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# OAR Box 1313 Prepped by LaTeia Shed



## Document

Number: 

# 78 ) ll-B-5 2 Docket Number: 

# A-88-0 2

Printed 6/12/20089:03:31 AM

Sheet 78of 99P. 2 

# MRI ® A-88-0 2 MIDWES TRESEARC H INSTITUT E X
- B-i'p Z Suite 35 0 40 1 Harriso n Oak

s Boulevar

d Cary

. N.C

. 2751 3



## Date : Jun e 13 , 198 8

(Finalize dAugus t 23 , 1988 ) Subject : Revise dMode l Plan t Parameters , Baselin e Controls , an d Regulator y

Alternative s fo r Chromiu m Electroplatin g an

dChromi c Aci dAnodizin g Operation s Chromiu m Electroplatin g NESHA P EP A Contrac t 68-02-3817 ; ES DProjec t 85/02 a ..-•:-• ' \ MR I Projec t 7717- K.,- • •:. • ' 7 ...,.-••"8 , • ' .."•

• • - " i . 8 

## From : Robi nBarker W 7 ' ... p\Y\\ \ To : Andre w

M . Smit hfr? * ..7\vA' , ESD/ISB/SS S (MD-13 ) ••••.• • \ ^*^%

^ - ^ U . S . Environmenta l Protectio nAgenc y \..- 7 .-~-"7 " " v 

## ^^3--" " Researc hTriangl e Park , N.C . 2771 1 \-7 \ \ . '. •5--' " I . Introductio n Preliminar y

mode l plan t parameter s fo r chromiu m electroplatin g an

d chromi c aci danodizin g facilitie s wer e develope dinDecembe r 198 6 (se e memorandu m from Strait , R. , MRI , t o Vervaert , A. , EPA/IS B [Decembe r 19 , 1986]) . Becaus e Offic e o f Managemen t an dBudge t approva l o f th e Sectio n11 4 informatio ncollectio nwa s no t receive dunti l Jun e 198 7 an d th e Sectio n11 4 informatio nreques t response s wer e no t receive dunti l Decembe r 1987 , thes e preliminar y mode l plant s wer e base donPhas e I Sectio n11 4 informatio nreques t responses , tri prepor t data , an dtelephon e contac t surveys . InMarc h1988 , the projec t tea m reevaluate dth e preliminar y mode l plan t parameter s usin g th e expande ddat a bas e develope dfro m th e * Sectio n11 4 infonnatio ncollectio nan dplan t visit s conducte dt o evaluat e candidat e facilitie s fo r testing . Table s 1 , 2 , an d3 presen t the revise d mode l plan t parameter s develope da s a resul t o f thi s reevaluation. . Th e majo r mode l plan t parameter s tha t wer e revise dwere : (1 ) plan t operatin g hours , (2 ) percen t tim e electrode s ar e energized , (3 ) operatin g current , an

d(4 ) productio nrat e interm s o f ampere-hour s pe r year . Som e adjustment s wer e als o mad e t o th e capacit y value s o f the mode l plant s t o represen t mor e accuratel y th e dat a containe dinthe expande ddat a base . Baselin e assumption s hav e als o bee nrevised . Assumption s oncontro l technique s applie dar e base doninformatio nobtaine dfro m th e Sectio n11 4 informatio ncollection . Assumption s regardin g achievabl e performanc e associate dwit heac htyp e o f contro l techniqu e applie dar e base donthe result s o f th e emissio ntes t program . Informatio nonbaselin e i s presente di nSectio nV

o f thi s memorandum .

/P. 3



### Sectio nV I o f thi s memorandum present s th e regulator y alternative s unde r consideration . Th e leve l o f emissio nreductio nassociate dwit heac h alternativ e ha s bee nrevise dbase donth e averag e performanc e leve l o f eac hcontro l device . II . Sectio n11 4 Informatio nDat a Bas e Infonnatio nobtaine dthroug hth e Sectio n11 4 informatio ncollectio n wa s compile dint o a dat a base . The.dat a bas e i s summarize din Attachmen t 1 . Th e dat a bas e contain s genera l informatio nfo r eac hplan t (name , location , an

dcontac t person) ; specifi c informatio nregardin g th e chromiu m platin g o r anodizin g operation , emissio ncontro l devices , stac k parameters ; an

deconomi c information . Thi s informatio nwa s obtaine dfo r 12 0 plant s whic hoperat e 21 5 har dchromiu m platin g tanks , 10 2 decorativ e chromiu m platin g tanks , an

d3 1 chromi c aci danodizin g tanks . Th e informatio ncollecte dwa s segregate daccordin g t o typ e o f operatio n(i.e. , har dplating , decorativ e plating , o r anodizing) . In severa l instances , a nindividua l facilit y reporte dtha t i t performe dmor e tha non e typ e o f operation . I naddition , insom e case s th e same proces s tankwa s use dt o perform two differen t operations . Facilitie s wit htwo o r mor e differen t operation s ar e treate da s i f eac hoperatio ni s an individua l facility . I f mor e tha non e operatio ni s performe di nth e same tank , tha t tan ki s categorize daccordin g t o th e operatio nfo r whic hi t i s use dth e majorit y

o f th e time . III . Tri pRepor t Dat a Bas e A tri prepor t dat a bas e wa s develope dusin g informatio nobtaine d fro m 1 7 hardchromiu

m platin g facilities , 1 1 decorativ e chromiu m platin g facilities , an

d3 chromi c aci danodizin g facilities . Th e tri prepor t dat a bas e contain s th e followin g information : (1 ) typ e o f operation , (2 ) plan t operatin g time , (3 ) numbe r o f proces s tanks , (4 ) tota l tankcapacity , an d (5 ) operatin g curren t an dvoltag e o f th e process . Thi s dat a bas e i s presente dinAttachmen t 2 an dwa s combine dwit hth e Sectio n11 4 dat a bas e fo r developin g mode l plan t parameters . IV . Developmen t o f Har dan dDecorativ e Chromiu m Electroplatin g an

d Chromi c Aci dAnodizin g Mode l Plant s Two constraint s wer e assume dinth e reevaluatio no f th e mode l plan t parameters : (1 ) th e contro l devic e configuration s woul dremai nthe same a s thos e develope dfo r th e preliminar y mode l plants , an

d(2 ) th e mode l tanksize s woul dremai nth e same . Bot hthe Sectio n11 4 an dtri prepor t informatio nwer e use dt o develo pth e revise dmode l plants . Th e analysi s include ddevelopmen t o f a frequenc y distributio nt o establis hth e mode l plan t size s an

da nevaluatio no f th e availabl e dat a onproces s operatin g condition s t o determin e typica l operatin g parameter s withi nvariou s plan t siz e ranges .

< ^P. 4



### A . Determinatio no f Mode l Plan t Size s Frequenc y

distribution s wer e prepare dusin g dat a ontota l tank volume s pe r plan t inth e hardan ddecorativ e chromiu m dat a bases . Thes e frequenc y

distribution s ar e show ninFigure s 1 an

d2 an dwer e use dt o determin e mode l plan t sizes . Thre e mode l plan t sizes , representativ e o f small , medium , an

dlarg e facilities , wer e selecte dfo r bot hth e hardan d decorativ e chromiu

m categories . Th e tankvolum e cutof f value s selecte d fo r har dchromiu

m electroplatin g shop s ar e les s tha n15,10 0 liter s (a ) (4,00 0 gallo n[gal] ) fo r a small-siz e plant , betwee n15,10 0 a an d37,85 0 a (4,00 0 an

d10,00 0 gal ) fo r a medium-siz e plant , an dgreate r tha n37,85 0 a (10,00 0 gal ) fo r a large-siz e plant . Th e cutof f value s fo r decorativ e chromium electroplatin g plant s ar e les s tha n7,57 0 a (2,00 0 gal ) fo r a small-siz e plant , betwee n7,57 0 a an d30,28 0 a (2,00 0 an d8,00 0 gallons ) fo r a medium-siz e plant , an dgreate r tha n30,28 0 a (8,00 0 gal ) fo r a large-siz e plant . A frequenc y

