p. 1



# OAR Box 1313 Prepped by LaTeia Shed



## Document

Number: 

# 20 ) ll-A-3 4

Docket Number: 

# A-88-0 2

Printed 6/12/200810:28:49AM

Sheet 20of 99P. 2 

# A-88-0 2

Unite d Sute s Environmenu l Protection Agenc y Offic eo f Ai rQualit

y Planningand Sundaid s Reseaic h Triangl e Parle

, N C 2771 1 453/R-93-03 1



## July1993 I I A 3 4 

## S E 

# & EP A

Technica l Assessmen t o fNe w Emissio n Contro l Technologie s Use d i n th e Har d Chromiu m Electroplatin g Industr y



# NESHA P

'•nzt&*

# SE- Q A n '



### 7 > - P. 3



## EP ANo
. 453/R-93-03 1

Jul y199 3

TECHNICAL ASSESSMENT O F NE W EMISSIONCONTRO L TECHNOLOGIE S USE D I NTH E HARD CHROMIU M ELECTROPLATIN

G INDUSTRY

Prepare d for :
Industria l Studie s Branc h Offic e o f Ai r Qualit yPlanning and Standard s U.S
. Environmenta l Protectio n Agenc y Researc hTriangl e Park , N C 2771 1

Prepare d by :
Midwes t Researc hInstitut e

Suit e 35 0 40 1 Harriso n Oak s Boulevar d Cary , Nort hCarolin a 2751 3

Jul y31 , 199 3



# m BP. 4



## NOTIC E Thi s repor t wa s prepare d b yMidwes t Researc hInstitute , Cary , Nort hCarolina

. I t ha s bee n re-Viewe d fo r technica l accurac yb

yth e Emissio n Standard s Divisio n o f th e Offic e o f Ai r Qualit yPlanning and Standard s and approve d fo r publication

. Mentio n o f trad e name s o r commercia l product s i s no t intende d t o constitut e endorsemen t o r recommendatio n o f use .

1 1 

# S 3P. 5

*
. •''
. T >



## PREFAC E Th e Offic e o f Ai r Qualit yPlanning an d Standard s i s responsibl e fo r establishin g national; ; emissio n standard s fo r hazardou s ai r pollutants

. Thi s documen t serve s a s a supplemen t
. t o Chromiu

mEmission s fromChromiu mElectroplatin g and Chromi c Aci d Anodizin g Operations--Background Informatio n fo r Propose d Standard s (BID) , whic hprovide s technica l suppor t fo r th e developmen t o f nationa l emissio n standard s fo r chromiu m electroplatin g operations

. Th e informatio n containe d herei n provide s a detaile d technica l assessmen t o f contro l technologie s tha t hav e bee n demonstrate d fo r us e i n th e har d chromiu m electroplatin g industrysinc e th e BI D wa s written

. Th e assessmen t include s performanc e evaluation s o f eac hne wcontro l technologya s wel l a s th e environmenta l an d economi c impact s associate d wit hth e us e o f th e technologies

.

1 1 1P. 6

i I



## TABL E O F CONTENT S Pag e LIS T O F FIGURE S .-* / v i LIS T O F TABLE S vi i LIS T O F ABBREVIATION S xi v 1. 0 INTRODUCTION1 2

. 0 BACKGROUND 2 2. 1 MESH

- PA

D MIS T ELIMINATOR S 2 2. 2 FIBER-BE D MIS T ELIMINATOR S 3 3. 0 DESCRIPTION S O F EMISSION S CONTRO L TECHNOLOGIE S 4 3. 1 COMPOSIT E MESH-PA D MIS T ELIMINATO R SYSTEM S 5 3.1. 1 Composit e Mes hPad s Use d i n Serie s 6 3.1. 2 Composit e Mes hPad s Use d i n Conjunctio n

wit hPacked-Be d Scrubber s 6 3. 2 FIBER-BE D MIS T ELIMINATOR S 7 4. 0 EMISSION S TES T DATA8 4. 1 COMPOSIT E MESH-PA D TEST S 9 4.1. 1 Mesh-Pa d Mis t Eliminator--Precisio n

Engineering , Seattle , Washingto n 9 4.1. 2 Mesh-Pa d Mis t Eliminator--Monro e Aut o

Equipment , Hartwell , Georgi a 1 6 4.1. 3 Packed-Be d Scrubber/Mesh-Pa d Mis t

Eliminato r System--Remc o Hydraulics , Inc. , Willits , Californi a 2 1 4.1. 4 Discussio n o f Composit e Mes hPad

Performanc e 3 1 4. 2 FIBER-BE D MIS T ELIMINATO R TESTS--NAVAL AVIATIO N

DEPOT , ALAMEDA , CALIFORNI A3 8 4.2. 1 Proces s Descriptio n 3 8 4.2. 2 Ai r Pollutio n Contro l 4 0 4.2. 3 Proces s Condition s Durin g Testin g 4 3 4.2. 4 Result s o f Emission s Testin g 4 3 4.2. 5 Discussio n o f Fiber-Be d Mis t Eliminato r

Performanc e 4 5 4. 3 SUMMARY O F EMISSIONTES T RESULT S 4 9 5. 0 ENVIRONMENTAL AND COS T IMPACT S 5 1 5. 1 AI R POLLUTIONIMPACT S 5 1 5. 2 ENERGY IMPACT S 7 5 3 5. 3 WASTEWATE R IMPACT S 5 7 5. 4 SOLI D WAST E IMPACT S 5 7 5. 5 MODE L PLANT COS T IMPACT S 6 0 5.5. 1 Mesh-Pa d Mis t Eliminator s wit hMes hPad s

i n Serie s 6 0 5.5. 2 Packed-Be d Scrubber/Mesh-Pa d Mis t

Eliminato r Syste m6 3 5.5. 3 Fiber-Be d Mis t Eliminator s 6 3 i vP. 7



## TABL E O F CONTENT S (continued ) Pag e 5. 6 SUMMARY O F ECONOMI C IMPACT S 6 4 6

. 0 CONCLUSIONS/SUMMARY 6 7 7. 0 REFERENCE S 6 9
APPENDI X A
. SUMMARIE S O F EMISSION S TES T DATAAND PROCES S

OPERATING PARAMETER S A- 1 APPENDI X B
. BASI S FOR TH E DEVELOPMENT O F MODE L PLANT

COST S FOR NE W EMISSIONCONTRO L TECHNOLOGIES
. B- 1 APPENDI X C
. SUMMARY O F MODE L PLANT CAPITAL AND ANNUALIZE D

COST S FOR NE W EMISSIONCONTRO L TECHNOLOGIES
. C- l



# 6

### LIS T O F FIGURE S P. 8



### Pag e
Figur e 1

.

Figur e 2

. Figur e 3

. Figur e 4

. Figur e 5
. Figur e 6

. Figur e 7
. Figur e 8

. Figur e 9

. Figur e 10

. Figur e B- 1

Figur e B- 2 Schemati c o f th e ventilatio n an d contro l syste m a t Precisio n Engineering , Seattle , Washingto n 1 1 Schemati c o f contro l syste ma t Remc o Hydraulics , Inc. , Willits , Californi a 2 5 Outle t chromiu mconcentratio n dat a fo r composit e mesh-pa d mis t eliminato r system s 3 3 Composit e mesh-pa d mis t eliminato r dat a - inle t versu s outle t concentration s 3 5 Composit e mesh-pa d mis t eliminato r dat a - efficienc yversu s inle t concentratio n 3 6 Composit e mesh-pa d mis t eliminato r dat a - efficienc yversu s inle t mas s rat e 3 6 Schemati c o f a typica l fiber-be d mis t eliminato r 4 1 Fiber-be d mis t eliminato r outle t concentration s 4 6 Fiber-be d mis t eliminato r outle t concentration s withou t hig htes t values..

. 4 8 Performanc e dat a fo r mis t eliminato r system s 5 0 Pla n vie wan d ductwor k specification s fo r th e smal l har d chromiu mplatin g mode l plan t B-2 7 Pla n vie wan d ductwor k specification s fo r th e mediu man d larg e har d chromiu mplatin g mode l plant s • . . . . B-2 8

v i

## LIS T O F TABLE S P. 9



## Pag e TABL E 1 ,

TABL E 2

TABL E 3a

.

TABL E 3b

.

TABL E 4

.

TABL E 5
.

TABL E 6

.

TABL E 7

TABL E 8a

.

TABL E 8b ,

TABL E 9 , DIMENSION S AND OPERATING PARAMETER S FOR TH E

HARD CHROMIU

M PLATING"'TANKS A T PRECISION ENGINEERING , SEATTLE , WASHINGTON1 0 AVERAG E OPERATING PARAMETER S MONITORE D DURING EAC H EMISSIONTES T RU NA T PRECISION ENGINEERING , SEATTLE , WASHINGTON1 4 PERFORMANC E DATAFOR TH E MESH-PA D MIS T ELIMINATO R A T PRECISIONENGINEERING , SEATTLE , WASHINGTON(TOTA L CHROMIU

M TES T RESULTS ) 1 5 PERFORMANC E DATAFOR TH E MESH-PAD MIS T ELIMINATO R A T PRECISIONENGINEERING , SEATTLE , WASHINGTON(HEXAVALEN T CHROMIUM TES T RESULTS ) 1 5 AVERAG E OPERATING PARAMETER S MONITORE D DURING EAC H EMISSIONTES T RU NA T MONRO E AUT O EQUIPMENT , HARTWELL , GEORGI A1 9 PERFORMANC E DATAFOR TH E MESH-PAD MIS T ELIMINATO R A T MONRO E AUT O EQUIPMENT , HARTWELL , GEORGI A2 0 DIMENSION S AND OPERATING PARAMETER S FOR TH E SEVE NHARD CHROMIU

M PLATIN

G TANK S A T REMC O HYDRAULICS , INC. , WILLITS , CALIFORNI A2 3 AVERAG E OPERATING PARAMETER S MONITORE D DURING EAC H EMISSIONTES T RU NA T REMC O HYDRAULICS , INC. , WILLITS , CALIFORNI A2 7 PERFORMANC E DATAFOR TH E PACKED-BE D SCRUBBER / MESH-PA D MIS T ELIMINATO R SYSTE M A T REMC O HYDRAULICS , INC. , WILLITS , CALIFORNI A (TOTA L CHROMIU

M TES T RESULTS ) 2 9 PERFORMANC E DATAFO R TH E PACKED-BE D SCRUBBER / MESH-PA D MIS T ELIMINATO R SYSTE M A T REMC O HYDRAULICS , INC. , WILLITS , CALIFORNI A (HEXAVALEN

T CHROMIU

M TES T RESULTS ) 2 9 PERFORMANC E DATAFOR COMPOSIT E MESH-PAD MIS T ELIMINATOR S 3 2

vl l 

# 8P.1 0



### LIS T O F TABLE S (continued )

TABL E 10

. CHROMIU M ELECTROPLATING ^ AJJ D CHROMI C ACI D ANODIZIN G TAN K SPECIFICATION S A T TH E NAVA L AVIATIO NDEPOT , ALAMEDA , CALIFORNI A
TABL E 11

. PERFORMANC E DAT AFO R THRE E SCRUBBER/FIBER-BE D

MIS T ELIMINATO R SYSTEM S A T TH E NAVA L AVIATIO NDEPOT , ALAMEDA , CALIFORNI A
TABL E 12

. PARAMETER S FO R TH E HAR D CHROMIU M

ELECTROPLATIN G MODE L PLANT S Pag e

3 9

44

5 2
TABL E 13

. HEXAVALEN T CHROMIU M EMISSIO NESTIMATE S

ASSOCIATE D WIT H TH E US E O F PACKED-BE D SCRUBBER S AN D NE W EMISSIO NCONTRO L TECHNOLOGIE S A T HAR D CHROMIU M ELECTROPLATIN G MODE L PLANT S 5 4
TABL E 14

