, V 

Tank operating current, amperes 

Current density, A/m2 (A/ft2) 

Emission capture system 

Type of hood 

3 "S r Ventilation rate, m/min (ft/min) 

E. Control technique 

Control device 

Number of control devices , 

Inlet gas flow rate, nr/min (ft^/mln)13 

ro 

(continued) 

"X 

V 
TABLE 1. (continued) 

Plant size 

Parameters Smal 1 

27 (80) 

2 

0.5 (2) 

400 (3) 

0.75 (3) 

800 (6) 

0.19 (0.75) 

0.5 .(2) 

0.25 (1) 

1 

9.1 (30) 

1.0 (3.3) 

27 (80) 

2 

340 (12,000) 

910 (3,000) 

Medium 

27 (80) 

2 

0.5 (2) 

400 (3) 

0.75 (3) 

800 (6) 

0.19 (0.-75) 

0.5 (2) 

0.25 (1) 

1 

9.1 (30) 

1.1 (3.8) 

27 (80) 

2 

990 (35,000) 

910 (3,000) 

L 

0. 

arge 

27 (80) 

2 

0.5 (2) 

400 (3) 

0.75 (3) 

800 (6) 

19 (0.75) 

0.5 (2) 

0.25 (1) 

2 

9.1 (30) 

2 § 1.1 (3.8) 

27 (80) 

2 

2 6 990 (35,000) 

910 (3,000) 

Control device (continued) 

Inlet gas temperature, *C (*F) 

Inlet gas moisture, % 

1. Single packed-bed scrubber, AP, kPa (In. w.c.) 

Liquid-to-gas ratio, i/min/1,000 nr/min 

(gal/min/1,000 ftVmin) 

2. Double packed-bed scrubber, AP, kPa (In. w.c.) 

Liquid-to-gas ratio, S,/min/1,000 nr/min 

(ga l/m In/1,000 ft-Vmin) 

3. Chevron-blade mist eliminator with single set of blades 

AP, kPa (In. w.c.) 

4. Chevron-blade mist eliminator with double set of blades, 

AP, kPa (in. w.c.) 

Mesh-pad mist eliminator, AP, kPa (in. w.c.) 

5 

Stack 

stacks 

(ft)e 

Number of 

Height, m 

Diameter, m (ft) 

Temperature, *C (*F) 

Moisture, % 

Gas flow rate, nr/min (ft*vmin) 

Gas velocity, m/min (ft/min) 

Parameter values for the small, medium, and large plant sizes are based on information obtained from Section 114 information 

requests and trip report information. 

^Tank freeboard space = 6 Inches. 

|:The ventilation rates for the capture systems were based on guidelines developed by the American National Standards Institute. 

Any control device may be used at any given plant. 

^Ventilation rates were rounded to the gas flow rates for which factory-assembled control devices are avallable. 

Stack height is the distance from ground level to the point of discharge. 

Uf 
TABLE 2. MODEL PLANT PARAMETERS FOR DECORATIVE CHROMIUM ELECTROPLATING OPERATIONS' 

Parameters Smal I 

Plant size 

Medium Large 

C. 

D. 

Production rate 

Total ampere-hours per year 

Time electrodes are energized, % 

Chromic acid usage, kg/yr (lb/yr) 

Operating time 

Hours/day 

Days/week 

Weeks/year 

Hours/year 

Process 

Number of tanks 

Tank dimensions, (I, w, d), m (ft) 

Total tank capacity, 8, (ga-J)D -> 

Total tank surface area, m (ft 

Chromic acid concentration, 

Catalyst 

g/S, (oz/gal) 

Chromic acid-to-catalyst ratio 

Temperature of plating solution, 'C CF ) 

Tank operating voltage, V 

Tank operating current, amperes 

Current density, A/nr (A/ftz) 

Emission capture system 

Type of hood 

Ventilation rate, m3/min (ft3/min)c d 

E. Control technique 

1. Chemical fume suppressant usage, kg/yr or H/yr 

(lb/yr or gal/yr) 

2. Control device 

Number of control devices 

Inlet gas flow rate, nr/min (ftvmin) 

Inlet gas temperature, *C (*F) 

Inlet gas moisture, % 

3.0x10° 

60 

900 (2,000) 

8 

5 

50 

2,000 

1 

3.6, 1.1, 1.8 

(12.0, 3.5, 6.0) 

6,550 (1,730) 

4.0 (42) 

300 (40) 

Sulfuric acid or fluoride 

100:1 

38-46 (100-115) 

6 

2,600 

1,330 (124) 

Double-sided 

lateral 

300 (10,500) 

17 or 120 

(37 or 32) 

1 

340 (12,000) 

27 (80) 

2 

12x10° 

60 

6,800 (15,000) 

16 

5 

50 

4,000 

2 § 3.6, 1.1, 1.8 

(12.0, 3.5, 6.0) 

13,100 (3,460) 

8.0 (84) 

300 (40) 

Sulfuric acid or 

fluoride 

100:1 

38-46 (100-115) 

6 

2 S 2,600 

1,330 (124) 

Double-sided 

lateral 

2 6 300 (10,500) 

67 or 480 

(148 or 128) 

2 § 340 (12,000) 

27 (80) 

2 

120x10° 

60 

68,000 (150,000) 