distributio nwa s no t use dt o determin e mode l plan t size s fo r chromi c aci danodizin g operation s becaus e i t wa s eviden t tha t al l bu t on e o f th e operation s coul db e divide dint o two , distinc t siz e ranges . Th e tota l tankvolume a t smal l operation s range dfro m 37 8 t o 7,57 0 a (10 0 t o 2,00 0 gallons) , an da t larg e operation s wa s ove r 37,87 0 a (10,00 0 gal) . On e operatio nreporte da tankvolume o f 2,73 0 a (7,20 0 gal) . Onl y

smal l an

dlarg e mode l plant s wer e define dfo r anodizin g operations . B . Proces s Parameter s Th e firs t se t o f proces s parameter s tha t wa s evaluate dfo r th e purpos e o f revisin g th e mode l plan t parameter s include d(1 ) numbe r o f tanks , (2 ) tota l tankcapacity , (3 ) operatin g time pe r year , an d (4 ) percen t time electrode s ar e energized . Th e informatio ni nth e dat a base s wa s groupe daccording t o th e mode l plan t size , an daverag e value s wer e calculate dfo r eacho f thes e parameters . Thes e averag e value s wer e the nuse da s th e base s fo r revisin g th e preliminar y mode l plan t parameters . Othe r proces s parameter s suc ha s chromi c aci dconcentration , sulfat e ratio , an

dtemperatur e o f th e platin g solutio nwer e revise da s neede dbase do na genera l review o f th e informatio nprovide db y al l plants . Th e operatin g curren t an dproductio nrat e values , expresse di nterm s o f ampere-hour s pe r year , fo r eac hhardan ddecorativ e chromiu m mode l plan t wer e revise dbasedonth e modifie dindividua l tan kparameter s an

d tankcapacit y

informatio ncollecte ddurin g th e emission s tes t program . Attachmen t 3 present s th e derivatio no f thes e value s fo r eac hhardan d decorativ e chromiu

m plating mode l plant . C . Captur e System , Contro l Device , an dStac kParameter s Parameter s fo r captur e systems , contro l devices , an dstack s wer e revised , a s appropriate , basedo nmodification s t o th e contro l devic e configuration s fo r eac hmode l plan t an dtechnica l dat a an

dcos t quotation sP. 5



### supplie db

y vendor s fo r eac ho f th e applicabl e contro l techniques . Th e contro l devic e configuration s fo r eac hmode l plan t ar e show ninFigure s 3 throug h7 . V . Baselin e Contro l Level s an dEmission s Baselin e contro l level s fo r eac htyp e o f operatio nwer e revise d base do ndat a inth e Sectio n11 4 informatio ndat a base . Informatio non contro l technique s applie dwa s obtaine dfro m 4 4 hardchromiu

m platin g facilities , 6 3 decorativ e chromiu m platin g facilities , an d2 5 chromi c aci d anodizin g facilities . A summary o f thes e dat a i s presente dinTabl e 4 . Th e revise dbaselin e leve l o f contro l fo r eac htyp e o f operatio ni s als o presente dinTabl e 4 . Fo r operation s tha t us e tw o differen t contro l device s i nseries , th e operatio nwa s considere dt o operat e wit honl y the mor e efficien t contro l device . Th e averag e performanc e leve l fo r eac h typ e o f contro l devic e wa s determine dfro m th e emission s tes t program , (se e Tabl e 5) . Uncontrolle demissio ndat a fo r eigh t har dchromiu m plating operation s an

dtw o decorativ e chromiu m platin g operation s ar e presente din Tabl e 6 . A

nuncontrolle dhexavalen t chromiu m emissio nfacto r o f 1 0 milligram s pe r ampere-hou r (mg/A»h ) (0.1 5 grain s pe r ampere-hou r [gr/A»h] ) i s considere dt o b e representativ e o f uncontrolle demission s fro m a hardchromiu

m electroplatin g operation . A nuncontrolle dhexavalen t chromiu m emissio nfacto r o f 2. 0 mg/A- h(0.03 0 gr/A-h ) i s considere dt o be representativ e o f a decorativ e chromiu m electroplatin g operation . Uncontrolle demissio ndat a fo r chromi c aci danodizin g wer e no t obtaine dthroughsourc e testin g o f ananodizin g facility . Instead , a mas s balanc e determinatio nwa s conducte do na scrubbe r use dt o contro l emission s fro

m a chromi c anodizin g operation . Th e result s o f thi s mas s balanc e indicat e tha t anuncontrolle dhexavalen t chromiu m emissio nfacto r o f 0. 6 m g pe r hou r pe r squar e mete r (mg/h/ m ) (0.00 9 grain s pe r hou r pe r squar e foot ) o f tanksurface^re a i s appropriat e t o characteriz e emission s fro m thi s typ e o f operation . VI . Regulator y

Alternative s Th e regulator y

alternative s unde r consideratio nfor eac htyp e o f operatio nar e presente dinTabl e 7 . Thes e regulator y alternative s wil l b e evaluate dt o determin e th e environmental , cost , an deconomi c impact s o f variou s level s o f chromiu m emissio nreduction .

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; Duc t Coaponen t ! Specificatio n

!Ga s flo w rate , cf a
'Duc t diameter , in . :Duc t length , ft . !No . o f 3 0 degre e entrie s
!No . o f on e ste ptaper s
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m plating , smal l chromi c aci danodizing an

dsmal l hardchromiu m plating mode l tanks .

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e elbo w 2,00 0 5,00 0 8,00 0 11,00 0 14,00 0 2,34 4 4,68 8 7,03 2 9,37 6 18,75 2 32,75 2

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an dductwor kspecification s o f th e mediu m an dlarg e har d chromium platin g mode l plant . o o



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### Figur e 5 . Pla n vie wand ductwor k specification s o f tw o 12-foo t tank s fo r th e larg e decorativ e chromiu m platin g mode l plant . 

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. Pla n vie wan d ductwor k specificatio n o f th e on e 12-foo t o f th e larg e decorativ e chromiu m platin g mode l plant

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an dductwor kspecification s o f th e larg e chromi c aci d anodizin g mode l plant .
C s ra N

## TABL E 1 . MODE L PLAN T PARAMETER S FO RHAR DCHROMIU

M ELECTROPLATINGOPERATIONS 3

Plan t siz e Parameter s Sma l 1
5.0x10 6 7 0 1,13 0 (2,500 )

8 5 5 0 2,00 0 1 3.6 , 1.1 , 1. 8 (12.0 , 3.5 , 6.0 )

6,55 0 (1,730 ) 4. 0 (42 ) 25 0 (33 ) Sulfuri c aci d 2. 5 (0.33 ) 49-6 5 (120-150 )

6- 9 3,62 5 2,80 0 (260 ) Double-side d latera l 30 0 (10,500 )

1 34 0 (12,000 ) Me d1u m 42x10 6 7 0 5,67 0 (12,500 )

1 4 5 5 0 3,50 0 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 ) 30,93 0 (8.170 ) 1 7 ift87 ) 25 0 (33 ) Sulfuri c aci d 2. 5 (0.33 ) 49-6 5 (120-150 )

6- 9 2,330 , 2 6 4,145 ,

6,47 5 2,80 0 (260 ) Push-pul1 , double-side d latera l 87 0 (30,750 )

1 99 0 (35,000 ) Larg e 160xl0 6 8 0 14,70 0 (32,500 )

2 4 5 5 0 6,00 0 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 ) 61,85 0 (16,340 ) 3 5 (374 ) 25 0 (33 ) Sulfuri c aci d 2. 5 (0.33 ) 49-6 5 (120-150 )

6- 9 2 6 2,330 , 4 §

4,145 , 2 S 6,47 5 2,80 0 (260 ) Push-pul1 , double-side d latera l 2 6 87 0 (30,750 )