. ANNUA L ENERG Y REQUIREMENT S ATTRIBUTABL E T O TH E

US E O F PACKED-BE D SCRUBBER S AN D NE W EMISSIO NCONTRO L TECHNOLOGIE S A T HAR D CHROMIU M PLATIN G MODE L PLANT S 5 5
TABL E 15

. SOLI D WAST E IMPACT S ASSOCIATE D WIT H TH E US E O F

PACKED-BE D SCRUBBER S AN D NE W EMISSIO N CONTRO L TECHNOLOGIE S A T HAR D CHROMIU M ELECTROPLATIN G MODE L PLANT S 5 9
TABL E 16

. CAPITA L COST S O F SINGL E PACKED-BE D SCRUBBER S

AN D NE W TECHNOLOGIE S FO R NE W AN D EXISTIN G HAR D CHROMIU M ELECTROPLATIN G MODE L PLANTS
. 6 1
TABL E 17

. NE T ANNUALIZE D COST S O F SINGL E PACKED-BE D

SCRUBBER S AN D NE W TECHNOLOGIE S FO R NE W AN D EXISTIN G HAR D CHROMIU M ELECTROPLATIN G MODE L PLANT S 6 2
TABL E 18

. ESTIMATE D PERCEN T CHANG E I NHAR D CHROMIU M

ELECTROPLATIN G COS T O F THRE E EN D PRODUCT S ATTRIBUTABL E T O VARIOU S CONTRO L TECHNOLOGIE S 6 6
TABL E 19

. ESTIMATE D CHANG E I NPRIC E O F FINA L PRODUCT S

ATTRIBUTABL E T O TH E INCREAS E I NHAR D CHROMIU M ELECTROPLATIN G COST S WHE NUSIN G VARIOU S CONTRO L TECHNOLOGIE S 6 8
TABLE
. A-1

. SUMMAR Y O F EMISSION S TES T DATA-

- PRECISIO N

ENGINEERING , SEATTLE , WASHINGTON
. MESH

PAD MIS T ELIMINATO R - INLE T A A- 2

v m

## LIS T O F TABLE S (continued ) p.1 1



## Pag e TABL E A- 2

TABL E A-3

.

TABL E A-4

.

TABL E A-5
.

TABL E A- 6

TABL E A-7
.

TABL E A- 8

TABL E A- 9

TABL E A-1 0

TABL E A-ll

.

TABL E A-12

.

TABL E A-1 3 SUMMARY O F EMISSION S TES T DATA--PRECISION

ENGINEERING , SEATTLE; " WASHINGTON
. MESH

PA D MIS T ELIMINATO R - INLE T B A- 3 SUMMARY O F EMISSION S TES T DATA--PRECISION ENGINEERING , SEATTLE , WASHINGTON
. MESH--PA D MIS T ELIMINATO R OUTLE T A- 4 SUMMARY O F EMISSION S TES T DATA--MONRO E AUT O EQUIPMENT , HARTWELL , GEORGIA
. MESH-PAD MIS T ELIMINATO R INLET , WITHOU T FOA M BLANKE T A- 5 SUMMARY O F EMISSION S TES T DATA--MONRO E AUT O EQUIPMENT , HARTWELL , GEORGIA
. MESH-PAD MIS T ELIMINATO R INLET , WIT H FOA M BLANKE T A- 6 SUMMARY O F EMISSION S TES T DATA--MONRO E AUT O EQUIPMENT , HARTWELL , GEORGIA
. MESH-PAD MIS T ELIMINATO R OUTLET , WITHOU T FOA M BLANKE T A- 7 SUMMARY O F EMISSION S TES T DATA--MONRO E AUT O EQUIPMENT , HARTWELL , GEORGIA
. MESH-PAD MIS T ELIMINATO R OUTLET , WIT H FOA M BLANKE T A- 8 SUMMARY O F EMISSION S TES T DATA--REMC O HYDRAULICS , INC. , WILLITS , CALIFORNIA
. SCRUBBER/MESH-PA

D MIS T ELIMINATO R - INLE T A
. A- 9 SUMMARY O F EMISSION S TES T DATA--REMC O HYDRAULICS , INC. , WILLITS , CALIFORNIA
. SCRUBBER/MESH-PA

D MIS T ELIMINATO R - INLE T B
. A-1 0 SUMMARY O F EMISSION S TES T DATA--REMC O HYDRAULICS , INC. , WILLITS , CALIFORNIA
. SCRUBBER/MESH-PA

D MIS T ELIMINATO R OUTLE T A-l l SUMMARY O F EMISSION S TES T DATA--NAVAL AVIATIO N DEPOT , ALAMEDA , CALIFORNIA
. LIN E G FIBER-BE D MIS T ELIMINATO R OUTLE T A-1 2 SUMMARY O F EMISSION S TES T DATA--NAVAL AVIATIO N DEPOT , ALAMEDA , CALIFORNIA
. LIN E L FIBER-BE D MIS T ELIMINATO R OUTLE T A-1 3 SUMMARY O F EMISSION S TES T DATA--NAVAL AVIATIO N DEPOT , ALAMEDA , CALIFORNIA
. LIN E M FIBER-BE D MIS T ELIMINATO R INLET/SCRUBBE R OUTLE T A

- 1 4

i x 

# 1 0P.1 2



## LIS T O F TABLE S (continued ) Pag e TABL E A-1 4

TABL E B-1

.

TABL E B-2

.

TABL E B-3

.

TABL E B- 4

TABL E B- 5

TABL E B- 6

TABL E B-7
.

TABL E B- 8

TABL E B- 9

TABL E B-10 ,

TABL E B-11 , SUMMARY O F EMISSION S TES T DATA--NAVAL AVIATION

DEPOT , ALAMEDA , CALIFORNIA
. LINE M FIBER-BE D MIS T ELIMINATO R OUTLE T A-1 5
PARAMETER S FOR TH E HAR D CHROMIU M ELECTRO

- . . PLATIN G MODE L PLANT S B-2 9 ANNUAL OPERATING COS T FACTOR S FOR MESH-PAD MIS T ELIMINATORS , PACKED-BE D SCRUBBERS / MESH-PA D MIS T ELIMINATO R SYSTEMS , AN D FIBER-BE D MIS T ELIMINATOR S B-3 0 CAPITAL AND ANNUALIZE D COS T DATASOURCE S FOR MESH-PAD MIS T ELIMINATORS , PACKED-BE D SCRUBBERS/MESH-PA

D MIS T ELIMINATO R SYSTEMS , AND FIBER-BE D MIS T ELIMINATOR S B-3 1 CAPITAL COS T ESTIMATE S PROVIDE D B Y VENDO R C FOR MESH-PAD MIS T ELIMINATOR S WIT H MES H PAD S I NSERIE S B-3 2 CAPITAL COS T ESTIMATE S O F MIS T ELIMINATOR S WIT H MES H PAD S I NSERIE S B

- 3 3 ESTIMATE D ANNUALIZE D COST S O F MIS T ELIMINATOR S WIT H MES H PAD S I NSERIE S B-3 4 ESTIMATE D CAPITAL COST S O F MESH-PAD MIS T ELIMINATO R UNIT S FOR NE W AND EXISTING HAR D CHROMIU M PLATIN

G MODE L PLANT S B-3 5 ESTIMATE D ANNUALIZE D COST S O F MESH-PAD MIS T ELIMINATO R UNIT S FOR NE W HAR D CHROMIU M PLATIN G MODE L PLANT S B-3 6 ESTIMATE D ANNUALIZE D COST S O F MESH-PAD MIS T ELIMINATO R UNIT S FOR EXISTIN G HAR D CHROMIUM PLATIN G MODE L PLANT S B-3 7 CAPITAL COS T ESTIMATE S PROVIDE D B Y VENDOR S A AND C FOR PACKED-BE D SCRUBBER/MESH-PA D MIS T ELIMINATO R SYSTEM S B-3 8 CAPITAL COS T ESTIMATE S O F PACKED-BE D SCRUBBER/MESH-PA

D MIS T ELIMINATO R SYSTE M (VENDO R A ) B-3 9



# @ 1 1P.1 3



## TABL E B-1 2

TABL E B-13

.

TABL E B-1 4

TABL E B-15

.

TABL E B-16

.

TABL E B-17

.

TABL E B-18

.

TABL E B-19

.

TABL E B-20

.

TABL E B-21

.

TABL E C-l

.

TABL E C-2

. LIS T O F TABLE S (continued ) Pag e

ANNUALIZE D COST S O F PACKED-BE D SCRUBBER/MESH

PA D MIS T ELIMINATO R SYSTE M (VENDO R A ) B-4 0 ESTIMATE D CAPITAL COST S O F PACKED-BE D SCRUBBER/MESH-PA

D MIS T ELIMINATO R SYSTEM S FO R NE W AND EXISTIN

G HARD CHROMIU

M PLATIN

G * MODE L PLANT S (VENDO R A ) B-4 1 ESTIMATE D ANNUALIZE D COST S O F PACKED-BE D SCRUBBER/MESH-PA

D MIS T ELIMINATO R SYSTEM S FOR NE W HAR D CHROMIU M PLATIN

G MODE L PLANT S

. (VENDO R A ) B-4 2 ESTIMATE D ANNUALIZE D COST S O F PACKED-BE D SCRUBBER/MESH-PA

D MIS T ELIMINATO R SYSTEM S FO R EXISTIN

G HAR D CHROMIU

M PLATIN

G MODE L PLANT S (VENDO

R A ) B-4 3 CAPITAL COS T ESTIMATE S PROVIDE D B Y MONSANT O ENVIRO-CHE M AND CEC O FILTERS , INC. , FOR FIBER-BE D MIS T ELIMINATOR S B-4 4 ESTIMATE D CAPITAL COST S FOR FIBER-BE D MIS T ELIMINATOR S N 

## . B-4 5 ANNUALIZE D COST S O F FIBER-BE D MIS T ELIMINATOR S B-4 6 CAPITAL COST S O F FIBER-BE D MIS T ELIMINATOR S FO R HARD CHROMIU

M PLATIN

G MODE L PLANT S B-4 7 ANNUALIZE D COST S FO R FIBER-BE D MIS T ELIMINATOR S FOR NE W HARD CHROMIU M PLATIN

G MODE L PLANTS
. B-4 8 ANNUALIZE D COST S FOR FIBER-BE D MIS T ELIMINATOR S FOR EXISTIN G HARD CHROMIUM PLATIN G OPERATION S B-4 9 CAPITAL COST S O F SINGL E PACKED-BE D SCRUBBER S FOR HARD CHROMIU

M ELECTROPLATIN

G MODE L PLANT S C- 2
ANNUALIZE D COST S FO R SINGL E PACKED-BE D SCRUBBER S FO

R NE W HARD CHROMIU M ELECTROPLATIN

G MODE L PLANT S C- 3

X I 

# 1 2P. M



## LIS T O F TABLE S (continued ) Pag e TABL E C- 3

TABL E C- 4

TABL E C- 5

TABL E C- 6

TABL E C-7 ,

TABL E C-8

. ANNUALIZE D COST S FOR SINGL E PACKED-BE D

SCRUBBER S FOR EXISTIN G HAR D CHROMIU

M ELECTROPLATIN

G MODE L PLANT S C- 4 CAPITAL COST S O F MESH-PAD MIS T ELIMINATORS

WIT H MES H PAD S I NSERIE S FOR HAR D CHROMIU M ELECTROPLATIN

G MODE L PLANT S C- 5
ANNUALIZE D COST S FOR MESH-PAD MIS T ELIMINATOR S WIT H MES H PAD S I NSERIE S FOR NE W HAR D CHROMIU M ELECTROPLATIN

G MODE L PLANT S C- 6 ANNUALIZE D COST S FOR MESH-PAD MIS T ELIMINATOR S WIT H MES H PAD S I NSERIE S FOR EXISTING HARD CHROMIU M ELECTROPLATIN

G MODE L PLANT S C- 7 CAPITAL COST S O F PACKED-BE D SCRUBBER/MESH-PA D MIS T ELIMINATO R SYSTEM S FOR HAR D CHROMIU M ELECTROPLATIN

G MODE L PLANT S C- 8
ANNUALIZE D COST S FO R PACKED-BE D SCRUBBER/MESH

PA D MIS T ELIMINATO R SYSTEM S FOR NE W HAR D CHROMIU M ELECTROPLATIN

G MODE L PLANT S C- 9
TABL E C-9

. ANNUALIZE D COST S FO R PACKED-BE D SCRUBBER/MESH

PA D MIS T ELIMINATO R SYSTEM S FOR EXISTING HARD CHROMIU

M ELECTROPLATIN

G MODE L PLANTS..
. C-1 0
TABL E C-10

.