24 

5 

50 

6,000 

5 § 3.6, 1.8, 2.7 

(12.0, 6.0, 9.0) 

86,650 (22,890) 

33 (360) 

300 (40) 

Sulfuric acid or 

fIuor i de 

100:1 

38-46 (100-115) 

10 

5 6 6,800 

1,330 (124) 

Push-pul I 

255 (9,000) 

2 g 510 (18,000) 

295 or 2,080 

(650 or 550) 

280 (10,000) 

2 e 510 (18,000) 

27 (80) 

2 

(continued) 

* Tl 

Eii 
TABLE 2. (continued) 

^ 

Plant size 

Parameters SmalI • Med Ium Large 

Control device (continued) 

a. Single packed-bed scrubber AP, kPa (In. w.c.) 0.5 (2) 0.5 (2) 0.5 (2) 

Liquid-to-gas ratio, 8,/min/l ,000 nT/mln 400 (3) 400 (3) 400 (3) 

(gal/min/1,000 ft-Vmln) 

b. Double packed-bed scrubber AP, kPa (In. w.c.) 0.75 (3) 0.75(3) 0.75(3) 

Llquld-to-gas ratio, H/mln/1,000 m*Vmln 800 (6) 800 (6) 800 (6) 

(gal/min/1,000 ft*Vmln) 

c. Chevron-blade mist eliminator with single set of blades, 0.19 (0.75) 0.19 (0.75) 0.19 (0.75) 

AP, kPa (in. w.c.) 

d. Chevron-blade mist eliminator with double set of blades, 0.5 (2) 0.5 (2) 0.5 (2) 

AP, kPa (In. w.c.) 

e. Mesh-pad mist eliminator AP, kPa (in.w.c.) 0.25 (1) 0.25 (1) 0.25 (1) 

F. Stack 

Number of stacks 1 2 3 

Height, m (ft)9 9.1 (30) 9.1 (30) 9.1 (30) 

Diameter, m (ft) 0.7 (2.3) 2 g 0.7 (2.3) 0.6 (2.1) 

2 8 0.8 (2.8) 

Temperature, 'C CF) 27 (80) 27 (80) 27 (80) 

Moisture , % 2 2 2 

Gas flow rate, nT/min (ft-Vmln) 340 (12,000) 2 % 340 (12,000) 280 (10,000) 

2 § 510 (18,000) 

Gas velocity, m/min (ft/mln) 910 (3,000) 910 (3,000) 910 (3,000) 

a II I 

Parameter values for the small, medium, and large plant sizes are based on information obtained from Section 114 information 

requests and trip report data. 

c.Tank freeboard space = 6 inches. 

For the medium size model plant, the two tanks are vented to two separate control devices. Foe the large model plant 

tanks are vented to three separate control devices. One tank with a ventilation rate of 255 nr/min (9,000 ft/min) i< 

ant, the five 

is vented to 

one control device and two tanks each with a combined ventilation rate of 510 nrVmln (18,000 ft-Vmin) are vented to two separate 

control devices. 

The ventilation rates for the capture systems were based on guidelines developed by the American National Standards Institute. 

A fume suppressant alone or In combination with a scrubber or mist eliminator may be used at any given plant. 

Ventilation rates were rounded to the gas flow rates for which factory-assembled control devices are available. 

-"Stack height is the distance from ground level to the point of discharge. 
TABLE 3. MODEL PLANT PARAMETERS FOR CHROMIC ACID ANODIZING OPERATIONS'1 

Parameters 

Plant size 

Smal 1 

70 

430 (1,000) 

8 

5 

50 

2,000 

1 

3.6, 1.1, 1.8 

(12.0, 3.5, 6.0) 

6,550 (1,730) 

4.0 (42) 

75 (10) 

32-35 (90-95) 

20 or 40 

Double-sided lateral 

297 (10;500) 

9.0 (20) 

1 

340 (12,000) 

27 (80) 

2 

0.5 (2) 

400 (3) 

0.75 (3) 

800 (6) 

0.19 (0.75) 

Large 

40 

5,900 (13,000) 

24 

5 

50 

6,000 

2 

2 § 9.1, 1.5, 2.7 

(30.0, 5.0, 9.0) 

72,190 (19,070) 

28 (300) 

75 (10) 

32-35 (90-95) 

20 or 40 

Push-pul1 

1,060 (37,500) 

72 (160) 

1 

1,130 (40,000) 

27 (80) 

2 

0.5 (2) 

400 (3) 

0.75 (3) 

800 (6) 

0.19 (0.75) 

A. Production rate 

Time electrodes are energized, % 

Chromic acid usage, kg/yr (lb/yr) 

B. Operating time 

Hours/day 

Days/week 

Weeks/year 

Hours/year 

C. Process 

Number of tanks 

Tank dimensions, (I, w, d), m (ft) 

Total tank capacity, 8. (gaJ,) 7 

Total tank surface area, nr (ft-*) 

Chromic acid concentration, g/i (oz/gal) 

Temperature of plating solution, *C CF ) 

Tank operating voltage, V 

Emission capture system 

Type of hood 

Ventilation rate, nr/min (ft /min)c 

Control technique 

1. Chemical fume suppressant usage, kg/yr (lb/yr) 

2. Control device 

Number of control devices , 

Inlet gas flow rate, nr/min (ft /mln)e 

Inlet gas temperature, "C CF ) 

Inlet gas moisture, % 

(in. w.c.) , 

/min (gal/min/1,000 ft-Vmln) 

c.) 

al/min/1,000 ffVmin) 

Single packed-bed scrubber, AP, kPa 

Liquid-to-gas ratio, £/mln/1,000 m 

Double packed-bed scrubber, AP, kPa (in. w 

Liquid-to-gas ratio, 2,/min/l ,000 nr/min (g<j./....../..wwu ., 

Chevron-blade mist eliminator with single set of blades, 

AP, kPa (in. w.c.) 