2 2 § 99 0 (35,000 ) A . Productio nrat e Tota l ampere-hour s pe r yea r Tim e electrode s ar e energized , % Chromi c aci dusage , kg/y r (lb/yr ) B . Operatin g time Hours/da y Days/wee k Weeks/yea r Hours/yea r C . Proces s Numbe r o f tank s Tan k dimensions , (I , w , d) , m (ft )

Tota l tan kcapacity , 4 , (ga4) D9 Tota l tan k surfac e area , n r (f t ) Chromi c aci dconcentration , g/S , (oz/gal ) Catalys t Catalys t concentration , g/fl , (oz/gal ) Temperatur e o f platin g solution , * C ("F ) Tan koperatin g voltage , V Tan koperatin g current , ampere s Curren t density , A/m 2 (A/ft 2 ) Emissio ncaptur e system Typ e o f hoo d 3 " S r Ventilatio nrate , m/mi n(ft/min ) E . Contro l techniqu e Contro l devic e Numbe r o f contro l device s , Inle t ga s flo

w rate , nr/mi n(ft^/mln) 1 3 r o

(continued )

"X 

# V

## TABL E 1 . (continued ) Plan t siz e Parameter s Sma l 1
2 7 (80 ) 2 0. 5 (2 ) 40 0 (3 ) 0.7 5 (3 ) 80 0 (6 ) 0.1 9 (0.75 ) 0. 5 .(2 ) 0.2 5 (1 ) 1 9. 1 (30 ) 1. 0 (3.3 ) 2 7 (80 ) 2 34 0 (12,000 ) 91 0 (3,000 ) Medium
2 7 (80 ) 2 0. 5 (2 ) 40 0 (3 ) 0.7 5 (3 ) 80 0 (6 ) 0.1 9 (0.-75 ) 0. 5 (2 ) 0.2 5 (1 ) 1 9. 1 (30 ) 1. 1 (3.8 ) 2 7 (80 ) 2 99 0 (35,000 ) 91 0 (3,000 ) 

## L

0 . arg e
2 7 (80 ) 2 0. 5 (2 ) 40 0 (3 ) 0.7 5 (3 ) 80 0 (6 ) 1 9 (0.75 ) 0. 5 (2 ) 0.2 5 (1 ) 2 9. 1 (30 ) 2 § 1. 1 (3.8 ) 2 7 (80 ) 2 2 6 99 0 (35,000 ) 91 0 (3,000 ) Contro l devic e (continued ) Inle t ga s temperature , * C (*F ) Inle t ga s moisture , % 1 . Singl e packed-be dscrubber , AP , kP a (In . w.c. ) Liquid-to-ga s ratio , i/min/1,00 0 nr/mi n (gal/min/1,00 0 ftVmin ) 2 . Doubl e packed-be dscrubber , AP , kP a (In . w.c. ) Liquid-to-ga s ratio , S,/min/1,00 0 nr/mi n (g a l/ m In/1,00 0 ft-Vmin ) 3 . Chevron-blad e mis t eliminato r wit hsingl e se t o f blade s AP , kP a (In . w.c. ) 4 . Chevron-blad e mis t eliminato r wit hdoubl e se t o f blades , AP , kP a (in . w.c. ) Mesh-pa dmis t eliminator , AP , kP a (in . w.c. ) 5 Stac k stack s

(ft) e Numbe r o f Height , m Diameter , m

(ft ) Temperature , * C (*F ) Moisture , % Ga s flo w rate , nr/mi n(ft*vmin ) Ga s velocity , m/mi n(ft/min ) Paramete r value s for th e small , medium , an dlarg e plan t size s ar e base do ninformatio nobtaine dfro m Sectio n11 4 informatio n request s an

dtri prepor t information . ^Tank freeboar dspac e = 6 Inches . |:Th e ventilatio nrate s fo r th e captur e system s wer e base do nguideline s develope db y th e America nNationa l Standard s Institute . An y contro l devic e ma y b e use dat an

y give nplant . ^Ventilatio nrate s wer e rounde dt o th e ga s flo w rate s fo r whic hfactory-assemble dcontro l device s ar e avallable . Stac kheigh t i s th e distanc e fro m groun dleve l t o th e poin t o f discharge .



# U f

## TABL E 2 . MODE L PLAN T PARAMETER S FO RDECORATIVE CHROMIU

M ELECTROPLATINGOPERATIONS '

Parameter s Sma l I Plan t siz e Medium Larg e

C .

D . Productio nrate Tota l ampere-hour s pe r yea r Time electrode s ar e energized , % Chromi c aci dusage , kg/y r (lb/yr ) Operatin g time Hours/da y Days/wee k Weeks/yea r Hours/yea r Proces s Numbe r o f tank s Tan kdimensions , (I , w , d) , m (ft ) Tota l tankcapacity , 8, (ga-J) D- > Tota l tanksurfac e area , m (f t Chromi c aci dconcentration , Catalys t g/S , (oz/gal ) Chromi c acid-to-catalys t rati o Temperatur e o f platin g solution , ' C CF ) Tank operatin g voltage , V Tank operatin g current , ampere s Curren t density , A/n r (A/ft z ) Emissio ncaptur e system Typ e o f hoo d Ventilatio nrate , m 3 /mi n(ft 3 /min) c d
E . Contro l techniqu e 1 . Chemica l fum

e suppressan t usage , kg/y r o r H/y r (lb/yr o r gal/yr ) 2 . Contro l devic e Numbe r o f contro l device s Inle t ga s flo

w rate , nr/mi n(ftvmin ) Inle t ga s temperature , * C (*F ) Inle t ga s moisture , % 3.0x10 ° 6 0 90 0 (2,000 )

8 5 5 0 2,00 0
1 3.6 , 1.1 , 1. 8 (12.0 , 3.5 , 6.0 ) 6,55 0 (1,730 ) 4. 0 (42 ) 30 0 (40 ) Sulfuri c aci do r fluorid e 100: 1 38-4 6 (100-115 )

6 2,60 0 1,33 0 (124 ) Double-side d latera l 30 0 (10,500 )

1 7 o r 12 0 (3 7 o r 32 )

1 34 0 (12,000 ) 2 7 (80 ) 2 12x10 ° 6 0 6,80 0 (15,000 )

1 6 5 5 0 4,00 0

2 § 3.6 , 1.1 , 1. 8 (12.0 , 3.5 , 6.0 ) 13,10 0 (3,460 ) 8. 0 (84 ) 30 0 (40 ) Sulfuri c aci do r

fluorid e 100: 1 38-4 6 (100-115 )

6 2 S 2,60 0 1,33 0 (124 ) Double-side d latera l 2 6 30 0 (10,500 )

6 7 o r 48 0 (14 8 o r 128 )
2 § 34 0 (12,000 )

2 7 (80 ) 2 120x10 ° 6 0 68,00 0 (150,000 )

2 4 5 5 0 6,00 0

5 § 3.6 , 1.8 , 2. 7 (12.0 , 6.0 , 9.0 ) 86,65 0 (22,890 ) 3 3 (360 ) 30 0 (40 ) Sulfuri c aci do r

fIuo r i d e 100: 1 38-4 6 (100-115 )

1 0 5 6 6,80 0 1,33 0 (124 ) Push-pu l I 25 5 (9,000 ) 2 g 51 0 (18,000 )
29 5 o r 2,08 0 (65 0 o r 550 )
28 0 (10,000 ) 2 e 51 0 (18,000 ) 2 7 (80 ) 2 (continued )

* T l Ei i

### TABL E 2

. (continued )