TABL E C-1 1

TABL E C-1 2 CAPITAL COST S O F FIBER-BE D MIS T ELIMINATOR S

FOR HARD CHROMIU

M ELECTROPLATING MODE L PLANT S C-1 1 ANNUALIZE D COST S FOR FIBER-BE D MIS T ELIMINATOR S FOR NE W HARD CHROMIU M ELECTROPLATIN

G MODE L PLANT S C-1 2
ANNUALIZE D COST S FOR FIBER-BE D MIS T ELIMINATOR S FOR EXISTIN G HAR D CHROMIU

M ELECTROPLATIN

G MODE L PLANT S C-1 3

x i 1 

# 1 3P.1 5



## ABBREVIATION S USE D I NTHI S DOCUMENT

A A h 

## ° C
cm Cr0 3 

## dsc f dsc m 

## ° F f t ft 2 

## ft 3


## g ga l g r h r h p in

. in. 2 

## in

. w.c . k g kP a k W kWh L l b lb f 

## /f t
m m 2



## m 3



## mg mi l mi n M W =

=

=

=

=

=

=

=

=

=

=

=

=

=

=

=

=

=

=

=

=

=

=

=

=

=

-

=

=

=

=

=

= 

## amper e

-. , '/ 

## ampere-hou r degree s Celsiu s centimete r chromiu manhydride , commonl yknown a s drystandar d cubi c foo t dr ystandar d cubi c mete r degree s Fahrenhei t foo t squar e foo t cubi c foo t gram gallo n grai n hou r horsepowe r inc h squar e inc h inche s o f wate r colum n kilogram kilopasca l kilowat t kilowatt-hou r lite r pound pound forc e pe r foo t mete r squar e mete r cubi c meter s milligram thousandt ho f a n inc h minut e megawat t - 

## chromi c aci d

x m 

# S 1 4

## o z

u m 

## V y r = ounc e

= micromete r

= vol t

= yea r (micron )

XI V P.1 6



# 1 5P.1 7



## TECHNICAL ASSESSMENT O F NE W EMISSIONCONTRO L TECHNOLOGIE S USE D I NTH E HAR D CHROMIU M ELECTROPLATIN

G INDUSTRY
1. 0 INTRODUCTION
. 8 I n 1989 , th e Californi a Ai r Resource s Boar d (CARB ) approve d
a n Airborn e Toxi c Contro l Measur e (ATCM ) fo r hexavalen t chromiu m emission s fromchromiu mplatin g and anodizin g operations

. 'Unde r th e ACT M fo r har d chromiu melectroplatin g tanks , emissio n reduction s ar e relate d t o th e facility-wid e emissio n leve l considerin g an

ypreexistin g control

. Facilitie s wit h emission s les s tha n o r equa l t o 0.9 1 kg/y r ( 2 lb/yr ) mus t reduc e emission s fromeac htank b

y9 5 percen t o r achiev e a n emissio n limi t o f 0.1 5 mg/A

h (0.00 2 gr/Ah)

. Facilitie s wit hemission s o f a t leas t 0.9 1 kg/y r ( 2 lb/yr ) bu t les s tha n 4. 5 kg/y r (1 0 lb/yr ) mus t reduc e emission s fromeac htank b y9 9 percen t o r achiev e a n emissio n limi t o f 0.0 3 mg/A h(0.00 5 gr/Ah)

. Facilitie s wit h emission s o f 4. 5 kg/y r (1 0 lb/yr ) o r greate r mus t reduc e emission s fromeac htank by99. 8 percen t o r achiev e a n emissio n limi t o f 0.00 6 mg/A h(9. 3 x 10" 4 

## gr/Ah)

. Th e effec t o f thi s ATC M wa s t o forc e developmen t o f innovativ e approache s t o contro l tha t migh t achiev e highe r reduction s tha n thos e presentl yachieve d wit hmor e conventiona l technologie s typicall yapplie d i n chromiu m electroplatin g and anodizin g operations

. Vendor s o f conventiona l equipmen t incorporate d th e us e o f composit e mes h pad s int o traditiona l contro l system s i n a n effor t t o increas e contro l devic e performance

. I n addition , base d o n th e hig hperformanc e level s o f fiber-be d mis t eliminator s i n controllin g sulfuri c aci d mists , thes e system s wer e examine d t o determin e thei r applicabilit yand effectivenes s i n controllin g chromi c aci d emissions

. Sectio n 2. 0 provide s background informatio n fo r th e ne w contro l technologies

. Sectio n 3. 0 present s brie f description s o f
eac hne wcontro l technology

. Performanc e dat a fo r eac h technolog

yar e presente d i n Sectio n 4.0

. Sectio n 5. 0 contain s assessment s o f cos t an d environmenta l impact s associate d wit h
eac htechnology

. Finally , conclusion s regardin g th e


# 1 6P.1 8



## applicabilit yand effectivenes s o f th e ne wcontro l technologie s ar e presente d i n Sectio n 6.0

. 2. 0 BACKGROUN

D - f 

## 2. 1 Mesh-Pa d Mis t Eliminator s Mesh-pa d mis t eliminator s designe d prio r t o 198 6 ha d a singl e mes hpa d consisting o f layer s o f wove n materia l "wit hfibe r diameter s o f 0.0 9 cm(3 6 mils)

. Th e unit s wer e designe d fo r vertica l ga s flo wand di d no t incorporat e a n interna l spray syste mfo r cleaning o f th e pad

. Becaus e o f th e tendenc yo f thes e unit s t o plug , theygenerall ywer e no t recommende d fo r controllin g chromi c aci d mist

. Subsequen t generation s o f mesh

pa d mis t eliminator s (designe d i n 198 8 - 1989 ) incorporate d tw o o r thre e mes hpad s tha t consiste d o f materia l wove n fromstrand s o f fibe r wit hth e same fibe r diameter , whic hvarie d betwee n 0.0 5
and 0.0 9 cm(2 0 and 3 6 mils)

. Thes e newe r unit s wer e equippe d wit hinterna l spra ysystem s t o clea n th e pad s and wer e designe d t o accommodat e th e remova l o f th e pad s fo r additiona l cleaning

. Thus , th e pluggin g potentia l wa s minimized

. I n addition , thes e unit s wer e designe d t o accommodat e horizonta l ga s flow , permittin g bette r drainag e o f th e system
. Th e second generatio n mesh-pa d mis t eliminato r system s ha d performanc e level s tha t approximate d thos e obtaine d throughth e us e o f traditiona l packed-be d scrubbers

. I n th e earl y1990's , th e performanc e leve l o f mesh-pa d mis t eliminato r system s wa s furthe r enhance d bychangin g th e pa d configuratio n t o facilitat e th e captur e o f particle s les s tha n 5 nm (0.2 0 mil)

. Th e mos t recen t desig n chang e involve s th e us e o f a composit e mes hpad

. Thes e pad s diffe r fromtraditiona l mes h pad s i n tha t th e composit e pad s ar e wove n wit hlayer s o f materia l wit hvaryin g fibe r diameter s instea d o f layer s o f materia l wit h th e same fibe r diameter

. Th e layer s i n th e cente r o f th e composit e mes hpa d consis t o f extremel ysmal l diamete r fiber s (0.0 1 t o 0.0 2 cm[ 4 t o 8 mils])

. Th e layer s o n eithe r sid e o f th e cente r ar e mad e up o f progressivel ylarge r diamete r fiber s (0.0 4 t o 0.0 9 cm

[1 6 t o 3 7 mils])

. Th e primar ypurpos e o f thi s



# 1 7P.1 9



## configuratio n i s t o produc e a coalescing effect

. Smal l mis t droplet s tha t imping e o n th e pa d coalesc e int o large r droplet s a s theytrave l throughth e fine r mes hlayers

. Th e enlarge d particle s ca n the n b e easil yremove d i n th e bac k layer s o f th e pa d o r i n a subsequen t stag e i n th e contro l system
. Thes e pad s ma yb e use d i n serie s wit hothe r standar d type s o f pad^ s i n mis t eliminators , o r i n conjunctio n wit hpacked-be d scrubbers , t o captur e chromi c aci d mists

. Whe n composit e mes hpad s ar e use d i n mis t eliminators , multipl e pad s (typicall ytw o t o four ) ar e use d i n series

. Th e desig n o f eac hpa d i s determine d b yth e siz e o f th e mis t droplet s t o b e collected

. Th e composit e pa d i s typicall yth e second o r thir d stag e i n thi s typ e o f contro l system
. Irrigatio n system s and provision s fo r pa d remova l t o facilitat e cleanin g hav e bee n incorporate d t o achiev e bette r chromiu memissio n contro l efficiencies

. Traditionally , packed-be d scrubber s use d t o contro l chromi c aci d mis t wer e horizonta l o r vertica l countercurrent-flo wunit s equippe d wit hon e o r tw o packe d bed s followe d bya chevron-blad e mis t eliminato r section

. Th e design s o f thes e conventiona l scrubbe r system s hav e bee n upgrade d i n a n effor t t o increas e th e performanc e level

. Overhea d spraysystem s hav e bee n adde d t o ensur e sufficien t wettin g o f th e packe d be d and t o preven t chromiu mbuildup

. Finally , th e additio n o f a composit e mes hpa d sectio n behind th e packe d bed(s ) ha s mad e i t possibl e t o improv e th e overal l performanc e o f th e scrubbe r uni t and eliminat e th e nee d fo r a chevron-blad e mis t eliminator

. 2. 2 Fiber-Be d Mis t Eliminator s Fiber-be d mis t eliminator s hav e bee n use d predominantl yt o contro l aci d mist s from sulfuric , phosphoric , an d nitri c aci d plants

. Fibe r bed s hav e als o bee n use d t o captur e soli d particulate s an

d mixture s o f liqui d mist s and solubl e solid s (e.g. , sodiu

mchloride , ammoniu m nitrate). 1 

## Th e transfe r o f thi s technolog

yt o th e contro l o f emission s o f chromi c aci d mis t from



# 1 8P.2 0



## chromiu melectroplatin g and chromi c aci d anodizin g operation s ha s occurre d onl yrecently

. Fiber-be d mis t eliminator s typicall yconsis t o f on e o r mor e fibe r beds