Chevron-blade mist eliminator with double set of blades, 

AP, kPa (in. w.c.) 

Mesh-pad mist eliminator, AP, kPa (in. w.c.) 

0.5 (2) 

0.25 (1) 

0.5 (2) 

0.25 (1) 

CTi 

(continued) 

fc Tl 
TABLE 3. (continued) 

Plant size 

Parameters Smal Large 

F. Stack 

Number of stacks 

Height, m (ft)' 

Diameter, m (ft) 

Temperature, 'C CF ) 

Moisture, $ , 

Gas flow rate, nr/min (ft/mln) 

Gas velocity, m/mln (ft/min) 

1 

9.1 (30) 

0.7 (2.3) 

27 (80) 

2 

340 (12,000) 

910 (3,000) 

1 

9.1 (30) 

1.2 (4.1) 

27 (80) 

2 

1,130 (40,000) 

910 (3,000) 

Parameter values for the small and large plant sizes are based on inforraation obtained from Section 114 Information requests and 

.trip report data. 

Tank freeboard space = 6 inches. 

^The ventilation rates for the capture systems were based on guidelines developed by the American National Standards Institute. 

A fume suppressant alone or in combination with a scrubber or mist eliminator may be used at any given plant. 

.Ventilation rates were rounded to the gas flow rates for which factory-assembled control devices are available. 

Stack height is the distance from ground level to the point of discharge. 

^ M 

Tl 

00 
P.19 

TABLE 4. 

18 

BASELINE LEVELS OF CONTROL FOR CHROMIUM PLATING AND 

ANODIZING OPERATIONS 

Operation/control technique 

Decorative plating 

Fume suppressant 

Fume suppressant and scrubber 

Fume suppressant and mist eliminator 

Scrubber 

Mist eliminator 

Uncontrolled 

Total 

Hard platinq 

Fume suppressant 

Fume suppressant and scrubber 

Fume spressant and mist eliminator 

Scrubber 

Mist eliminator 

Electrostatic precipitator 

Uncontrolled 

Total 

Chromic acid anodizing 

Fume suppressant 

Fume spressant and mist eliminator 

Scrubber 

Mist eliminator 

Uncontrolled 

Total 

Plant 

No. 

28 

17 

3 

4 

2 

9 

63 

3 

4 

3 

13 

7 

1 

13 

44 

6 

1 

5 

2 

11 

25 

data 

Percent 

45 

27 

5 

6 

3 

14 

100 

7 

9 

7 

30 

16 

2 

30 

101 

24 

4 

20 

8 

44 

100 

Baseline 

condition, 

percent 

80 

5 

15 

100 

40 

30 

30 

100 

30 

20 

10 

40 

100 

/ / 
TABLE 5. PERFORMANCE LEVELS OF INDIVIDUAL CONTROL DEVICES 

Plant Control device 

No. of 

test runs 

Average 

removal 

efficiency 

for Cr+ , 

percent Ref. 

Hard chromium plating 

Able Machine Company 

Consolidated Engravers Corp. 

Greensboro Industrial Platers 

Norfolk Naval Shipyard 

Carolina Plating Company 

Piedmont Industrial Platers 

Steel Heddle Company 

Roll Technology 

Decorative chromium plating 

Automatic Die Casting Specialties, Inc. 

Automatic Die Casting Specialties, Inc. 

Mist eliminator (double set 

of overlapping type blades) 

Mist eliminator (single set of 

wave-type blades) 

Mist eliminator (single set of 

wave-type blades 

Mesh pad mist eliminator 

Double packed-bed scrubber 

Single packed-bed scrubber 

Double packed-bed scrubber 

Double packed-bed scrubber in 

conjunction with a mist 

eliminator containing a 

single set of wave-type 

blades 

Foam blanket 

Wetting agent/foam blanket 

3 

3 

4 

3 

3 

12 

3 

6 

98 

91 

88 

94a 

96a 

99 

96 

95 

1 

2 

3 

4 

5 

6 

7 

8 

3 

3 

>99 

>99 

9 

9 

laO 

aBased on total chromium emission data. 
TABLE 6. UNCONTROLLED EMISSION TEST DATAa 

Plant 

No. of 

test runs 

Process conditions 

No. of 

tanks 

Total tank 

surface area, 

m

2 " (ft2) 

Amperehours 

Actual 

gas flow 

rate, 

m / m I n 

(ft3/min) 

Mass emission 

rate, kg/h (lb/h) 

Total Cr Cr+ b 

Process 

C r+ 6 

emission 

rate, 

mg/A«h 

(gr/A«h) Ref, 

Hard chromium plating 

Able Machine Company 3 

Carolina Plating Company 3 

Greensboro Industrial 4 

Platers 

Norfolk Naval Shipyard 3 

Piedmont Industrial 12 

Platers 

Steel Heddle Company 3 

Consolidated Engravers 3 

Corp. 