^ Plan t siz e Parameter s Smal I • Me d Iu mLarg e Contro l devic e (continued ) a . Singl e packed-be d scrubbe r AP , kP a (In . w.c. ) 0. 5 (2 ) 0. 5 (2 ) 0. 5 (2 ) Liquid-to-ga s ratio , 8,/min/ l ,00 0 nT/ml n 40 0 (3 ) 40 0 (3 ) 40 0 (3 ) (gal/min/1,00 0 ft-Vmln ) b . Doubl e packed-be d scrubbe r AP , kP a (In . w.c. ) 0.7 5 (3 ) 0.75(3 ) 0.75(3 ) Llquld-to-ga s ratio , H/mln/1,00 0 m*Vml n 80 0 (6 ) 80 0 (6 ) 80 0 (6 ) (gal/min/1,00 0 ft*Vmln ) c . Chevron-blad e mis t eliminato r wit h singl e se t o f blades , 0.1 9 (0.75 ) 0.1 9 (0.75 ) 0.1 9 (0.75 ) AP , kP a (in
. w.c. ) d . Chevron-blad e mis t eliminato r wit h doubl e se t o f blades , 0. 5 (2 ) 0. 5 (2 ) 0. 5 (2 ) AP , kP a (In . w.c. ) e . Mesh-pad mis t eliminato r AP , kP a (in.w.c. ) 0.2 5 (1 ) 0.2 5 (1 ) 0.2 5 (1 ) F . Stac k Numbe r o f stack s 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 ) 2 7 (80 ) 2 7 (80 ) 2 7 (80 ) Moisture , %2 2 2 Ga s flo wrate , nT/mi n (ft-Vmln ) 34 0 (12,000 ) 2 %34 0 (12,000 ) 28 0 (10,000 ) 2 § 51 0 (18,000 ) Ga s velocity , m/mi n (ft/mln ) 91 0 (3,000 ) 91 0 (3,000 ) 91 0 (3,000 )

a II I Paramete r value s for the small , medium , an d larg e plan t size s ar e base d o n information obtaine d fro mSectio n 11 4 information request s an

d tri p repor t data . .Tan k freeboard spac e = 6 inches
. c Fo r the mediu

msiz e mode l plant , th e tw o tank s ar e vente d t o tw o separat e contro l devices
. Fo e th e large mode l plan t tank s ar e vented t o thre e separat e contro l devices
. On e tan k wit h a ventilatio n rat e o f 25 5 nr/mi n (9,00 0 ft/min ) i < ant , the fiv

e i s vente d t o on e contro l devic e an d two tank s each wit h a combine d ventilatio n rat e o f 51 0 nrVml n (18,00 0 ft-Vmin ) ar e vente d t o tw o separat e contro l devices
. The ventilatio n rate s for the captur e system s wer e base d o n guideline s develope d b ythe American Nationa l Standard s Institute
. Afum e suppressan t alon e o r I n combinatio n wit h a scrubbe r o r mis t eliminato r ma yb e used a t an

y give n plant . Ventilatio n rate s wer e rounded t o the ga s flo wrate s fo r whic h factory-assemble d contro l device s ar e available
. -"Stac k heigh t i s the distanc e fro mgroun d leve l t o th e poin t o f discharge
.TABL E 3 . MODE L PLAN TPARAMETER S FO R CHROMI C ACI D ANODIZIN G OPERATIONS' 1
Parameter s Plan t siz e Sma l 1

7 0 43 0 (1,000 )

8 5 5 0 2,00 0 1 3.6 , 1.1 , 1. 8 (12.0 , 3.5 , 6.0 ) 6,55 0 (1,730 ) 4. 0 (42 ) 7 5 (10 ) 32-3 5 (90-95 ) 2 0 o r 4 0 Double-side dlatera l

29 7 (10;500 ) 9. 0 (20 ) 1 34 0 (12,000 ) 2 7 (80 ) 2 0. 5 (2 ) 40 0 (3 ) 0.7 5 (3 ) 80 0 (6 ) 0.1 9 (0.75 ) Larg e
4 0 5,90 0 (13,000 )

2 4 5 5 0 6,00 0 2 2 § 9.1 , 1.5 , 2. 7 (30.0 , 5.0 , 9.0 ) 72,19 0 (19,070 ) 2 8 (300 ) 7 5 (10 ) 32-3 5 (90-95 ) 2 0 o r 4 0 Push-pul 1 1,06 0 (37,500 )
7 2 (160 ) 1 1,13 0 (40,000 ) 2 7 (80 ) 2 0. 5 (2 ) 40 0 (3 ) 0.7 5 (3 ) 80 0 (6 ) 0.1 9 (0.75 ) A . Productio nrat e Tim e electrode s ar e energized , % Chromi c aci dusage , kg/y r (lb/yr ) B . Operatin g tim e Hours/da y Days/wee k Weeks/yea r Hours/yea r Proces s C . Numbe r o f tank s Tan kdimensions , (I , w , d) , m (ft ) Tota l tankcapacity , 8 . (gaJ, ) 7 Tota l tan ksurfac e area , n r (ft - * ) Chromi c aci dconcentration , g/ i (oz/gal ) Temperatur e o f platin g solution , * C CF ) Tan k operatin g voltage , V Emissio ncaptur e system Typ e o f hoo d Ventilatio nrate , nr/mi n(f t /min) c Contro l techniqu e 1 . Chemica l fum

e suppressan t usage , kg/y r (lb/yr ) 2 . Contro l devic e Numbe r o f contro l device s , Inle t ga s flo

w rate , nr/mi n(f t /mln) e Inle t ga s temperature , " C CF ) Inle t ga s moisture , % (in . w.c. ) , /mi n(gal/min/1,00 0 ft-Vmln )

c. ) al/min/1,00 0 ffVmin ) Singl e packed-be dscrubber , AP , kP a Liquid-to-ga s ratio , £/mln/1,00 0 m Doubl e packed-be dscrubber , AP , kP a (in . w Liquid-to-ga s ratio , 2,/min/ l ,00 0 nr/mi n(g<j./....../.. ww u. , Chevron-blad e mis t eliminato r wit hsingl e se t o f blades , AP , kP a (in . w.c. ) Chevron-blad e mis t eliminato r wit hdoubl e se t o f blades , AP , kP a (in . w.c. ) Mesh-pa dmis t eliminator , AP , kP a (in . w.c. ) 0. 5 (2 ) 0.2 5 (1 ) 0. 5 (2 ) 0.2 5 (1 ) CT

i

(continued )


# fc T l

### TABL E 3 . (continued ) Plan t siz e Parameter s Sma l Larg e F . Stac k stack s Numbe r o f Height , m

(ft) ' Diameter , m

(ft ) Temperature , ' C CF ) Moisture , $

, Ga s flo w rate , nr/mi n(ft/mln ) Ga s velocity , m/ml n(ft/min ) 1 9. 1 (30 ) 0. 7 (2.3 ) 2 7 (80 ) 2 34 0 (12,000 ) 91 0 (3,000 ) 1 9. 1 (30 ) 1. 2 (4.1 ) 2 7 (80 ) 2 1,13 0 (40,000 ) 91 0 (3,000 ) Paramete r value s fo r th e smal l an dlarg e plan t size s ar e base do ninforraationobtaine dfro m Sectio n11 4 Informatio nrequest s and .tri prepor t data . Tan kfreeboar dspac e = 6 inches . ^Th e ventilatio nrate s fo r th e captur e system s wer e base do nguideline s develope db y th e America nNationa l Standard s Institute . A fume suppressan t alon e o r i ncombinatio nwit ha scrubbe r o r mis t eliminato r ma y b e use da t any

give nplant . .Ventilatio nrate s wer e rounde dt o th e ga s flo w rate s fo r whic hfactory-assemble dcontro l device s ar e available . Stac kheigh t i s th e distanc e fro m groun dleve l t o th e poin t o f discharge .