. Eac hbe d consist s o f a hollo wcylinde r forme d from tw o concentri c screen s wit hth e fibe r packe d int o th e annula r spac e betwee n th e tw o screens . Thes e contro l system s use " inertia l impactio n an d Brownia n diffusio n t o remov e contaminant s froma ga s stream
. Fiber-be d unit s ar e designe d fo r horizontal , concurren t gas-liqui d flo wthroughth e bed

. A s th e ga s stream flow s towar d th e downstreamfac e o f th e bed , th e aci d mis t i n the ga s streamimpact s o n th e surfac e o f th e fiber s an d drain s down th e oute r fac e o f th e be d t o th e sum p whil e th e cleane d ga s flow s up and ou t th e top o f th e unit

. Thes e system s ar e equippe d wit h spraynozzle s t o reduc e th e potentia l fo r plugging

. I n a furthe r effor t t o preven t plugging , mos t vendor s recommend a pre filtering system
. 3. 0 DESCRIPTION S O F EMISSION S CONTRO L TECHNOLOGIE S Thi s sectio n present s basi c description s and operatin g principle s fo r eac ho f th e technologie s examined

. Th e mis t eliminato r an d packed-be d scrubbe r system s operat e wit hinertia l impactio n and direc t interceptio n a s th e primar y contro l mechanisms

. Inertia l impactio n involve s th e collisio n o f larg e particle s wit ha stationarysurfac e t o whic hthe yadhere

. Whe n th e mechanis m i s direc t interception , particle s attemp t t o follo wth e streamlin e around th e collectio n surface , bu t becaus e o f thei r siz e an

d relativ e velocity , the yar e intercepte d b yth e flui d laye r tha t surround s th e collectio n surface

. Collecte d liqui d droplet s drai n t o th e botto mo f th e collectio n devic e du e t o gravity

. Anothe r contro l mechanis muse d i n fiber-be d mis t eliminator s i s Brownia n diffusion

. Brownia n diffusio n i s th e rando mmovemen t o f particle s du e t o collision s o n a molecula r level

. Thi s rando m motio n place s th e particle s o n a collisio n pat hwit hth e collectio n media

. Brownia n diffusio n i s no t a majo r facto r fo r particle s large r than 3 /x m(0.1 2 mil)

.



# I 1 9P.2 1



## 3. 1 Composit e Mesh-Pa d Mis t Eliminato r System s Th e principa l contro l mechanism s fo r mesh-pa d mis t eliminator s ar e drople t impactio n and ' interception

. Inertia l impactio n occur s whe n large r particles , traveling wit hsufficien t velocity , collid e wit hth e pa d filament s and adher e t o thei r surface

. Othe r particles , becaus e o f thei r siz e and relativ e velocity , ar e intercepte d b yth e flui d laye r surroundin g th e surfac e o f th e filament

. I n th e composit e mesh-pa d 'system , th e materia l layer s i n th e cente r o f th e pa d ar e compose d o f extremel ysmall-diamete r (0.0 1 t o 0.0 2 cm[ 4 t o 8 mil] ) fibers

. Th e materia l layer s o n eithe r sid e o f th e cente r ar e compose d o f progressivel ylarge r (0.0 4 t o 0.0 9 cm[1 6 t o 3 7 mil] ) diamete r fibers

. A s th e ga s streamflow s throughth e composit e mes hpad , th e smal l particle s tha t escap e th e collectio n devic e upstreamo f th e mes hpa d (e.g. , packed-be d scrubbe r o r othe r mes hpads ) imping e o n th e composit e pa d an d coalesc e int o large r droplets

. Thi s proces s i s accomplishe d b

yusin g a pa d comprise d o f layer s o f materia l wit h variou s fibe r diameter s an d operatin g th e pa d a t it s floo d point

. Th e floo d poin t i s th e conditio n i n whic hth e liqui d flo wi n th e pa d i s hampere d causing liqui d t o buil d u p i n th e pad

. Th e enlarge d particle s ar e the n remove d i n th e bac k sid e o f th e composit e mes hpa d o r i n th e backup mes hpa d downstreamo f th e composit e pad

. Whe n composit e mes hpad s ar e use d i n series , th e pressur e dro p acros s th e systemtypicall yrange s from1. 2 t o 1. 7 kP a ( 5 t o 7 in

. w.c)

. Th e performanc e o f mesh-pa d mis t eliminator s i s dependen t upo n th e fibe r diameter , voi d fractio n (amoun t o f fre e volume) , and th e ai r velocit ypassin g throughth e pad

. On e o f th e majo r factor s tha t affect s mesh-pa d mis t eliminato r performanc e i s th e tendenc yo f th e uni t t o plug , wit hth e tendenc ybein g inversel y proportiona l t o th e siz e o f th e fiber

. Regula r cleanin g o f th e pad s i s critica l t o optimizin g performance

. Th e voi d fractio n influence s performanc e becaus e th e highe r th e voi d fraction , th e



# 2 0P.2 2



## greate r th e resistanc e t o plugging

. Mes hpad s wit hhighe r voi d fraction s ca n handl e heavie r contaminan t loadings

. Ga s streamvelocit yaffect s performanc e becaus e th e entraine d particle s mus t hav e adequat e velocit yt o collid e wit h th e fibers

. However , ga s velocitie s tha t ar e to o hig hca n caus e collecte d particle s t o b e reentraine d i n th e ga s stream
. Therefore , ga s velocitie s shoul d b e maintaine d hig h enoug ht o optimiz e collectio n throughinertia l impactio n ye t no t caus e reentrainment

. Composit e mes hpad s ar e use d i n variou s configuration s and
ar e availabl e throughmanychromiu melectroplatin g equipmen t suppliers

. 3.1. 1 Composit e Mes hPad s Use d i n Series

. Whe n mes hpad s ar e use d i n series , th e firs t stage s o f th e uni t generall yserv e t o reduc e th e loadin g o n th e pads

. Th e firs t stag e i s sometime s a singl e o r doubl e se t o f chevro n blades

. Thes e parallel , chevron-shape d baffle s ar e use d t o remov e th e larg e particles , whic hconstitut e th e majorit yo f chromiu memissions

. Th e us e o f chevro n blade s reduce s th e tendenc yfo r th e pad s t o plug

. Th e chevron-blad e sectio n ma yb e followe d bya coars e mes hpa d tha t i s use d t o furthe r reduc e th e loadin g o n th e composit e pad

. Thi s firs t mes hpa d i s sometime s irrigate d wit hwate r t o promot e th e coalescin g (enlargement ) o f th e mis t droplets , whic hmake s th e droplet s easie r t o remove. 2 

## Th e primar ypurpos e o f th e second pa d (composit e pad ) i s t o increas e th e siz e o f th e particle s tha t penetrate d th e firs t pad

. Th e large r particle s ar e the n collecte d o r reentraine d i n th e bac k sid e o f th e second pad. 2 

## Th e las t pa d i s use d t o captur e th e reentraine d materia l tha t wa s no t collecte d byth e previou s pads

. I n som e mesh-pa d systems , al l th e pad s ar e operate d dry wit hperiodi c washin g t o clea n th e pads

. 3.1. 2 Composit e Mes hPad s Use d i n Conjunctio n wit hPacked-Be d Scrubbers

. Remova l o f chromi c aci d mis t i s accomplishe d byimpingemen t o f th e droplet s o n th e packin g materia l i n th e upgrade d scrubbe r



# S 2 1P.2 3



## systems
. Th e velocit yo f th e ga s strea mi s reduce d a t th e scrubbe r inle t t o maximiz e impingemen t efficiency

. Wate r i s spraye d countercurren t t o th e flo wof/ 8 th e ga s stream , .thereb y enlargin g th e mis t droplet s containe d i n th e ga s streamand causing some droplet s t o dro p t o th e botto mo f th e scrubber

. Th e ga s stream'the n passe s throughth e packe d be d wher e chromi c aci d droplet s imping e o n th e packin g materia l and ar e washe d t o th e botto mo f th e scrubber

. Th e packin g materia l use d i n th e newe r scrubber s ha s a highsurfac e area-to-volum e rati o (presenting mor e impactio n opportunities ) and th e capacit yt o distribute , collect , and re'dispers e th e scrubbing liqui d quickly

. Composit e mes hpads , whic har e locate d behind th e packe d bed , ar e use d t o remov e an

yreentraine d droplet s tha t ar e carrie d ove r from th e packed-be d section , a s wel l a s particle s tha t ar e to o smal l t o b e capture d b

yth e packe d bed

. On e o r tw o coars e mes hpad s follo w th e composit e pa d and ar e use d t o remov e an yenlarge d droplet s tha t ar e reentraine d fromth e composit e pad

. 3. 2 Fiber-Be d Mis t Eliminator s Fiber-be d mis t eliminator s remov e contaminant s from a ga s streamusin g th e mechanism s o f inertia l impactio n and Brownia n diffusion

. Whe n inertia l impactio n i s th e principa l contro l mechanism , fiber-be d mis t eliminator s ar e mor e efficien t tha n othe r contro l device s usin g thi s mechanis m(e.g. , typica l mesh

pa d mis t eliminator s and packed-be d scrubbers ) becaus e o f th e highe r surfac e area-to-volum e ratios

. Thes e highe r ratio s resul t i n greate r obstructio n o f th e ga s flow , permittin g additiona l opportunitie s fo r impactio n o f th e mis t droplet s ont o th e be d fibers

. Fibe r bed s designe d fo r contaminan t remova l byBrownia n diffusio n a s wel l a s inertia l impactio n ar e th e mos t efficien t mis t eliminator s currentl yavailable

. Fiber-be d unit s ar e designe d fo r horizontal , concurren t gas liqui d flo wthroughth e bed

. Th e contaminate d ga s streamflow s towar d th e downstreamfac e o f th e bed

. Th e aci d mis t i n th e ga s streamimpact s o n th e surfac e o f th e fiber s and drain s down th e oute r fac e o f th e be d t o th e sum p whil e th e cleane d ga s flow s up



# 2 2

## and ou t the top o f th e unit

. Fiber-be d unit s ar e equippe d wit ha

wate r spraysyste mt o was hdown an ylarg e particulate s tha t may clo g th e unit

. Th e sprayi s activate d i n respons e t o a n increas e i n pressur e dro p ove r tha t specifie d i n th e desig n o f th e unit

. Pressur e drop s fo r impactio n unit s rang e from0.1 5 t o 2. 0 kP a (0. 5 t o 8 in

. w.c) , and pressur e drop s fo r Brownia n diffusio n unit s rang e from1. 2 t o 3. 7 kP a ( 5 t o 1 5 in

. w.c)

. Th e majo r factor s affectin g th e performanc e o f fiber-be d mis t eliminator s ar e th e velocit yo f th e inle t ga s stream , pressur e dro p acros s th e fibe r bed , and th e wate r recirculatio n rate
. Wit himpaction-typ e units , th e velocit yo f th e ga s flowing t o th e uni t mus t b e maintaine d abov e a certai n lowe r limi t becaus e o f th e decreas e i n efficienc yo f inertia l impactio n a t lo wflo wrates. 3 

## Thi s lowe r limi t varies , dependin g o n th e specifi c desig n o f th e impactio n bed , bu t typicall yrange s from 3 0 m/mi n (10 0 ft/min ) fo r some fibe r bed s t o 11 0 m/mi n (35 0 ft/min ) fo r othe r beds. 4 