RoiI Technology 6 

Average 

Decorative chromium plating 

Automatic Die Casting 3 

Specialists. Inc. 

Delco Products Division 3 

Average 

5.2 

(56) 

8.5 

(92) 

5.8 

(63) 

5.6 

(60) 

9.2 

(99) 

6.7 

(72.5) 

2.5 

(26.5) 

8.5 

(92) 

2.8 

(30.3) 

22.3 

(240) 

20,458 

54,667 

13,983 

2,480 

8,524 

8,790 

14,400 

20,050 

6,500 

96,840 

177 

(6,260) 

300 

(10,400) 

226 

(7,970) 

242 

(8,540) 

298 

(10,500) 

512 

(18,100) 

153 

(5,390) 

330 

(11,600) 

130 

(4,700) 

990 

(35,000) 

0.08 

(0.17) 

0.024 

(0.052) 

0.029 

(0.064) 

0.009 

(0.019) 

0.100 

(0.221) 

0.045 

(0.10) 

0.008 

(0.018) 

0.050 

(0.11) 

d 

0.0561 

(0.124) 

0.08 

(0.17) 

0.011 

(0.025) 

0.026 

(0.057) 

c 

c 

0.102 

(0.225) 

0.045 

(0.10) 

0.0152 

(0.0333) 

0.039 

(0.09) 

0.0036 

(0.0080) 

0.0658 

(0.145) 

9.0 

2.2 

4.0 

3.5 

22.5 

15.5 

3.2 

4.6 

9.8 

1.4 

2.0 

1.7 

(0.14) 

0.03)b 

(0.06) 

0.05)b 

(0.35) 

(0.24) 

(0.05) 

(0.07) 

(0.15) 

(0.02) 

(0.03) 

(0.03) 

1 

5 

3 

4 

6 

7 

2 

8 

9 

10 

r-o 

o 

All tests were performed by EPA except for the Norfolk Naval 

Environmental Support Activity, Port Hueneme, California. 

Not included in average value because data is based on total 

^Hexavalent chromium emissions were not reported. 

Total chromium emissions were not determined. 

Shipyard test which was performed by the Naval Energy and 

chromium. 

fe T 

ho 
P.22 

21 

TABLE 7. CONTROL TECHNIQUES UPON WHICH THE REGULATORY ALTERNATIVE 

COST IMPACTS ARE BASED 

Type of operation/ 

Regulatory Alternative (RA) Control technique 

Hard chromium plating 

RA I (no action) 

RA II 

RA III 

Decorative chromium plating 

RA I (no action) 

RA II 

RA III 

RA III 

Chromic acid anodizing 

RA I (no action) 

RA II 

RA III 

Existing (baseline) level of control 

• 30 percent of operations uncontrolled 

• 30 percent of operations controlled by mist eliminators with 

single sets of blades that reduce uncontrolled emissions by 

90 percent 

• 40 percent of operations controlled by single packed-bed 

scrubbers that reduce uncontrolled emissions by 97 percent 

Mist eliminators (single sets of blades) that reduce uncontrolled emissions by 90 percent 

Single packed-bed scrubbers that reduce uncontrolled emissions 

by 97 percent 

Existing (baseline) level of control 

• 15 percent of operations uncontrolled 

• 85 percent of operations controlled by chemical fume 

suppressants or single packed-bed scrubbers that reduce 

uncontrolled emissions by 97 percent 

Single packed-bed scrubbers that reduce uncontrolled emissions 

by 97 percent 

Chemical fume suppressants applied in accordance with 

monitoring and recordkeeping requirements that would ensure 

that vendor recommendations on use are foilowed. 

Uncontrolled emissions reduced by 99 percent 

Trivalent chromium plating processes that reduce hexavalent 

chromium emissions by 100 percent 

Existing (baseline) level of control 

• 40 percent of operations uncontrolled 

• 30 percent of operations controlled by chemical fume 

suppressants that reduce uncontrolled emissions by 

97 percent 

• 20 percent of operations controlled by packed-bed scrubbers 

that reduce uncontrolled emissions by 97 percent 

• 10 percent of operations controlled by mist eliminators that 

reduce uncontrolled emissions by 90 percent. 

Single packed-bed scrubbers that reduce uncontrolled emissions 

by 97 percent 

Chemical fume suppressants applied in accordance with 

monitoring and recordkeeping requirements that would ensure 

that vendor recommendations on use are foilowed. 

Uncontrolled emissions reduced by 99 percent 

=2/ 
P.23 

22 

VII. References 

1. Chromium Electroplaters Test Report: Able Machine Company, Taylors, 

South Carolina. PEI Associates, Inc., Cincinnati, Ohio. Prepared 

for the U. S. Environmental Protection Agency, Research Triangle 

Park, North Carolina. EMB Report 86-CEP-3. June 1986. p. 2-6. 

2. Chromium Electroplaters Test Report: Consolidated Engravers 

Corporation, Charlotte, North Carolina. Peer Consultants, Dayton, 

Ohio. Prepared for the U. S. Environmental Protection Agency, 

Research Triangle Park, North Carolina. EMB Report 87-CEP-9. 