^ M T l 0 0P.1 9



## TABL E 4 . 1 8

BASELIN E LEVEL S O F CONTRO L FO RCHROMIU

M PLATIN GAN D ANODIZINGOPERATION S
Operation/contro l techniqu e Decorativ e plating Fum e suppressan t Fum e suppressan t an

dscrubbe r Fum e suppressan t an

dmis t eliminato r Scrubbe r Mis t eliminato r Uncontrolle d Tota l Hardplatin q Fum e suppressan t Fum e suppressan t an

dscrubbe r Fum e spressan t an

dmis t eliminato r Scrubbe r Mis t eliminato r Electrostati c precipitato r Uncontrolle d Tota l Chromi c aci danodizin g Fum e suppressan t Fum e spressan t an

dmis t eliminato r Scrubbe r Mis t eliminato r Uncontrolle d Tota l Plan t No .

2 8 1 7 3 4 2 9 6 3

3 4 3 1 3 7 1 1 3 4 4

6 1 5 2 1 1 2 5 dat a Percen t

4 5 2 7 5 6 3 1 4 10 0

7 9 7 3 0 1 6 2 3 0 10 1

2 4 4 2 0 8 4 4 10 0 Baselin e

condition , percen t

8 0
5 1 5 10 0

4 0 3 0 3 0 10 0

3 0 2 0 1 0 4 0 10 0

/ /

### TABL E 5 . PERFORMANC E LEVEL S O F INDIVIDUA L CONTRO L DEVICE S

Plan t Contro l devic e No . o f tes t run s Averag e

remova l efficienc y fo r Cr + 

### , percen t Ref . Hardchromiu

m platin g Abl e Machin e Company Consolidate dEngraver s Corp . Greensbor o Industria l Plater s
Norfol kNava l Shipyar d Carolin a Platin g Company Piedmon t Industria l Plater s Stee l Heddl e Company Rol l Technolog y

Decorativ e chromiu

m platin g Automati c Di e Castin g Specialties , Inc . Automati c Di e Castin g Specialties , Inc . Mis t eliminato r (doubl e se t o f overlappin g typ e blades ) Mis t eliminato r (singl e se t o f wave-typ e blades ) Mis t eliminato r (singl e se t o f wave-typ e blade s Mes hpadmis t eliminato r Doubl e packed-be dscrubbe r Singl e packed-be dscrubbe r Doubl e packed-be dscrubbe r Doubl e packed-be d scrubbe ri n conjunctio n wit h a mis t eliminato rcontainin g a singl e se t o f wave-typ e blade s
Foa m blanke t Wettin g agent/foa m blanke t 3 3
4 3 3 1 2 3 6 9 8

9 1
8 8 94 a 

### 96 a 

### 9 9 9 6 9 5 1

2
3
4 5 6 7 8

3 3 >9 9

>9 9 9

9 la

O

a 

### Base do ntota l chromiu m emissio ndata .

## TABL E 6 . UNCONTROLLE DEMISSIO N TES T DATA a

Plan t No . o f tes t run s Proces s condition s

No . o f tank s Tota l tank

surfac e area , m 2 " (ft 2 ) Ampere hour s Actua l

ga s flo w rate , m / m I n (ft 3 /min ) Mas s emissio n

rate , kg/ h(lb/h ) Tota l C r Cr + b Proces s C r + 6 emissio n rate , mg/A« h (gr/A«h ) Ref ,

Hardchromiu

m platin g Abl e Machin e Compan y 3 Carolin a Platin g Company 3 Greensbor o Industria l 4 Plater s Norfol k Nava l Shipyar d3 Piedmon t Industria l 1 2 Plater s Stee l Heddl e Company 3 Consolidate dEngraver s 3 Corp . Roi I Technology

6 Averag e Decorativ e chromiu

m platin g Automati c Di e Castin g 3 Specialists . Inc . Delc o Product s Divisio n3 Averag e 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 ) 20,45 8

54,66 7 13,98 3 2,48 0 8,52 4 8,79 0 14,40 0 20,05 0

6,50 0 96,84 0 17 7

(6,260 ) 30 0 (10,400 ) 22 6 (7,970 ) 24 2 (8,540 ) 29 8 (10,500 ) 51 2 (18,100 ) 15 3 (5,390 ) 33 0 (11,600 )

13 0 (4,700 ) 99 0 (35,000 ) 0.0 8

(0.17 ) 0.02 4 (0.052 ) 0.02 9 (0.064 ) 0.00 9 (0.019 ) 0.10 0 (0.221 ) 0.04 5 (0.10 ) 0.00 8 (0.018 ) 0.05 0 (0.11 )

d 0.056 1 (0.124 ) 0.0 8

(0.17 ) 0.01 1 (0.025 ) 0.02 6 (0.057 ) c c 0.10 2 (0.225 ) 0.04 5 (0.10 ) 0.015 2 (0.0333 ) 0.03 9 (0.09 )

0.003 6 (0.0080 ) 0.065 8 (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 1 0 r-

o o

Al l test s wer e performe db y EPA excep t for th e Norfol k Nava l Environmenta l Suppor t Activity , Por t Hueneme , California . No t includedi

naverag e valu e becaus e dat a i s base do ntota l ^Hexavalen t chromiu

m emission s wer e no t reported . Tota l chromiu

m emission s wer e no t determined . Shipyar dtes t whic hwa s performe db y th e Nava l Energy

an d chromium . 

# fe
T h oP.2 2



## 2 1 TABL E 7 . CONTRO L TECHNIQUE S UPO N WHIC HTH E REGULATOR YALTERNATIVE COS T IMPACT S AR E BASE D Typ e o f operation / Regulator y

Alternativ e (RA ) Contro l techniqu e Har dchromiu

m platin g R A I (n o action )

R A I I
R A II I Decorativ e chromiu

m platin g R A I (n o action )

R A I I
RA II I

R A II I Chromi c aci danodizing R A I (n o action )

R A I I

R A II I Existin g (baseline ) leve l o f contro l • 3 0 percen t o f operation s uncontrolle d • 3 0 percen t o f operation s controlle db y mis t eliminator s wit h singl e set s o f blade s tha t reduc e uncontrolle demission s b y 9 0 percen t • 4 0 percen t o f operation s controlle db y singl e packed-be d scrubber s that reduc e uncontrolle demission s b y 9 7 percen t Mis t eliminator s (singl e set s o f blades ) tha t reduc e uncon trolle demission s b y 9 0 percen t Singl e packed-be dscrubber s tha t reduc e uncontrolle demission s b y 9 7 percen t

Existin g (baseline ) leve l o f control • 1 5 percen t o f operation s uncontrolle d • 8 5 percen t o f operation s controlle db y chemica l fum

e suppressant s o r singl e packed-be dscrubber s tha t reduc e uncontrolle demission s b y 9 7 percen t Singl e packed-be dscrubber s tha t reduc e uncontrolle demission s b y 9 7 percen t Chemica l fume suppressant s applie di naccordanc e wit h monitorin g andrecordkeepin g requirement s tha t woul densur e tha t vendo r recommendation s o nus e ar e foilowed . Uncontrolle demission s reduce db y 9 9 percen t Trivalen t chromiu

m platin g processe s that reduc e hexavalen t chromiu m emission s b

y 10 0 percen t

Existin g (baseline ) leve l o f contro l • 4 0 percen t o f operation s uncontrolle d • 3 0 percen t o f operation s controlle db y chemica l fum

e suppressant s that reduc e uncontrolle demission s b y 9 7 percen t • 2 0 percen t o f operation s controlle db y packed-be dscrubber s that reduc e uncontrolle demission s b y 9 7 percen t • 1 0 percen t o f operation s controlle db y mis t eliminator s tha t reduc e uncontrolle demission s b y 9 0 percent . Singl e packed-be dscrubber s tha t reduc e uncontrolle demission s b y 9 7 percen t Chemica l fum

e suppressant s applie di naccordanc e wit h monitorin g an

drecordkeepin g requirement s tha t woul densur e tha t vendo r recommendation s o nus e ar e foilowed . Uncontrolle demission s reduce db y 9 9 percen t