## Th e Brownian-diffusio n typ e unit s hav e n o lowe r limi t o n ga s flo wrat e becaus e mis t collectio n increase s a s th e ga s flo wrat e approache s zero . Th e maximumga s flo wrat e i n fiber-be d mis t eliminator s i s define d byth e poin t
a t which : (1 ) collectio n efficienc ybegin s t o dro p belo w acceptabl e levels , o r (2 ) th e gas-phas e pressur e dro p become s excessive. 3 

## Performanc e ma yb e affecte d a s a resul t o f pluggin g o f th e be d i f th e wate r spraysyste mi s no t activate d i n respons e t o a n increas e i n th e pressur e drop

. Mos t vendor s d o no t recommend fiber-be d mis t eliminator s a s th e firs t stag e o f th e contro l syste mbecaus e o f thei r tendenc y t o plug

. I t i s recommende d tha t coars e pre-filterin g b e provide d upstreamo f th e fibe r bed s t o preven t plugging

. Th e pre filterin g device s rang e froma serie s o f mes hpad s t o a complet e packed-be d scrubbe r unit

. 4. 0 EMISSION S TES T DAT A Thi s sectio n present s th e result s o f full-scal e emissio n testing conducte d o n commercia l unit s use d t o contro l chromiu m emission s from

har d chromiu

melectroplatin g and chromi c aci d 8 

# a 2 3P.2 5



## anodizin g operations

. Sample s t o b e analyze d fo r hexavalen t an d tota l chromiu

m wer e obtaine d throughisokineti c samplin g usin g a modifie d EPAMetho d 5 samplin g trai n 8(4 0 CFR Par t 6 0 - Appendi x A)

. Th e trai n wa s modifie d b yeliminatin g th e filter , usin g glass-line d probe s and glas s nozzles , and usin g 0. 1 norma l sodiu mhydroxid e instea d o f wate r i n th e impingers

. Metho d 5 , whic hals o require s th e us e o f EP AMethod s 1 throug h4 , provide s detaile d procedures , equipmen t criteria , and othe r consideration s necessaryt o obtai n accurat e and representativ e emission s samples

. Th e collecte d sample s wer e analyze d usin g io n chromatograph

ywit ha post-colum n reacto r fo r hexavalen t chromiu m and atomi c absorptio n fo r tota l chromium

. I n tw o o f th e emission s test s describe d i n thi s section , bot hhexavalen t and tota l chromiu m wer e measured

. I n th e remaining two , onl ytota l chromiu mwa s measured

. Result s o f th e emission s test s performe d b yEP At o evaluat e performance s o f contro l technique s fo r chromiu memission s indicat e tha t hexavalen t chromiu mconstitute s th e majorit yo f tota l chromiu m emission s fromchromiu melectroplatin g and anodizin g operations. 5 

## Thus , fo r thos e test s i n whic honl ytota l chromiu mwa s measured , th e result s ar e assume d t o b e representativ e o f hexavalen t chromiu mlevels

. Mor e detaile d informatio n abou t eac htes t i s presente d i n tabula r for

m i n Appendi x A
. 4. 1 Composit e Mesh-Pa d Test s 4.1. 1 Mesh-Pa d Mis t Eliminator--Precisio n Engineering

. Seattle

. Washington 6 

## Emissio n sourc e test s wer e conducte d b yEP Aa t Precisio n Engineerin g o n Decembe r 17-19 , 1991 , t o evaluat e th e performanc e o f a state-of-the-ar t mesh-pa d mis t eliminator

. Precisio n Engineerin g i s a mediu msiz e jo b sho p tha t perform s har d chromiu m platin g o f industria l rolls , hydrauli c cylinders , and miscellaneou s smal l parts
. 4.1.1. 1 Proces s Description

. Th e platin g sho p typicall y operate s 2 4 hour s pe r day , 5 day s pe r week

. Ther e ar e si x har d 9 

# 8 2 4P.2 6



## chromiu mplatin g tank s a t thi s facility

. Durin g th e sourc e tests , Tank s 1 , 2 , and 7 wer e tested

. Tabl e l present s th e dimension s an

d operatin g parameters^fo r eac hproces s tank

. Al l thre e platin g tank s ar e divide d int o tw o cell s and eac hcel l i s equippe d wit ha rectifie r t o contro l th e curren t flow

. Curren t rating s (per cell ) o f th e rectifier s ar e 5,00 0 A , 3,00 0 A,

- and 10,00 0 Afo r Tank s 1 , 2 , and 7 , respectively

. Th e platin g solutio n i n eac htank consist s o f chromi c aci d a t a concentratio n o f 25 0 g/ L (3 3 oz/gal)

. Th e temperatur e o f th e platin g solutio n i s maintaine d a t approximatel y6 0 C (140°F)

.

TABL E 1

. DIMENSION S AND OPERATING PARAMETER S FOR TH E HARD CHROMIU M PLATIN

G TANK S A T PRECISIONENGINEERING , SEATTLE , WASHINGTON

Tan k NO
. Dimension s

(1 , w , d ) , m(ft ) 2.0 , 1.3 , 3. 7 (6.5 , 4.2 , 12.0 ) 2.0 , 1.3 , 3. 7 (6.5 , 4.2 , 12.0 ) 1.2 , 1.8 , 5. 5 (4.0 , 5.9 , 18.0 ) Capacity , L (gal ) 9,28 0 (2,450 ) 9,28 0 (2,450 ) 11,83 0 (3,120 ) Maximumrate d

curren t pe r cell , A 5,00 0 3,00 0 10,00 0 1
2
7

Al l o f th e platin g tank s ar e service d b yoverhea d hoist s tha t ar e use d t o transfe r part s i n and ou t o f th e tanks

. Heatin g and cooling system s ar e locate d i n eac h tank t o maintai n uniform solutio n temperature
. I n addition , eac ho f th e tank s i s equippe d wit ha n ai r agitatio n syste mt o ai d i n maintainin g unifor mbat h concentratio n and temperature
. 4.1.1. 2 Ai r Pollutio n Control. 2 

## * 6 

## Aschemati c o f th e ventilatio n syste man d contro l devic e servicin g th e platin g tank s i s show n i n Figur e 1

. Th e syste m wa s installe d i n 1991

. Eac htank i s equippe d wit h a double-side d hoo d fo r ventilation

. Moistur e extractor s ar e locate d i n th e
1 0


# S 2 5P.2 7

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### 1 1 

# 2 6P.2 8



## hoo d uptake s t o remov e th e coarse r mis t droplet s fromth e exhaus t stream , thereb

yreducing th e inle t loadin g t o th e mis t eliminator

. Tank s l an d 2 ar e ducted?'togethe r t o formon e inle t le g t o th e mis t eliminator , whil e Tank 7 i s ducte d separatel yt o for manothe r inle t le g t o th e mis t eliminator

. Th e tw o inle t leg s joi n jus t prio r t o th e inle t plenu m o f th e mis t eliminator

. Th e mesh-pa d mis t eliminato r i s locate d o n th e roo f o f th e platin g sho p and i s a firs t generatio n Spectr a V manufacture d b

y KC H Services , Inc
. Th e uni t consist s o f a se t o f chevron-blad e baffle s followe d b ya serie s o f thre e mes h pads

. Th e mes h pad s wer e manufacture d b yKimre , In c Th e firs t pa d i n th e serie s i s a coars e mes htha t consist s o f materia l wove n fromstrand s o f fibe r wit hth e same fibe r diameter , whic hrange s from0.0 4 t o 0.0 9 cm(1 6 t o 3 7 mils)

. Thi s pa d remove s th e majorit yo f th e chromi c aci d mis t particles

. Th e second pa d (th e composit e mes h pad ) serve s t o enlarg e th e siz e o f th e particle s tha t penetrat e th e firs t pad , an

d thes e particle s the n imping e o n th e bac k sid e o f th e second pa d and coalesc e int o large r droplets

. Thi s pa d i s comprise d o f layer s o f materia l wit hfibe r diameter s typicall y rangin g from0.00 5 t o 0.0 4 cm( 2 t o 1 6 mils)

. Th e materia l layer s i n th e cente r o f thi s second pa d contai n th e smalles t diamete r fibers , wit hth e layer s o n eithe r sid e o f th e cente r containin g progressivel ylarge r diamete r fibers

. Th e purpos e o f th e thir d pad , whic hi s identica l t o th e firs t pad , i s t o remov e an

yreentraine d droplet s carrie d ove r fromth e second pad

. Th e desig n pressur e dro p acros s th e mis t eliminato r i s 1. 7 kP a ( 7 in

. w.c)

. A n increas e i n pressur e dro p abov e th e norma l operatin g rang e fo r a give n pa d indicate s tha t th e pa d
*Mentio n o f trad e name s o r commercia l product s i s no t intende d t o constitut e endorsemen t o r recommendatio n fo r use .

1 2 

# S 2 7P.2 9



## need s t o b e washe d down t o remov e chromiu mtha t ha s buil t up o n th e pad

. Thi s i s accomplishe d wit ha serie s o f spraynozzle s locate d i n fron t o f eac hmes hpad

. 4.1.1. 3 Proces s Condition s Durin g Testing. 6 

## Thre e sampl e '
run s wer e conducte d a t eac ho f th e tw o inle t location s ( Aand B )
and a t th e outle t (stack , C ) o f th e mis t eliminator

. Testin g a t th e thre e location s wa s performe d simultaneously

. Eac htes t run wa s 4 t o 6 hour s i n duration

. Proces s operatin g parameter s monitore d durin g eac hsampl e run include d th e voltage , current , ampere-hours , and-platin g solutio n temperatur e fo r eac hplatin g tank i n operation

. Averag e value s fo r eac hsampl e run ar e presente d i n Tabl e 2

. Hydrauli c cylinder s wer e plate d durin g eac htes t run . Th e surfac e area s o f th e part s plate d durin g th e tes t programar e include d i n Tabl e 2

. Pressur e drop s acros s eac h
mes hpa d and acros s th e overal l uni t wer e monitore d durin g eac h tes t run an d n o increas e i n pressur e dro p wa s noted

. 4.1.1. 4 Result s o f Emission s Testing. 6 

## Result s o f th e emission s testing ar e presente d i n Table s 3 a an d 3b

. Tota l chromiu memission s from

Tank s 1 and 2 measure d a t Inle t A average d 0.3 5 mg/dsc m(0.1 5 x 10" 3 

## gr/dscf) , o r 5. 6 x 10" 3 

## kg/h r (1 2 x 10" 3 

## lb/hr)

. A t Inle t B , tota l chromiu memission s from Tan k 7 average d 0.1 5 mg/dsc m(0.0 6 x IO" 3 

## gr/dscf) , o r 1. 3 x IO" 3 

## kg/h r (2. 9 x IO" 3 

## lb/hr)

. Tota l chromiu m emission s measure d a t th e outle t o f th e mesh-pa d mis t eliminato r average d 0.01 1 mg/dsc m( 5 x IO" 6 

## gr/dscf) , o r 0.2 7 x IO" 3 

## kg/h r (0.5 8 x IO" 3 

## lb/hr)

. Hexavalen t chromiu m emission s fromTank s 1 and 2 measure d a t Inle t Aaverage d 0.3 4 mg/dsc m(0.1 5 x IO" 3 

## gr/dscf) , o r 5. 3 x IO' 3 

## kg/h r (1 2 x IO" 3 

## lb/hr)

. Hexavalen t chromiu m emission s fromTan k 7 a t Inle t B average d 0.1 5 mg/dsc m (0.0 6 x IO" 3 

## gr/dscf) , o r 1. 3 x IO" 3 

## kg/h r (2. 9 x IO" 3 

## lb/hr)

. A t th e outle t o f th e mesh-pa d mis t eliminator , hexavalen t chromiu memission s average d 0.01 0 mg/dsc m(0.00 5 x IO" 3 

## gr/dscf) , o r 0.2 5 x IO" 3 

## kg/h r (0.5 5 x IO" 3 

## lb/hr)

.