May 1987. p. 16. 

3. Chromium Electroplaters Test Report: Greensboro Industrial Platers, 

Greensboro, North Carolina. Entropy Environmentalists, Inc., 

Research Triangle Park, North Carolina. Prepared for the U. S. 

Environmental Protection Agency, Research Triangle Park, North 

Carolina. EMB Report 86-CEP-l. March 1986. p. 3-6. 

4. Chromium Electroplaters Test Report: Norfolk Naval Shipyard, 

Portsmouth, Virginia. Naval Energy and Environmental Support 

Activity, Port Hueneme, California. Source Emission Testing of the 

Building 195 Plating Shop at Norfolk Naval Shipyard, Portsmouth, 

Virginia, March 11-18, 1985. NEESA 2-124. May 1985. p. 25. 

&5L 
P.24 

23 

5. Chromium Electroplaters Test Report: Carolina Plating Company, 

Greensville, South Carolina. Entropy Environmentalists, Inc., 

Research Triangle Park, North Carolina. Prepared for the U. S. 

Environmental Protection Agency, Research Triangle Park, North 

Carolina. EMB Report 85-CHM-ll. December 1985. p. 3-9. 

6. Draft Chromium Electroplaters Test Report: Piedmont Industrial 

Platers, Statesville, North Carolina. Entropy Environmentalists, 

Inc., Research Triangle Park, North Carolina. Prepared for the U. S. 

Environmental Protection Agency, Research Triangle Park, North 

Carolina. EMB Report 86-CEP-4. September 1986. p. 3-6. 

7. Chromium Electroplaters Test Report: Steel Heddle, Inc., Greenville, 

South Carolina. PEI Associates, Inc., Cincinnati, Ohio. Prepared 

for the U. S. Environmental Protection Agency, Research Triangle 

Park, North Carolina. EMB Report 86-CEP-2. June 1986. p. 2-6. 

8. Draft Chromium Electroplaters Test Report: Roll Technology, Inc., 

Greenville, South Carolina. Peer Consultants, Dayton, Ohio. 

Prepared for the U. S. Environmental Protection Agency, Research 

Triangle Park, North Carolina. EMB Report 87-CEP-6. September 

1988. 

9. Draft Chromium Electroplaters Test Report: Automatic Die Casting 

Specialists, Inc., St. Clair, Shores, Michigan. Peer Consultants, 

Dayton, Ohio. Prepared for the U. S. Environmental Protection 

Agency, Research Triangle Park, North Carolina. EMB 

Report 88-CEP-ll. April 1988. 

10. Chromium Electroplaters Test Report: Delco Products Division, 

General Motors Corporation, Livonia, Michigan. Peer Consultants, 

Dayton, Ohio. Prepared for the U. S. Environmental Protection 

Agency, Research Triangle Park, North Carolina. EMB 

Report 86-CEP-7. March 1987. p. 3-3. 

11. Memo from Barker, R., MRI, to Vervaert, A., EPA/ISB. May 15, 1987. 

Engineering Analysis—Reliable Plating and Polishing Company. 

1987. p. 5. 

4 Attachments 

a2L3 
P.25 

ATTACHMENT 1. 