# =2 /P.2 3



## 2 2

VII . Reference s 1 . Chromiu

m Electroplater s Tes t Report : Abl e Machin e Company , Taylors , Sout hCarolina . PE I Associates , Inc. , Cincinnati , Ohio . Prepare d fo r th e U . S . Environmenta l Protectio nAgency , Researc hTriangl e Park , Nort hCarolina . EM B Repor t 86-CEP-3 . Jun e 1986 . p . 2-6 . 2 . Chromiu

m Electroplater s Tes t Report : Consolidate dEngraver s Corporation , Charlotte , Nort hCarolina . Pee r Consultants , Dayton , Ohio . Prepare dfo r th e U . S . Environmenta l Protectio nAgency , Researc hTriangl e Park , Nort hCarolina . EM B Repor t 87-CEP-9 . Ma y 1987 . p . 16 . 3 . Chromiu

m Electroplater s Tes t Report : Greensbor o Industria l Platers , Greensboro , Nort hCarolina . Entropy Environmentalists , Inc. , Researc hTriangl e Park , Nort hCarolina . Prepare dfo r th e U . S . Environmenta l Protectio nAgency , Researc hTriangl e Park , Nort h Carolina . EM

B Repor t 86-CEP-l . Marc h1986 . p . 3-6 . 4 . Chromiu

m Electroplater s Tes t Report : Norfol kNava l Shipyard , Portsmouth , Virginia . Nava l Energy an dEnvironmenta l Suppor t Activity , Por t Hueneme , California . Sourc e Emissio nTesting o f the Buildin g 19 5 Platin g Sho pa t Norfol kNava l Shipyard , Portsmouth , Virginia , Marc h11-18 , 1985 . NEES A 2-124 . Ma y

1985 . p . 25 .

&5LP.2 4



## 2 3

5 . Chromium

Electroplater s Tes t Report : Carolin a Platin g Company , Greensville , Sout hCarolina . Entropy Environmentalists , Inc. , Researc hTriangl e Park , Nort hCarolina . Prepare dfo r th e U . S . Environmenta l Protectio nAgency , Researc hTriangl e Park , Nort h Carolina . EM

B Repor t 85-CHM-ll . Decembe r 1985 . p . 3-9 . 6 . Draf t Chromiu

m Electroplater s Tes t Report : Piedmon t Industria l Platers , Statesville , Nort hCarolina . Entrop y Environmentalists , Inc. , Researc hTriangl e Park , Nort hCarolina . Prepare dfo r th e U . S . Environmenta l Protectio nAgency , Researc hTriangl e Park , Nort h Carolina . EM

B Repor t 86-CEP-4 . Septembe r 1986 . p . 3-6 . 7 . Chromium

Electroplater s Tes t Report : Stee l Heddle , Inc. , Greenville , Sout hCarolina . PE I Associates , Inc. , Cincinnati , Ohio . Prepare d fo r th e U . S . Environmenta l Protectio nAgency , Researc hTriangl e Park , Nort hCarolina . EMB Repor t 86-CEP-2 . Jun e 1986 . p . 2-6 . 8 . Draf t Chromiu

m Electroplater s Tes t Report : Rol l Technology , Inc. , Greenville , Sout hCarolina . Pee r Consultants , Dayton , Ohio . Prepare dfo r th e U . S . Environmenta l Protectio nAgency , Researc h Triangl e Park , Nort hCarolina . EM B Repor t 87-CEP-6 . Septembe r 1988 . 9 . Draf t Chromiu

m Electroplater s Tes t Report : Automati c Di e Castin g Specialists , Inc. , St . Clair , Shores , Michigan . Pee r Consultants , Dayton , Ohio . Prepare dfo r th e U . S . Environmenta l Protectio n Agency , Researc hTriangl e Park , Nort hCarolina . EM B Repor t 88-CEP-ll . Apri l 1988 . 10 . Chromium

Electroplater s Tes t Report : Delc o Product s Division , Genera l Motor s Corporation , Livonia , Michigan . Pee r Consultants , Dayton , Ohio . Prepare dfo r th e U . S . Environmenta l Protectio n Agency , Researc hTriangl e Park , Nort hCarolina . EM B Repor t 86-CEP-7 . Marc h1987 . p . 3-3 . 11 . Mem o fro

m Barker , R. , MRI , t o Vervaert , A. , EPA/ISB . Ma y 15 , 1987 . Engineerin g Analysis—Reliabl e Platin g an dPolishin g Company . 1987 . p . 5 . 4 Attachment s

a2L 3P.2 5



## ATTACHMEN T 1 . PROCES S OPERATION

DATA BASE S



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______. _. _- -a—•trto^-**"o o c^ o o * —<s

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c ^Pa- e So . 2

i'6/oe/e e

FA C I D

11 7 10 3 16 9 11 5 22 7 11 4 16 4 10 0 16 2 15 0 17 0 11 9 15 7 TYP E O F OPERATIO N

D 0 D D D D C D D D D D D SH E

O F OPERATIO H
S 5 S S S S S s s s n H n DATABAS E FORDECORATIVE PLATINGPLANT S AriPERE-HOUR S

PE R VEA R

132.100 0 a.OOO O 22.6B0 0 28.100 0 3.000 0 18.000 0 0.031 0 10.500 0 5.200 0 3.000 0 15.000 0 0.000 0 0.000 0 NUHBER

O F TANK S

9 1 3 3 1 1 3 3 1 1 4 3 3 TOTA L TAN K CAPACIT Y 6ALL0N S

1458.6 0 1570.8 0 1649.3 4 1678.1 5 2154.2 4 2165.0 1 2423.5 2 2546.9 4 2591.6 2 3293.4 4 3821.5 4 4089.6 9 6736.6 8 OPERATIN G TIH E HOURS/YEA R

3928.9 0 2000.0 0 3500.0 0 3400.0 0 4250.0 0 6000.0 0 4250.0 0 4680.0 0 2288.0 0 6000.0 0 2964.0 0 3840.0 0 2733.3 0 ITIM E ELECTRODES ENERGIZE D

47.2 2 50.0 0 80.0 0 96.6 7 27.0 0 100.0 0 34.6 7 50.0 0 32.0 0 4.5 0 95.0 0 60.0 0 93.3 3



## 5 UKag e NO . 1

06/08/8 8

FACI D TYP E

16 8 18 1 194 b 188 a 19 7 18 5 19 8 179 b !B9 b IB6 a 187 a 182 a 19 6 140 a 177 a 191 a 174 a 17 9 19 5 146 a 184 a 18 3 173 a 22B a 18 0 O F OPERATIO H
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 SU E

O F OPERATIO N
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 DATABAS E FO RCHRONI C ACI DANODIZIN

GPLANT S ANPERE-HOUR S

PE R YEAR

0.000 0 0.011 4 0.125 0 0.001 5 0.052 0 0.000 1 0.002 2 0.1270 0.093 6 0.000 0 0.159 1 0.300 0 0.1100 0.0000 0.750 0 0.400 0 2.8000 0.000 0 0.6200 0.000 0 4.6000 0.000 0 0.000 0 19.594 0 3.6000 NUMBER

O F TANK S

2

3 2 TOTA

L TAN K CAPACIT Y 6ALL0N S

162.7 6 235.6 2 314.1 6 314.1 6 366.5 2 403.9 2 538.5 6 556.3 3 628.3 2 628.3 2 641.4 1 686.6 6 695.6 4 897.6 0 942.4 8 942.4 8 942.4 8 1211.7 6 1413.7 2 1615.6 8 1974.7 2 2019.6 0 7195.7 6 18908.2 6 33213.0 0 OPERATIHGTIKE

HOURS/YEA R

2000.0 0 416.0 0 2340.0 0 104.0 0 520.0 0 100.0 0 192.0 0 468.0 0 624.0 0 975.0 0 2175.0 0 600.0 0 3120.0 0 864.0 0 4160.0 0 2000.0 0 4000.0 0 500.0 0 960.0 0 2040.0 0 3120.0 0 7B0.0 0 7020.0 0 8400.0 0 2500.0 0 1 TIK E ELECTRODE S ENERGIZE D
80.0 0 80.0 0 100.0 0 100.0 0 75.0 0 100.0 0 70.0 0 90.0 0 100.0 0 20.0 0 100.0 0 50.0 0 12.5 0 50.0 0 35.0 0 50.0 0 100.0 0 100.00 50.0 0 20.0 0 50.0 0 100.0 0 50.0 0 31.3 3 45.0 0P.3 0