1 3


# m 

# a28P.3 0



### TABL E 2

. AVERAG E OPERATING PARAMETER S DURING EAC H EMISSION S TES T RU

NA T PRECISIONENGINEERING , SEATTLE , WASHINGTO N

Ru n No
. 1

2

3

- 

### Tan k No
. I A I B 2 A 2 B 7 A 7 B I A I B 2 A 2 B 7 A 7 B I A I B 2 A 2 B 7 A 7 B Operatin g voltage , V 7. 0 7. 0 7. 6 7. 6 8. 0 6. 4 6. 3 7. 2 7. 4 6. 6 6. 4 6. 4 6. 4 7. 7 7. 8 6. 0 7. 3 Operatin g

current , A 4,30 0 3,70 0 2,30 0 1,40 0 7,00 0 3,60 0 3,40 0 1,70 0 1,85 0 1,30 0 2,00 0 2,97 0 2,80 0 2,00 0 1,70 0 1,00 0 7,20 0 Temperatur e

o f platin g solution , ° C (°F ) 14 0 14 0 14 0 14 0 14 0 14 0 14 0 14 0 14 0 14 0 14 0 14 0 14 0 14 0 14 0 14 0 14 0 14 0 « Surfac e

are a plate d m 2 

### 36 8 16 7 33 2

36 8 16 7 46 9

26 0 16 7 474 -(ft z 

### ) (3,960 ) (1,800 ) (3,570 )
(3,960 ) (1,800 ) (5,050 )
(2,800 ) (1,800 ) (5,100 )

1 4 

# a2 9

## TABL E 3a

. PERFORMANC E DATAFO R TH E MESH-PAD MIS T ELIMINATO R A T PRECISIO N ENGINEERING , SEATTLE , WASHINGTON(TOTA L CHROMIUM TES T RESULTS )

Inle t A Inle t B Outle t (C) Tota l chromiu memission s Tota l chromiu memission s Tota l chromiu memission s RunProces s kg/h r Proces s kg/h r Proces s kg/h r %Effi

No

. current , A

hmg/dsc m(IO" 3 ) mg/A hcurrent , A hmg/dsc m(IO* 3 ) mg/A hcurrent , Ahmg/dsc m(IO' 3 ) mg/A hciency a 1 2 3 AV G 67,00 0

42,00 0 38,00 0 49,00 0 0.3 1

0.2 9 0.4 5 0.3 5 4. 8

4. 4 7. 5 5. 6 0.42 9 0.41 9 0.78 9 0.54 6 42,00 0

28,70 0 32,80 0 34,50 0 0.1 5

0.1 4 0.1 5 0.1 5 1. 4

1. 3 1. 2 1. 3 0.20 0 0.18 1 0.14 6 0.17 6 109,00 0

70,70 0 70,70 0 83,50 0 0.01 3

0.01 1 0.00 9 0.01 1 0.3 2

0.2 5 0.2 3 0.2 7 0.01 8 0.01 4 0.01 3 0.01 5 94. 8

95. 6 97. 4 95. 9
•-Efficiencie s ar e calculate dfrommas s emissio nrates , an dth e averag e i s base do naveragin g efficiencie s fo r eac hrun . Becaus e ther e wer e tw o inle t samplin g locations , efficiencie s wer e determine dby usin g th e sum s o f th e tw o inle t

mas s emissio nrates

.

u i



## C O 

# o TABL E 3b

. PERFORMANC E DATAFO R TH E MESH-PAD MIS T ELIMINATO R A T PRECISIO N ENGINEERING , SEATTLE , WASHINGTON(HEXAVALEN T CHROMIUM TES T RESULTS )

Run No

. 1 2 3 AV G Proces s current , Ah 67,00 0 42,00 0 38,00 0 49,00 0 Inle t

A Hexavalen t

chromiu m emission s mg/dsc m 0.2 9 0.2 8 0.4 4 0.3 4 kg/h r

(IO" 3 ) 4. 6 4. 2 7. 2 5. 3 mg/A h 0.41 1 0.40 0 0.75 8 0.52 3 Proces s current , A

h 42,00 0 28,70 0 32,80 0 34,50 0 Inle t

B Hexavalen t

chromiu m emission s mg/dsc m 0.1 5 0.1 3 0.1 7 0.1 5 kg/h r

(IO" 3 ) 1. 4 1. 1 1. 4 1. 3 mg/A h 0.20 0 0.15 3 0.17 1 0.17 5 Proces s current , Ah 109,00 0 70,70 0 70,70 0 83,50 0 Outle t

(C ) Hexavalen t

chromiu m emission s kg/h r mg/dsc m(\0) 0.01 4 0.3 4 0.00 9 0.2 2 0.00 8 , 0.2 0 0.01 0 0.2 5 mg/A h

0.01 9 0.01 2 0.01 1 0.01 4 %Effi

ciency * 94. 3 95. 8 97. 7 95. 9
Efficiencie s ar e calculate dfrommas s emissio nrates , an dth e averag e i s basedo naveragin g efficiencie s fo r eac hrun . Becaus e ther e wer e tw o inle t samplin g locations , efficiencie s wer e determine dby usin g th e sum s o f th e tw o inle t

mas s emissio nrates

.P.3 2



## I n calculatin g th e overal l remova l efficienc yo f th e mesh

pa d mis t eliminator , th e tota l mas s emissio n rate s fo r Inlet s A
an d B wer e compare d t o th e outle t mas s emissio n rate
. Th e apparen t effectivenes s o f th e moistur e extractor s i s indicate d b y th e inle t loading values , which , despit e th e relativel yhig h proces s current , ar e unusuall ylow

. Th e remova l efficienc y average d 95. 9 percen t fo r bot htota l chromiu mand hexavalen t chromium

. Th e averag e tota l curren t applie d t o th e tank s durin g outle t testin g wa s 83,50 0 Ah

. 'Therefore , th e proces s emissio n rate s base d o n tota l and hexavalen t chromiu mmeasurement s wer e 0.01 5 mg/A

h(2^ 3 x IO" 4 

## gr/Ah ) and 0.01 4 mg/A h(2. 2 x IO" 4 

## gr/Ah)

. 4.1. 2 Mesh-Pa d Mis t Eliminator--Monro e Aut o Equipment

. Hartwell

. Georgia 7 

## Sourc e testing wa s conducte d a t Monro e Aut o Equipment , Hartwell , Georgia , o n Decembe r 1 8 - 20 , 1991 , t o evaluat e th e performanc e o f a composit e mesh-pa d mis t eliminator

. Emission s testing wa s performe d b yIEA , Inc , o f Researc hTriangl e Park , Nort hCarolina , and observe d bya representativ e o f th e U.S
. EPA
. Th e Monro e Aut o Equipmen t platin g operatio n use s a chemica l fume suppressan t t o inhibi t misting

. Therefore , testin g wa s performe d wit han d withou t th e fume suppressan t i n th e platin g bath

. Monro e Aut o Equipmen t perform s har d chromiu melectroplatin g o f shoc k absorber s o f variou s sizes

. Th e platin g lin e i s typicall yoperate d 5 day s pe r wee k and 1 6 hour s pe r day

. 4.1.2. 1 Proces s Description. 7 

## * 8 

## Th e shoc k absorbe r rod s ar e loade d int o a carrier , si x a t a time , and th e carrie r i s conveye d from

tank t o tank throughth e platin g line

. Ther e i s on e chromiu

melectroplatin g tank i n th e platin g line ; i t i s 1. 4 m (4. 5 ft ) wid e b

y9. 1 m (3 0 ft ) long b

y0.9 1 m(3. 0 ft ) dee p and hold s abou t 11,40 0 L (3,00 0 gal ) o f platin g solution

. Th e platin g solutio n i n th e tank contain s chromi c aci d i n a concentratio n o f 24 0 g/ L (3 2 oz/gal)

. Th e norma l operatin g bat h temperatur e i s 54° C (130°F)

. Th e platin g tank i s equippe d wit h heatin g an

d cooling system s an d i s ai r agitate d t o maintai n a 1 6 

# a3 iP.3 3



## uniformplatin g bat htemperatur e an d composition

. Th e tank i s service d bya n 11,00 0 A , 1 2 V rectifie r and i s operate d a t a curren t ranging from3,30 0 At o 10,00: 0 Adependin g o n th e lengt h
o f th e shoc k absorbe r rods

. 4.1.2. 2 Ai r Pollutio n Control. 2,7, 9 

## Th e chromiu memission s fromth e platin g tank ar e exhauste d t o a mesh-pa d mis t eliminato r syste mconsisting o f tw o set s o f double-side d chevro n blade s followe d b

ya serie s o f thre e mes hpads

. Th e mes hpad s wer e manufacture d b

yKimre , Inc
. Th e contro l system , a Spectr a V , manufacture d b

yKC H Services , In c , wa s installe d i n Novembe r o f 1991

. Th e firs t pa d i n th e serie s o f pad s i s a coars e mes htha t typicall yconsist s o f materia l wove n fromstrand s o f fibe r wit h th e same fibe r diameter , whic hvarie s betwee n 0.0 4 and 0.0 9 cm (1 6 and 3 7 mils)

. Thi s pa d remove s th e majorit yo f th e chromi c aci d mis t particles

. Th e second pa d (th e composit e mes h pad )
serve s t o enlarg e th e siz e o f th e particle s tha t penetrat e th e firs t pad , and thes e large r particle s the n imping e o n th e bac k sid e o f th e second pad

. Thi s pa d i s comprise d o f layer s o f materia l wit hfibe r diameter s typicall yranging from0.00 5 t o 0.0 4 cm( 2 t o 1 6 mils)

. Th e materia l layer s i n th e cente r o f thi s second pa d contai n th e smalles t diamete r fibers , wit h th e layer s o n eithe r sid e o f th e cente r containin g progressivel y large r diamete r fibers

. Th e purpos e o f th e thir d pad , whic hi s identica l t o th e firs t pad , i s t o remov e an yreentraine d droplet s carrie d ove r from

th e second pad

. Th e mesh-pa d mis t eliminato r syste mi s designe d t o accommodat e a flo wrat e o f 80 0 m 3 

## /mi n (28,00 0 ft 3 

## /min ) and ha s a desig n pressur e dro p acros s th e entir e syste m o f 1. 3 kP a (5.2 5 in

. w.c)

. Th e contro l syste mi s operate d drybu t i s equippe d
Mentio n o f trad e name s o r commercia l product s i s no t intende d t o constitut e endorsemen t o r recommendatio n fo r use .