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117 

103 

169 

115 

227 

114 

164 

100 

162 

150 

170 

119 

157 

TYPE 

OF 

OPERATION 

D 

0 

D 

D 

D 

D 

C 

D 

D 

D 

D 

D 

D 

SHE 

OF 

OPERATIOH 

S 

5 

S 

S 

S 

S 

S 

s 

s 

s 

n 

H 

n 

DATABASE FOR DECORATIVE PLATING PLANTS 

AriPERE-HOURS 

PER 

VEAR 

132.1000 

a.OOOO 

22.6B00 

28.1000 

3.0000 

18.0000 

0.0310 

10.5000 

5.2000 

3.0000 

15.0000 

0.0000 

0.0000 

NUHBER 

OF 

TANKS 

9 

1 

3 

3 

1 

1 

3 

3 

1 

1 

4 

3 

3 

TOTAL TANK 

CAPACITY 

6ALL0NS 

1458.60 

1570.80 

1649.34 

1678.15 

2154.24 

2165.01 

2423.52 

2546.94 

2591.62 

3293.44 

3821.54 

4089.69 

6736.68 

OPERATING 

TIHE 

HOURS/YEAR 

3928.90 

2000.00 

3500.00 

3400.00 

4250.00 

6000.00 

4250.00 

4680.00 

2288.00 

6000.00 

2964.00 

3840.00 

2733.30 

ITIME 

ELECTRODES 

ENERGIZED 

47.22 

50.00 

80.00 

96.67 

27.00 

100.00 

34.67 

50.00 

32.00 

4.50 

95.00 

60.00 

93.33 

5U 
Kage NO

. 1 

06/08/88 

FACID TYPE 

168 

181 

194b 

188a 

197 

185 

198 

179b 

!B9b 

IB6a 

187a 

182a 

196 

140a 

177a 

191a 

174a 

179 

195 

146a 

184a 

183 

173a 

22Ba 

180 

OF 

OPERATIOH 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

SUE OF 

OPERATION 

S 

S 

S 

S 

S 

S 

S 

S 

S 

S 

S 

S 

S 

S 

S 

s 

s 

s 

s 

s 

s 

s 

s 

L 

L 

DATABASE FOR CHRONIC ACID ANODIZING PLANTS 

ANPERE-HOURS 

PER 

YEAR 

0.0000 

0.0114 

0.1250 

0.0015 

0.0520 

0.0001 

0.0022 

0.1270 

0.0936 

0.0000 

0.1591 

0.3000 

0.1100 

0.0000 

0.7500 

0.4000 

2.8000 

0.0000 

0.6200 

0.0000 

4.6000 

0.0000 

0.0000 

19.5940 

3.6000 

NUMBER OF 

TANKS 

2 

3 

2 

TOTAL TANK 

CAPACITY 

6ALL0NS 

162.76 

235.62 

314.16 

314.16 

366.52 

403.92 

538.56 

556.33 

628.32 

628.32 

641.41 

686.66 

695.64 

897.60 

942.48 

942.48 

942.48 

1211.76 

1413.72 

1615.68 

1974.72 

2019.60 

7195.76 

18908.26 

33213.00 

OPERATIHG TIKE 

HOURS/YEAR 

2000.00 

416.00 

2340.00 

104.00 

520.00 

100.00 

192.00 

468.00 

624.00 

975.00 

2175.00 

600.00 

3120.00 

864.00 

4160.00 

2000.00 

4000.00 

500.00 

960.00 

2040.00 

3120.00 

7B0.00 

7020.00 

8400.00 

2500.00 

1 TIKE 

ELECTRODES 

ENERGIZED 

80.00 

80.00 

100.00 

100.00 

75.00 

100.00 

70.00 

90.00 

100.00 

20.00 

100.00 

50.00 

12.50 

50.00 

35.00 

50.00 

100.00 

100.00 

50.00 

20.00 

50.00 

100.00 

50.00 

31.33 

45.00 
P.30 

ATTACHMENT 2. 

TRIP REPORT DATA BASE 

Jlf 
CONPANY NANE 

:::::::::::::::::::::!:::: 

CAROLINA PLATIN6 

6REENVILLE, SC 

C S . OHN NANUF. 

STERLING HEI6HTS, Nl 

GENERAL PLATIN6 

OETROIT, NI 

61BBS PLATIN6 CO. 

CHARLOTTE, NC 

GREENSBORO IND. PLATERS 

6REENSB0R0, NC 

NODERN HARD CHROME 

UARREN, NI 

TIS BRASS AND BRONZE 

TRAVLERS REST.SC 

CONSOLIDATED EN6RAVERS 

CHARLOTTE, NC 

ABLE MACHINE CO. 

TAYLORS, SC 

E.F. BREMER CO 

MENOMOMEE FALLS, 111 

MILWAUKEE PLAT1N6 CO. 

MILWAUKEE, HI 

6.E. MEDICAL SYSTEMS 

MILWAUKEE, HI 

BR166S AND STRATTON 

6LENDALE, HI 

DELCO PRODUCTS DIV. 

LIVONIA, MI 

CIR CHROME SERVICES 

GASTONIA, NC 

CHROME CRAFT CORP. 

HIGHLAND PARK, Ml 

DIAMOND CHROME PLATING 

HOHELL, MI 

TYPE OF YEAR OF 

OPERATION VISIT 

;=:=:::===:==;======;==:== 

H 

D 

D 

H 

H 

H 

D 

H 

H 

0 

0 

D 

D 

D 

H 

D 

H 

OPERATING NUNBER 

TIME, HRS/YR OF TANKS 

TOTAL TANK OPERATING OPERATING 

CAPACITY, GAL V0LTA6E RANGE CURRENT RANGE 

19B5 

1985 

1985 

1984 

1984 

1985 

1985 

1986 

1986 

1987 

19B7 

1987 

1986 

1986 

19B6 

1986 

1986 

8400 

7488 

6240 

2500 

2000 

7500 

2500 

2000 

5200 

5200 

3000 

4000 

5400 

12140 

2800 

2400 

450 

6140 

18700 

1000 

10-12 4000-30000 

5900 

1300 

1350 

800 

580 

85000 

2800 

3000 

12700 

13 18000 

9000 

3000 

2000 

5 5000-10000 

5 2400-2500 

7.5 8000 

4-5 1200-1500 

16-17 8500-10000 

2-6 150-2000 

8-9 5000-6000 

12 3500-17000 

Tl 
BUICK-OLDS-CADILLAC 

DETROIT, Ml 

1987 26900 3000 

HAMILTON STANDARD 

HINDSOR LOCKS, CT 

1987 7488 1570 40 

PRATT AIID WHITNEY 

E. HARTFORD, CT 

1987 7488 5360 20-40 200-400 

RELIABLE PLATIN6 CO. 

BRIDGEPORT, CT 

1987 2000 500 40 200-300 

MAREMONT CORPORATION 

PULASKI, TENN. 