## ATTACHMEN T 2 . TRI P REPOR T DAT A

BAS E



# JlfCONPAN

YNAN E :::::::::::::::::::::!::: : CAROLIN A PLATIN 6 6REENVILLE , S C C S . OH N NANUF . STERLIN GHEI6HTS , N

l GENERA L PLATIN 6 OETROIT , N

I 61BB S PLATIN 6 CO . CHARLOTTE , N

C GREENSBOR O IND . PLATER S 6REENSB0R0 , N

C NODER N HAR DCHROM E UARREN , N I TI S BRAS S AN

DBRONZ E TRAVLER S REST.S C CONSOLIDATEDEN6RAVER S CHARLOTTE , N

C ABLE MACHIN

E CO . TAYLORS , S C E.F . BREME

RCO MENOMOME E FALLS , 11

1 MILWAUKEE PLAT1N 6 CO . MILWAUKEE , HI 6.E . MEDICA

L SYSTEM S MILWAUKEE , HI BR166 S AN DSTRATTO N 6LENDALE , HI DELC O PRODUCT S DIV . LIVONIA , M

I CIRCHROM E SERVICE S GASTONIA , N

C CHROM E CRAF T CORP . HIGHLAN DPARK , M l DIAMON DCHROM E PLATIN G HOHELL , M I TYP E O F YEA

RO F OPERATIO N VISI T ;=:=:::===:==;======;==:= = H

D

D

H

H

H

D

H

H
0
0

D

D

D

H

D

H OPERATIN GNUNBER TIME , HRS/Y

RO F TANK S TOTA

L TAN KOPERATIN

GOPERATIN

G CAPACITY , GA

L V0LTA6 E RANGE CURREN

T RANGE

19B 5

198 5
198 5

198 4

198 4
198 5

198 5

198 6

198 6

198 7

19B 7

198 7

198 6
198 6
19B 6

198 6

198 6 840 0

748 8

624 0

250 0

200 0

750 0

250 0

200 0

520 0

520 0
300 0

400 0

540 0 1214 0
280 0

240 0
45 0

614 0

1870 0

100 0 10-1 2 4000-3000 0

590 0

130 0

135 0
80 0
58 0

8500 0

280 0

300 0

1270 0 1 3 1800 0

900 0
300 0

200 0

5 5000-1000 0

5 2400-250 0

7.5 800 0

4- 5 1200-150 0

16-1 7 8500-1000 0

2- 6 150-200 0

8- 9 5000-600 0

1 2 3500-1700 0

T lBUICK-OLDS-CADILLAC

DETROIT , M l 198 7 2690 0 300 0

HAMILTON STANDAR D HINDSO RLOCKS , CT 198 7 748 8 157 0 4 0

PRAT T AII DWHITNE Y E . HARTFORD , C T 198 7 748 8 536 0 20-4 0 200-40 0

RELIABL E PLATIN6 CO . BRIDGEPORT , CT 198 7 200 0 50 0 4 0 200-30 0

MAREMONT CORPORATION PULASKI , TENN . 198 6 200 0 1200 0

METAL S APPLIE D CLEVELAND , OHI O 198 6 840 0 1670 0

PIEDMON T -IND . PLATER S STATESVILLE , N

C 198 6 386 0

RELIABL E PLATINGHORK S MILWAUKEE , HI 198 6 416 0 160 0 1 1 6000-800 0

SAXONI A FRANK E O F AMERICA H SPARTANBURG , S C 19B 6 220 0 53 0 600 0

STEE L HEDDL E 6REENVILLE , S C 198 6 200 0 182 0 5 1000-200 0

UNITE DMETA

L FINISHIN 6 6REENSB0RO , N

C 198 6 600 0 236 0

A- 1 CHROME NEHIN6T0N , C

T 198 7 208 0 126 0 1000-300 0

SAC ODEFENS E SACO , MAINE 198 8 500 0 1 8 994 3 1 2 1000-300 0

VERMONT AMERICA

N COR P TOCCOA , G A 19B 8 873 6 159 0 6 2000-400 0

ta
- r oP.3 3

ATTACHMEN T3 . PRODUCTIO N RAT E CALCULATION S



# 3*-P.3 4



## DETERMINATION

O F ELECTROCHEMICA L EQUIVALEN T ATTACHMEN T 3 , PAR T I



# £ 3EQUATION S FORCALCULATINGTH E ELECTROCHEMICA L EOUIVALEN T FG RCHROMIU M

Definition : Th e electrocheaica l equivalen t i s define da s the aaoun t o f curren t require d t o plat e a par t wit ha surfac e are a o f on e squar e foo t wit ha plat e thicknes s o f on e ei l a t a cathod e efficienc y

o f 10 0 percent . Equatio n1 : Plat e Thicknes s = (weigh t o f chrosiua ) (densit y o f chrosiua)(surfac e are a plated )
Faraday' s Law : Durin g electrolysi s 96,48 7 couloab s (aapere-seconds ) o f electricit y reduc e an doxidize , respectively , on e gras-equivalen t of th e oxidizin g an

dthe reducin g agent . Equatio n2 : 96,50 0 aapere-second s ire require dt o deposi t the (aetal s atoni c weight)/(valence ) i ngrass .
ASSUMPTIONS : Plat e thicknes s = 1 ai l Surfac e are a of par t = 1 squar e foo t Cathod e efficienc y

= 10 0 percen t GIVEN : Densit y o f wate r = 62.4 3 lb/ft 3 Specifi c gravit y

o f CR= 7. 1

B y rearrangin g equatio n1 , Heigh t o f chrosiu a = (thickness)(densit y o f CR)(surfac e are a plated ) Weigh t o f chroaiu s = (.00 1 in/1 2 in/ft)(7.1){62.4 3 lb/ft3)( l ft2 ) Heigh t o f chroaiu s = ,036 9 lb- 16.7 4 gras s Usin g equatio n2 , 96,50 0 Ampere-second s = xAapere-second s x- 18640 0 aapere-second s 5 2 grass/+ 6 16.7 4 gras s
Convertin g aapere-second s t o aapere-hours , 18640 0 A- s
= 51. 8 A- hi s require dto plat e a par t wit ha surfac e are a o f on e squar e foo t an d 360 0 s/ han

da plat e thicknes s o f 1 si i a t a cathod e efficienc y o f 10 0 percent . Correctio nfor cathod e efficienc y o f 1 0 percen t for hexavalen t chroaius , (51.8)(10.0 ) = 51 8 Aapere-hour s require dt o plat e a par t wit ha surfac e are a o f on e squar e foo t

an da plat e thicknes s o f 1 si i a t a cathod e efficienc y

o f 1 0 percent . 

# siP.3 6



## HARDCHROMIU

M PLATINGPRODUCTIO N

RAT E CALCULATION S ATTACHMEN T 3 , PAR T I I



## S55

### TABL E 1 . AVERAG E SURFAC E AREA-TO-VOLUM E RATIO S FOR HAR DCHROMIU

M PLATINGPLANT S TESTE DDURIN GTH E EMISSION TES T PROGRA

M

Plan t
Stee l Heddl e

Rol l Technology

Greensbor o Industria l Plater s Abl e Machin e Compan

y Averag e Tan kNo . 1 2 4 1 2 3 7 

## 1 1 Capacity , f t

9 4 4 5 4 3 16 1 30 2 48 6 32 4 

## 34 7 53 2 Averag e

surfac e are a plated , f t 5.6 3 4.0 8 4.6 4 7.1 4 11.4 8 13.8 1 5.5 9 18.2 9
34.7 4 Surfac e

area-to volum e rate , f t /f t 0.0 6 0.0 9 0.1 1 0.0 4 0.0 4 0.0 3 0.0 2 0.0 5
0.0 7 0.0 6

3<t>

### HAR D CHROMIUM PLATING MODE L TANK S

Tan k No . Dimensions , 1 , w , d (ft ) Capacity , f t (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 23 1 (1,728 ) 26 4 (1,975 ) 41 3 (3,089 ) 15 2 (1,137 ) Surfac e are a plate d i n eac h tan k calculate d byusin g facto r o f 0.0 6 f t /f t fro mTabl e 1 ,

Tan k No . 