1 7 

# S 3 2P.3 4



## wit ha spraysystemt o was hth e individua l pad s whe n th e pressur e dro p acros s th e syste mincreases

. Durin g th e emission s testing , a ^chemica l fume suppressan t (a n M& T Fumetro l 21 0 combinatio n foa mblanke t and wettin g agen t ) wa s use d durin g hal f o f th e emission s tes t runs . Th e "foa m i s designe d t o inhibi t chromi c aci d mistin g from th e platin g bat hb ytrapping th e mis t i n th e foa m layer

. Th e wettin g agen t inhibit s mistin g b

ylowering th e surfac e tensio n o f th e platin g bath , allowin g th e gase s t o escap e a t th e surfac e wit hles s o f a burstin g effect

. 4.1.2. 3 Proces s Condition s Durin g Testing. 7 

## Si x emission s tes t run s wer e conducte d a t th e inle t and outle t o f th e mesh-pa d mis t eliminato r systemt o characteriz e th e overal l performance

. Eac htes t run wa s approximatel ytw o hour s i n duration

. Tes t Run s 1 , 3 , and 4 wer e performe d whe n n o fume suppressan t wa s used , and tes t Run s 2 , 5 , an d 6 wer e performe d whe n th e combinatio n foa m blanke t and wettin g agen t wa s use d i n th e bath

. Tabl e 4 present s th e averag e operatin g parameter s (voltage , current , and temperatur e o f th e platin g solution ) monitore d durin g eac htes t
run . Th e pressur e dro p acros s th e mesh-pa d mis t eliminato r syste m di d no t increas e durin g an yo f th e tes t runs ; therefore , n o washin g o f th e pad s wa s necessary . Th e foa mblanke t use d durin g tes t Run s 2 , 5 , and 6 wa s maintaine d a t a thicknes s betwee n 3 and 8 c m( 1 and 3 in. ) wit hth e heavie r layer s i n th e corner s o f th e tank

. 4.1.2. 4 Result s o f Emission s Testing. 7 

## Tabl e 5 present s th e performanc e dat a fo r th e mesh-pa d mis t eliminato r syste m teste d a t Monro e Aut o Equipment

. Emission s measure d a t th e inle t
*Mentio n o f trad e name s o r commercia l product s i s no t intende d t o constitut e endorsemen t o r recommendatio n fo r use .

1 8 

# fi 3 3P.3 5



## TABL E 4

. AVERAG E OPERATIN G PARAMETER S MONITORE D DURING EAC H EMISSION S TES T RU NA T MONRO E AUT O EQUIPMENT , HARTWELL , GEORGI A

Run No
. 1 2 3 4 5 6 Operatin g voltage , V 6. 4 6. 4 6. 4

. 6. 3 7. 2 7. 2 Operatin g

current , A 6,80 0 6,80 0 6,80 0 6,80 0 10,10 0 10,20 0 Temperatur e

o f platin g solution , ° C (°F) - 14 1 14 1 14 1 14 0 14 4 14 3

whe n a fume suppressan t wa s no t use d o n th e platin g bat haverage d 0.9 5 mg/dsc m(4. 2 x IO" 4 

## gr/dscf) , o r 41. 6 x IO" 3 

## kg/h r (91/ 7 x IO" 3 

## lb/hr)

. Emission s measure d a t th e outle t o f th e mesh-pa d mis t eliminato r syste mwhe n a fume suppressan t wa s no t use d average d 0.01 1 mg/dsc m(0. 5 x IO" 5 

## gr/dscf) , o r 0.5 2 x 10" 3 

## kg/h r (1. 1 x 10" 3 

## lb/hr)

. Th e remova l efficienc yo f th e mesh-pa d mis t eliminato r contro l syste mi n th e absenc e o f a fume suppressan t average d 98. 7 percent
. Th e averag e tota l
curren t applie d t o th e electroplatin g tank durin g outle t testin g average d 13,60 0 Ah

. Therefore , th e proces s emissio n rate , base d
o n tota l chromiu

m measurements , wa s 0.07 9 mg/A h( 1 x 10" 3 

## gr/Ah)

. Whe n a fume suppressan t wa s used , emission s measure d a t th e inle t t o th e mesh-pa d mis t eliminato r syste mrange d from 0.1 7 mg/dsc m

t o 0.6 0 mg/dsc m

( 8 x IO" 5 

## t o 2 6 x IO" 5 

## gr/dscf) , o r 7.3 5 x IO" 3 

## t o 26. 3 x IO" 3 

## kg/h r (16. 2 x IO" 3 

## t o 60. 0 x IO" 3 

## lb/hr)

. Emission s measure d a t th e inle t whe n th e foa mblanke t
wa s use d average d 0.3 8 mg/dsc m(1 6 x IO" 5 

## gr/dscf) , o r 16. 7 x 10" 3 

## kg/h r (36. 9 x IO" 3 

## lb/hr)

. Th e averag e o f emission s measure d a t th e outle t o f th e contro l devic e whe n th e fume suppressan t wa s use d wa s

1 9 

# 8 3 4

## TABL E 5
. PERFORMANC E DATAFO R TH E MESH-PAD MIS T ELIMINATO R A T MONRO E AUT O EQUIPMENT , HARTWELL , GEORGI A

o Ru n No

. Proces s Inle t Tota l chromiu memission s

current , Ahmg/dsc m Withou t Fum e Suppressan t 1 3 4 AV G 13,60 0

13,60 0 13,60 0 13,60 0 WithFum e Suppressan t 2 5 6 AV G 13,60 0

20,20 0 20,40 0 18,10 0 0.9 7

1.0 6 0.8 2 0.9 5

0.1 7 0.6 0 0.3 6 0.3 8 kg/h r

(10" 3 )

41. 7 47. 1 35. 9 41. 6

7.3 5 26. 3 16. 6 16. 7 mg/A h

6.1 4 6.9 4 5.2 8 6.1 2

1.0 8 2.6 0 1.6 3 1.77 Proces s

current , A

h

13,60 0 13,60 0 13,60 0 13,60 0

13,60 0 20,20 0 20,40 0 18,10 0 Outle t

Tota l chromiu memission s
mg/dsc m

0.00 9 0.01 2 0.01 3 0.01 1

0.00 5 0.00 7 0.01 2 0.00 8 kg/h r

(IO" 3 )

0.3 9 0.5 6 0.6 1 0.5 2

0.2 3 0.3 1 0.5 4 0.3 6 mg/A h

0.06 3 0.08 3 0.09 0 0.07 9

0.03 5 0.03 3 0.05 6 0.04 1 % Effi

ciency 8

99. 1 98. 8 98. 3 98. 7

96. 9 ,/98. 8 96. 7 97. 5
"Efficiencie s ar e calculate dfrommas s emissio nrate s (kg/hr) , an dth e averag e i s base do naveragin g efficiencie s fo r eac hrun .P.3 7



## 0.00 8 mg/dsc m(0. 3 x IO" 5 

## gr/dscf) , o r 0.3 6 x IO" 3 

## kg/h r (0.7 9 x IO" 3 

## lb/hr)

. Th e remova l efficienc yo f th e mesh-pa d mis t eliminato r syste mwhe n a fume suppressan t wa s use d average d 97. 5 percent
. Th e averag e tota l curren t applie d t o th e tank during outle t testing wa s 18,10 0 Ah

. Therefore , th e proces s emissio n rate , base d o n tota l chromiu mmeasurements , wa s 0.04 1 mg/A

h( 1 x IO" 3 

## gr/Ah)

. Th e dat a presente d i n Tabl e 5 indicat e a lowe r emissio n rat e a t th e inle t whe n th e combinatio n foa mblanke t and wettin g agen t
wa s presen t i n th e platin g tank

. Thes e decrease d inle t concentration s ma yhav e resulte d i n slightl ylowe r mesh-pa d mis t eliminato r chromiu

m remova l efficiencie s fo r th e run s associate d wit hth e us e o f th e fume suppressant
. However , th e performanc e o f th e overal l system remaine d th e same , a s indicate d byth e outle t concentratio n level s fo r al l si x runs . Thi s suggest s tha t
us e o f th e fume suppressan t represent s a redundan t leve l o f control

. 4.1. 3 Packed-Be d Scrubber/Mesh-Pa d Mis t Eliminato r System--Remc o Hydraulics

. Inc. , Willits , California 1 0 

## I n February1989 , Remc o Hydraulics , Inc
. installe d a contro l syste mconsistin g o f a packed-be d scrubbe r wit ha chevron-blad e sectio n t o contro l emission s fromthei r chromiu m electroplatin g operations

. Emissio n test s showe d tha t thi s contro l syste mcoul d
no t achiev e California' s propose d hexavalen t chromiu mstandar d o f 0.00 6 mg/Ah

. Th e systemwa s the n modifie d byeliminatin g th e chevron-blad e sectio n and installing a two-stag e mesh-pa d mis t eliminator

. Th e modifie d syste mwa s teste d i n Augus t 198 9 bu t agai n faile d t o mee t th e propose d standard

. I t wa s suspecte d tha t bypas s problem s du e t o sea l degradatio n wer e probabl y contributin g t o th e inadequat e performanc e levels

. Bot hmes h pad s wer e replace d wit hne wpads , whic hwer e installe d i n a housin g wit ha doubl e sea l syste m t o eliminat e th e bypas s problems

. Aserie s o f spraynozzle s wa s adde d t o th e uni t fo r continuou s pa d irrigation

. Emission s testin g wa s conducte d

2 1 

# a 3 6P.3 8



## June , 1991 , and th e contro l syste mme t th e require d emissio n level

. Th e U.S
. EP Adirecte d th e source/testin g o f th e packed-be d scrubber/mesh-pa d mis t eliminato r syste ma t Remc o Hydraulics , Inc. , Willits , Californi a o n Jun e 19-21 , 1991

. Th e performanc e o f th e emissio n contro l system , whic hincorporate s the-use~o f a composit e mes hpad , wa s determine d b ytesting a t th e inle t and outle t o f th e system
. Remc o i s a larg e jo b sho p tha t perform s har d chromiu m electroplatin g o f hydrauli c cylinders , shoc k absorbers , offshor e equipment , and accumulators

. Th e sho p typicall yoperate s 5 day s pe r week , 1 6 hour s pe r day , and 5 2 week s pe r year . 4.1.3. 1 Proces s Description. 1 0 

## Ther e ar e seve n har d chromiu melectroplatin g tank s a t thi s facility

. Tabl e 6 present s th e description s and maximu moperatin g parameter s fo r eac ho f thes e tanks

. Th e platin g solutio n i n eac htank consist s o f chromi c aci d a t a concentratio n o f 24 0 g/ L (3 2 oz/gal) , and sulfuri c acid , a catalyst , a t a concentratio n o f 2. 4 g/ L (0.3 2 oz/gal)

. Th e norma l operatin g bat htemperatur e rang e i s 49° C t o 54° C (120° F t o 130°F)

. Al l tank s ar e equippe d wit h heatin g an

d cooling system s and ar e ai r agitate d t o maintai n uniformplatin g bat htemperatur e an d composition

. Tank s 1 and 2
ar e divide d int o tw o cell s wit hon e rectifie r use d t o contro l th e curren t flo wi n eac hcell

. Tank s 3 through 5 ar e eac hcontrolle d b yon e rectifier , and Tank s 6 and 7 ar e eac hcontrolle d bytw o rectifiers

. 4.1.3. 2 Ai r Pollutio n Control. 1 0 

## Tank s 1 and 2 ar e equippe d wit hdouble-side d hood s and th e roun d tank s (Nos

. 3 through7 ) ar e equippe d wit hcircula r hoods

. Durin g th e tests , th e ventilatio n syste mappeare d t o b e effectiv e i n directin g th e mis t fromth e platin g tank s t o th e contro l device

. Th e chromiu m emission s from

th e platin g tank s ar e exhauste d t o th e packed-be d scrubber/mesh-pa d mis t eliminato r syste mlocate d o n a mezzanin e besid e th e platin g tanks