1986 2000 12000 

METALS APPLIED 

CLEVELAND, OHIO 

1986 8400 16700 

PIEDMONT -IND. PLATERS 

STATESVILLE, NC 

1986 3860 

RELIABLE PLATING HORKS 

MILWAUKEE, HI 

1986 4160 1600 11 6000-8000 

SAXONIA FRANKE OF AMERICA H 

SPARTANBURG, SC 

19B6 2200 530 6000 

STEEL HEDDLE 

6REENVILLE, SC 

1986 2000 1820 5 1000-2000 

UNITED METAL FINISHIN6 

6REENSB0RO, NC 

1986 6000 2360 

A-1 CHROME 

NEHIN6T0N, CT 

1987 2080 1260 1000-3000 

SACO DEFENSE 

SACO, MAINE 

1988 5000 18 9943 12 1000-3000 

VERMONT AMERICAN CORP 

TOCCOA, GA 

19B8 8736 1590 6 2000-4000 

ta- ro 
P.33 

ATTACHMENT 3. 

PRODUCTION RATE CALCULATIONS 

3*-
P.34 

DETERMINATION OF ELECTROCHEMICAL EQUIVALENT 

ATTACHMENT 3, PART I 

£3 
EQUATIONS FOR CALCULATING THE ELECTROCHEMICAL EOUIVALENT FGR CHROMIUM 

Definition: The electrocheaical equivalent is defined as the aaount of current required 

to plate a part with a surface area of one square foot with a plate thickness of one eil 

at a cathode efficiency of 100 percent. 

Equation 1: Plate Thickness = (weight of chrosiua) 

(density of chrosiua)(surface area plated) 

Faraday's Law: During electrolysis 96,487 couloabs (aapere-seconds) of electricity reduce 

and oxidize, respectively, one gras-equivalent of the oxidizing and the reducing agent. 

Equation 2: 96,500 aapere-seconds ire required to deposit the (aetals atonic weight)/(valence) 

in grass. 

ASSUMPTIONS: 

Plate thickness = 1 ail 

Surface area of part = 1 square foot 

Cathode efficiency = 100 percent 

GIVEN: 

Density of water = 62.43 lb/ft3 

Specific gravity of CR = 7.1 

By rearranging equation 1, 

Height of chrosiua = (thickness)(density of CR)(surface area plated) 

Weight of chroaius = (.001 in/12 in/ft)(7.1){62.43 lb/ft3)(l ft2) 

Height of chroaius = ,0369 lb - 16.74 grass 

Using equation 2, 

96,500 Ampere-seconds = x Aapere-seconds x - 186400 aapere-seconds 

52 grass/+6 16.74 grass 

Converting aapere-seconds to aapere-hours, 

186400 A-s 

= 51.8 A-h is required to plate a part with a surface area of one square foot and 

3600 s/h and a plate thickness of 1 sii at a cathode efficiency of 100 percent. 

Correction for cathode efficiency of 10 percent for hexavalent chroaius, 

(51.8)(10.0) = 518 Aapere-hours required to plate a part with a surface area of one square foot 

and a plate thickness of 1 sii at a cathode efficiency of 10 percent. 

si 
P.36 

HARD CHROMIUM PLATING PRODUCTION RATE CALCULATIONS 

ATTACHMENT 3, PART II 

S55 
TABLE 1. AVERAGE SURFACE AREA-TO-VOLUME RATIOS FOR 

HARD CHROMIUM PLATING PLANTS TESTED DURING THE EMISSION 

TEST PROGRAM 

Plant 

Steel Heddle 

Roll Technology 

Greensboro Industrial 

Platers 

Able Machine Company 

Average 

Tank No. 

1 

2 

4 

1 

2 

3 

7 

1 

1 

Capacity, ft 

94 

45 

43 

161 

302 

486 

324 

347 

532 

Average 

surface 

area 

plated, 

ft 

5.63 

4.08 

4.64 

7.14 

11.48 

13.81 

5.59 

18.29 

34.74 

Surface 

area-tovolume 

rate, 

ft /ft 

0.06 

0.09 

0.11 

0.04 

0.04 

0.03 

0.02 

0.05 

0.07 

0.06 

3<t> 
HARD CHROMIUM PLATING MODEL TANKS 

Tank No. 

Dimensions, 

1, w, d (ft) Capacity, ft (gal) 

1 

2 

3 

4 

12, 3.5, 6.0 

12, 4.0, 6.0 

25, 3.0, 6.0 

4.0, 4.0, 10.0 

231 (1,728) 

264 (1,975) 

413 (3,089) 

152 (1,137) 

Surface area plated in each tank calculated by using factor of 

0.06 ft /ft from Table 1, 

Tank No. 

1 

2 

3 

4 

Capacity, 

231 

264 

413 

152 

ft3 

Volume, 

factor, ft 

0.06 

0.06 

0.06 

0.06 

/ft3 

Surface area 

plated, ft 

14.0 

16.0 

25.0 

9.0 

Process parameter assumptions: 

Plate thickness = 1 mil 

Plating time = 2 hours 

Electrochemical equivalent = 

mil • ft 

at 10 percent cathode efficiency 

Ampere-hour requirement for each tank to plate the surface area values 

stated above, 

Tank No. 

Plate 

thickness, 

mils 

Electrochemical 

equivalent. 

A-h/miWt 

518 • 

518 

518 

518 

Surface2 

area, ft 

14.0 

16.0 

25.0 

9.0 

A«h 

7,250 

8,290 

12,950 

4,660 

1 

2 

3 

4 

2>7 
P.39 

Current settings for each model tank, 

Tank No. 