## 1 2 3 4 Capacity ,



## 23 1 26 4 41 3 15 2 ft 3 

### Volume ,

factor , f t 0.0 6 0.0 6 0.0 6 0.0 6 /ft 3 

### Surfac e are a plated , f t 14. 0 16. 0 25. 0 

## 9. 0
Proces s paramete r assumptions : Plat e thicknes s = 1 mi l Platin g tim e = 2 hour s Electrochemica l equivalen t = mi l • f t a t 1 0 percen t cathod e efficienc y Ampere-hou r requiremen t fo r eac htank t o plat e th e surfac e are a value s state d above ,

Tan k No . Plat e

thickness , mil s Electrochemica l

equivalent
. A-h/miW t 51 8 • 

## 51 8 51 8 51 8 Surface 2



### area , f t 14. 0 16. 0 25. 0 

## 9. 0 A«

h 7,25 0 8,29 0 12,95 0 4,66 0 

## 1 2 3 4



## 2>7P.3 9



### Curren t setting s fo r eac hmode l tank ,

TankNo . 

## 1 2 3 4
Mode l plan t Smal l mode l produc t

plan t Ampere-hou r requiremen t 7,25 0 8,29 0 12,95 0 4,66 0 io nrate s Platin g time , h 

## 2. 0 2. 0 2. 0 2. 0 Curren t amp s

3,62 5 4,14 5 6,47 5 2,33 0

No . o f tank s = 1 Siz e o f tank= 12 , 3.5 , 6. 0 (Tan kNo . 1 ) Curren t setting o f tank= 3,62 5 Operatin g tim

e = 2,00 0 h/y r Percen t tim

e electrode s ar e energize d= 7 0 percen t Ampere-hours/yea r = (3,62 5 A)(2,00 0 h/yr)(0.70 ) = 5.0xl0 6 

### A*»h/y r Mediu m mode l plan t No . o f tank s = Siz e o f tank s =

Curren t setting s =
Operatin g tim

e = 1 a t (4.0 , 4.0 , 10.0 ) (TankNo . 4 )

2 a t (12.0 , 4.0 , 6.0 ) (TankNo . 2 ) 1 a t (25.0 , 3.0 , 6.0 ) (TankNo . 3 ) 1 a t 2,33 0 ampere s 2 a t 4,14 5 ampere s 1 a t 6,47 5 ampere s 3,50 0 h/y r Percen t tim

e electrode s ar e energize d= 7 0 percen t Ampere-hours/yea r = [(2,33 0 A)+(2)(4,14 5 A)+(6,47 5 A)](3,50 0 h/yr)(0.70 ) = 42.0x1 0 A»h/yr



# sfP.4 0



### Larg e mode l plan t No . o f tank s = 8 Siz e o f tank s = 2 a t (4.0 , 4.0 , 10.0 ) (Tan kNo . 4 ) 4 a t (12.0 , 4.0 , 6.0 ) (Tan kNo . 2 ) 2 a t (25.0 , 3.0 , 6.0 ) (Tan kNo . 3 ) Curren t setting s = 2 a t 2,33 0 A 4 a t 4,14 5 A 2 a t 6,47 5 A Operatin g tim

e = 6,00 0 h/yr Percen t time electrode s ar e energize d= 8 0 percen t Ampere-hours/yea r = [2(2,33 0 A)+4(4,145)+2(6,475)](6,00 0 h/yr)(0.80 ) = 164x1 0 A-h/y r



# i ?P.4 1



## DECORATIV E CHROMIU

M PLATINGPRODUCTION

RAT E CALCULATION S ATTACHMEN T 3 , PAR T II I



# #6

### Surfac e area-to-volume rati o fo r decorativ e chromiu m platin g operation s GMC-Delc o Tes t Dat a No . o f tank s = 1 Siz e o f tank= (20.0 , 12.0 , 9.0 ) Capacit y = 2,04 0 f t (15,26 0 gallons ) Tankhold s = Thre e rack s o f bumpe r Rac kcontain s = 8 bumper s Squar e footag e i ntank= ( 3 racks)( 8 bumpers/rack)( 8 f t / l bumper ) = 19 2 ft 2

192 3 ft 3 

## P art s 

## = 0.0 9 ftVft 3 

### 2,04 0 f t platin g solutio n DECORATIVE CHROMIU

M PLATINGMODE L TANK S Dimensions , TankNo . 1 , w , d(ft ) Capacity , f t (gal ) 1 12.0 , 3.5 , 6. 0 23 1 (1,728 ) 2 12.0 , 6.0 , 9. 0 61 2 (4,578 ) Surface 2 

### are a plate di neac htankcalculate db y using facto r o f 0.0 9 f t /f t fro

m above ,

3 

### Volum ^ 3 

### Surfac e are £ TankNo . Capacity , f t factor , f t /f t plated , f t 1 23 1 0.0 9 2 1 2 61 2 0.0 9 5 5
Proces s paramete r assumptions : Plat e thicknes s = 0.01 2 mil s Plating time = 3 0 minute s = 0.0 5 hour s 51 8 A # 

### h Electrochemica l equivalen t = j - a t 1 0 percen t cathod e efficienc y mil-f t



# ftP.4 3



### Ampere-hou r requiremen t fo r eac htank t o plat e th e surfac e are a value s state d above ,



## Tan kNo . 1 2
Curren t

Tan k No . 1 2 Plat e

thickness , mil s 0.01 2 0.01 2 setting s fo r eac hmode l

Ampere-hou r requiremen t 13 0 34 0 Electrochemica l

equivalent , A'h/miW t 51 8 51 8 tank ,

Platin g time ,

0.0 5 0.0 5 Surface 2 

### area , f t A» h 2 1 13 0 5 5 34 0

, h Curren t amp s

2,60 0 6,80 0 Mode l plan t productio n rate s Smal l mode l plan t No . o f tank s = 1 Siz e o f tan k = (12.0 , 3.5 , 6.0 ) (Tank No . 1 ) Curren t settin g o f tank = 2,60 0 ampere s Operatin g tim e = 2,00 0 h/yr Percen t tim e electrode s ar e energize d = 6 0 percen t Ampere-hours/yea r = (2,60 0 A)(2,00 0 h/yr)(0.60 ) = 3.0xl0 6 

### A»h/y r Mediummode l plan t No . o f tank s = Siz e o f tank s = Curren t setting s = Operatin g tim e = 2 a t (12.0 , 3.5 , 6.0 ) (Tan k No . 1 ) 2 a t 2,60 0 ampere s 4,00 0 h/yr Percen t tim e electrode s ar e energize d = 6 0 percen t Ampere-hours/yea r = (2)(2,60 0 A)(4,00 0 h/yr)(0.60 ) = 12.0xl0 6 

### A»h/y r

//&P.4 4



### Larg e mode l plan t No . o f tank s = 5 Siz e o f tank s = 5 a t (12.0 , 6.0 , 9.0 ) (Tan kNo . 2 ) Curren t setting s = 5 a t 6,80 0 A Operatin g time = 6,00 0 h/yr Percen t tim

e electrode s ar e energize d= 6 0 percen t Ampere-hours/yea r = (5)(6,80 0 A)(6,00 0 h/yr)(0.60 ) = 122xl0 6 

### A«h/yr

*&