1 

2 

3 

4 

Model plant 

Small model 

product 

plant 

Ampere-hour 

requirement 

7,250 

8,290 

12,950 

4,660 

ion rates 

Plating time, h 

2.0 

2.0 

2.0 

2.0 

Current amps 

3,625 

4,145 

6,475 

2,330 

No. of tanks = 1 

Size of tank = 12, 3.5, 6.0 (Tank No. 1) 

Current setting of tank = 3,625 

Operating time = 2,000 h/yr 

Percent time electrodes are energized = 70 percent 

Ampere-hours/year = (3,625 A)(2,000 h/yr)(0.70) = 5.0xl06 A*»h/yr 

Medium model plant 

No. of tanks = 

Size of tanks = 

Current settings = 

Operating time = 

1 at (4.0, 4.0, 10.0) (Tank No. 4) 

2 at (12.0, 4.0, 6.0) (Tank No. 2) 

1 at (25.0, 3.0, 6.0) (Tank No. 3) 

1 at 2,330 amperes 

2 at 4,145 amperes 

1 at 6,475 amperes 

3,500 h/yr 

Percent time electrodes are energized = 70 percent 

Ampere-hours/year = [(2,330 A)+(2)(4,145 A)+(6,475 A)](3,500 h/yr)(0.70) = 

42.0x10 A»h/yr 

sf 
P.40 

Large model plant 

No. of tanks = 8 

Size of tanks = 2 at (4.0, 4.0, 10.0) (Tank No. 4) 

4 at (12.0, 4.0, 6.0) (Tank No. 2) 

2 at (25.0, 3.0, 6.0) (Tank No. 3) 

Current settings = 2 at 2,330 A 

4 at 4,145 A 

2 at 6,475 A 

Operating time = 6,000 h/yr 

Percent time electrodes are energized = 80 percent 

Ampere-hours/year = [2(2,330 A)+4(4,145)+2(6,475)](6,000 h/yr)(0.80) = 

164x10 A-h/yr 

i? 
P.41 

DECORATIVE CHROMIUM PLATING PRODUCTION RATE CALCULATIONS 

ATTACHMENT 3, PART III 

#6 
Surface area-to-volume ratio for decorative chromium plating operations 

GMC-Delco Test Data 

No. of tanks = 1 

Size of tank = (20.0, 12.0, 9.0) 

Capacity = 2,040 ft (15,260 gallons) 

Tank holds = Three racks of bumper 

Rack contains = 8 bumpers 

Square footage in tank = (3 racks)(8 bumpers/rack)(8 ft /l bumper) = 

192 ft2 

192

3

ft3 Part s = 0.09 ftVft3 

2,040 ft plating solution 

DECORATIVE CHROMIUM PLATING MODEL TANKS 

Dimensions, 

Tank No. 1, w, d (ft) Capacity, ft (gal) 

1 12.0, 3.5, 6.0 231 (1,728) 

2 12.0, 6.0, 9.0 612 (4,578) 

Surface2area plated in each tank calculated by using factor of 

0.09 ft /ft from above, 

3 Volum^ 3 Surface are£ 

Tank No. Capacity, ft factor, ft /ft plated, ft 

1 231 0.09 21 

2 612 0.09 55 

Process parameter assumptions: 

Plate thickness = 0.012 mils 

Plating time = 30 minutes = 0.05 hours 

518 A#h Electrochemical equivalent = j- at 10 percent cathode efficiency 

mil-ft 

ft 
P.43 

Ampere-hour requirement for each tank to plate the surface area values 

stated above, 

Tank No. 

1 

2 

Current 

Tank No. 

1 

2 

Plate 

thickness, 

mils 

0.012 

0.012 

settings for each model 

Ampere-hour 

requirement 

130 

340 

Electrochemical 

equivalent, 

A'h/miWt 

518 

518 

tank, 

Plating time, 

0.05 

0.05 

Surface2 

area, ft A»h 

21 130 

55 340 

, h Current amps 

2,600 

6,800 

Model plant production rates 

Small model plant 

No. of tanks = 1 

Size of tank = (12.0, 3.5, 6.0) (Tank No. 1) 

Current setting of tank = 2,600 amperes 

Operating time = 2,000 h/yr 

Percent time electrodes are energized = 60 percent 

Ampere-hours/year = (2,600 A)(2,000 h/yr)(0.60) = 3.0xl06 A»h/yr 

Medium model plant 

No. of tanks = 

Size of tanks = 

Current settings = 

Operating time = 

2 at (12.0, 3.5, 6.0) (Tank No. 1) 

2 at 2,600 amperes 

4,000 h/yr 

Percent time electrodes are energized = 60 percent 

Ampere-hours/year = (2)(2,600 A)(4,000 h/yr)(0.60) = 12.0xl06 A»h/yr 

//& 
P.44 

Large model plant 

No. of tanks = 5 

Size of tanks = 5 at (12.0, 6.0, 9.0) (Tank No. 2) 

Current settings = 5 at 6,800 A 

Operating time = 6,000 h/yr 

Percent time electrodes are energized = 60 percent 

Ampere-hours/year = (5)(6,800 A)(6,000 h/yr)(0.60) = 122xl06 A«h/yr 

*&