. Th e captur e and contro l syste mwa s

2 2


# S 3 7P.3 9



## TABL E 6

. DIMENSION S AND OPERATIN G PARAMETER S FOR TH E SEVE N HARD CHROMIU

M PLATIN

G TANK S A T REMC O HYDRAULICS , INC. , WILLITS , CALIFORNI A

Dimensions , (1 , w , d ) o r Tank (dia , ht ) , Capacity , No
. m(ft ) L (gal ) Maximu m rate d voltag e pe r cell , V Maximumrate d

curren t pe r cell , A 1

2

3

4

5

6

7 

## a 4 (13

. 3 (12

. .1 , 1.5 , 2. 1 3 , 4.9 , 7.0 ) .7 , 1.7 , 2. 1 0 , .5.5 , 6.9 ) 0.91 , 9. 4 (3.0 , 31.0 ) 1.2 , 11. 6 (4.0 , 38.0 ) 0.91 , 6. 1 (3.0 , 20.0 ) 1.2 , 15. 2 (4.0 , 50.0 ) 1.2 , 18. 3 (4.0 , 60.0 ) 11,36 0

(3,000 ) 11,36 0 (3,000 ) 6,06 0 (1,600 ) 13,25 0 (3,500 ) 4,00 0 (1,060 ) 17,79 0 (4,700 ) 21,58 0 (5,700 ) 2

2

2

2 @

@

@

@ 

### 1 5

1 5

1 5

1 5

1 5

1 5

1 5 1 0

1 2 ,000 ; 3,00 0
,000 ; 3,00 0
8,00 0
16,00 0
8,00 0

2 @ 12,00 0

2 @ 12,00 0



## -Platin g tank wa s no t operate d during th e emissio n test ,

2 3 

# I 3 8P.4 0



## manufacture d b

yDual l Industries , Inc
. Th e mes hpad s wer e manufacture d b

yKimre , Inc
. Packing dept hi n mor e conventiona l scrubber s i s abou t 0.3 0 m (1. 0 ft)

. Th e scrubbe r a t thi s facilit yha s a packed-be d 1. 8 m (6. 0 ft ) deep , followe d b yth e mesh-pa d mis t eliminato r sectio n locate d directl ybehind th e scrubber

. Becaus e o f th e extende d dept ho f th e packed-bed , th e scrubbe r i s als o equippe d wit ha n overhea d spraysystemi n whic hspraynozzle s ar e use d t o ensur e sufficien t wettin g o f th e be d packin g media

. Th e unusuall ydee p packe d be d wa s installe d t o mee t th e Stat e o f California' s propose d regulatio n governin g hexavalen t chromiu memissions

. Figur e 2 present s a detaile d schemati c o f th e contro l system
. Th e platin g tank s ar e ventilate d b ya 50-h

p fa n locate d downstream

o f th e scrubber

. Th e desig n airflo wrat e o f th e scrubbe r i s 85 0 m 3 

## /mi n (30,00 0 ft 3 

## /min)

. Th e scrubbin g wate r flo wrat e i s approximatel y1,14 0 L/mi n (30 0 gal/min)

. Th e desig n pressur e dro p acros s th e entir e contro l syste m(packed-be d scrubbe r and mesh-pa d mis t eliminator ) i s 1. 5 kP a (6. 0 in

. w.c)

. Withi n th e scrubbe r system , th e velocit yo f th e ga s stream i s reduce d t o les s tha n 15 0 m/mi n (50 0 ft/min) , and th e ga s streami s humidifie d b ya strea

mo f water , whic hi s spraye d countercurren t t o th e ga s flo wthrough2 2 spraynozzles

. Th e saturate d ga s strea mthe n passe s througha packe d be d consistin g o f spherica l polypropylen e packing

. Th e be d i s approximatel y 2. 4 m(8. 0 ft ) high , 3. 0 m(1 0 ft ) wide , and 1. 8 m(6. 0 ft ) deep

. Th e desig n pressur e dro p acros s th e be d packin g medi a i s 0.3 0 kP a (1. 2 in

. w.c)

. Entraine d mis t an d wate r droplet s imping e o n th e packin g an d drai n t o th e recirculatio n tank

. Aserie s o f 5 wate r line s wit h1 0 spraynozzle s pe r lin e ar e locate d ove r th e packe d
Mentio n o f trad e name s o r commercia l product s i s no t intende d t o constitut e endorsemen t o r recommendatio n fo r use .

2 4 

# a3 9t

o 

### SAMPLIN G SAMPLIN G SAMPLIN G SAMPLIN G SAMPLIN G SAMPLIN G SAMPLIN G SAMPLIN G SAMPLIN G SAMPLIN G SAMPLIN G LOCATIO

N A A T INLE T LOCATIO N B

_AT INLE T LOCATIO N C

_ A T OUTLE T LOCATIO N D

_TAN K1 LOCATIO N E

_TAN K2 LOCATIO N £ TAN K3 LOCATIO N G

_TAN K4 LOCATIO N H ^ TAN K5 LOCATIO N J

_ TAN K6 LOCATIO N J ^ TAN K7 LOCATIO N KSCRUBBERWATER
Figur e 2 . Schemati c o f contro l syste m a t Remc o Hydraulics , Inc. , Willits , California ,



## O

j* >P.4 2



## bed

. Th e spraysystem i s use d fo r complet e wettin g o f th e packin g t o preven t chromiu m buildu p and t o ai d i n chromiu m removal

. " ' Behind th e packe d bed , a mis t eliminatio n sectio n remove s entraine d wate r droplets

. Th e firs t stag e o f thi s sectio n allow s larg e droplet s t o settl e b ygravit yt o th e botto mo f th e scrubber

. Th e nex t stag e consist s o f a composit e mes hpa d followe d bya backup mes hpad

. I n th e composit e mes hpad , th e fiber s i n th e cente r o f th e pa d ar e 0.0 1 t o 0.0 2 c m( 4 t o 8 mils ) i n diameter

. Th e diameter s o f th e fiber s i n th e layer s o n eithe r sid e o f th e cente r rang e from0.0 4 t o 0.0 9 cm (1 6 t o 3 7 mils)

. Smal l particle s tha t escape d th e packe d be d coalesc e int o larg e droplet s a s theypas s throughth e inne r layer s o f th e pad

. Th e enlarge d particle s ar e the n remove d i n th e bac k sectio n o f th e composit e pa d o r i n th e backup mes hpad

. Th e backup mes hpa d ha s multipl e layer s o f materia l wit hfiber s 0. 9 c m(3 7 mils ) i n diameter

. Eac ho f th e mes hpad s i s spli t int o tw o sections , eac h approximatel y2. 4 m( 8 ft ) hig hand 0.0 9 m(3. 7 ft ) wide

. Th e composit e mes hpa d i s 16. 5 c m (6. 5 in. ) thick , an d th e backup pa d i s 6. 1 c m

(2. 4 in. ) thick

. Th e desig n pressur e dro p acros s th e mes hpad s i s 1. 2 kP a (4.7 5 in

. w.c)

. Th e desig n o f th e mesh-pa d sectio n specifie d continuou s irrigatio n o f th e composit e mes h pad

. Th e backup pa d i s designe d t o be-washe d down o n a n as neede d basis

. 4.1.3. 3 Proces s Condition s Durin g Testing. 1 0 

## Thre e mas s emissio n tes t run s wer e conducte d simultaneousl ya t th e inle t an d outle t o f th e packed-be d scrubber/mesh-pa d mis t eliminato r syste m t o characteriz e th e overal l performanc e o f th e contro l system
. Si x o f th e seve n chromiu melectroplatin g tank s ducte d t o th e contro l syste mwer e i n operation , an d th e proces s wa s operatin g normall ydurin g th e tests
. Tabl e 7 present s th e averag e operatin g parameter s monitore d durin g eac hemission s tes t run . Prio r t o testing , th e exhaus t rat e throug hth e scrubbe r wa s determine d t o b e les s tha n hal f o f th e desig n ai r flo wrate
. Modification s mad e t o increas e th e exhaus t rat e include d 2 6 

# I 4 1P.4 3



### TABL E 7
. AVERAG E OPERATIN G EMISSION S TES T RU NA T REMC O PARAMETER S MONITORE D DURIN G EAC H HYDRAULICS , INC. , WILLITS , CALIFORNI A

Ru n No
. Tan k

No
. Surfac e are a

plated , 

## n r (ft- 4 

### ) Operatin g

voltage , V Operatin g

current , A Temperatur e

o f platin g solution , ° C (<>F ) 1

2

3 1- A 1- B 2- A 2- B 3 4 5 6

1- A 1- B 2- A 2- B 3 4 5 6

1- A 1- B 2- A 2- B 3 4 5 6 1. 4

0.9 5 1. 9 1. 1 3. 3 3. 3 3. 3 4. 8

1. 4 0.9 5 1. 9 1. 1 3. 3 3. 3 3. 3 4. 8

1. 4 0.9 5 1. 9 1. 1 3. 3 3. 3 3. 3 4. 8 (15 ) (10 ) (20 ) (12 ) (36 )

r 

### 36 ) (36 ) 51 )

15 ) (10 ) 20 ) 12 ) 36 ) 36 ) 36 ) 51 ) •

15 ) (10 ) 20 ) 12 ) 36 ) 36 ) 36 ) 51 ) 8. 0

8. 3 9. 0 8. 0 7. 7 12. 1 7. 1 11. 9 11. 8 8. 0 8. 4 9. 6 8. 0 7. 4 11. 4 7. 0 11. 5 11. 5 8. 0 8. 4 9. 6 8. 0 7. 7 11. 2 7. 2 11. 4 11. 2 8,60 0

2,70 0 8,80 0 2,70 0 6,30 0 10,90 0 7,30 0 7,40 0 5,70 0 8,50 0 2,70 0 9,40 0 2,70 0 5,80 0 10,60 0 7,40 0 7,10 0 5,80 0 8,30 0 2,70 0 9,60 0 2,70 0 6,00 0 10,40 0 7,30 0 6,70 0 5,40 0 5 2 (

5 2 1 5 3 1 5 3 5 1 ( 5 9 ( 5 6 ( 5 7 ( 5 7 5 2 1 5 3 -5 2 5 2 5 2 < 5 9 5 5 5 8 5 8 4 9 4 9 5 1 5 1 4 9 5 7 5 3 5 2 5 2 126 ) 126 ) 127 ) 127 ) 124 ) 139 ) 133 ) 134 ) 134 ) 126 ) 127 ) 126 ) 126 ) 125 ) 138 ) 131 ) 137 ) 137 ) 121 ) 121 ) (123 ) (123 ) (121 ) (135 ) (127 ) (125 ) (125 )



## 2 7 

# e 4 2P.4 4



## increasing th e fa n spee d and shutting down th e recirculatio n spray s t o th e composit e mes hpad

. Thes e procedure s increase d th e exhaus t rat e t o approximatel y8 4 percen t o f th e desig n rate , allowin g th e scrubbe r t o operat e withi n it s intende d ga s velocit y range . Th e adjustment s als o resulte d i n th e captur e efficienc y o f th e ventilatio n syste m bein g sufficien t t o servic e al l si x o f th e operatin g platin g tanks

. Th e shutting down o f th e recirculatio n spray s t o th e composit e mes hpa d lowere d th e pressur e dro p acros s th e pa d t o abou t 5 0 percen t o f th e desig n value

. Nevertheless , th e scrubber/mis t eliminato r syste mwa s operatin g a t o r nea r optima l condition s durin g th e cours e o f th e testing

. Becaus e th e uni t wa s designe d t o hav e continuou s washdown , th e vendo r wa s contacte d t o determin e th e potentia l effect s o n th e performanc e o f th e uni t i f onl yperiodi c washdown wer e used

. Th e vendo r advise d tha t periodi c washdown woul d b e sufficien t bu t recommende d tha t th e pressur e dro p acros s th e uni t b e closel ymonitore d t o minimiz e th e pluggin g potential

. Th e pressur e dro p wa s monitore d throughou t th e testin g perio d and n o increas e i n pressur e dro p wa s observed

. Durin g emission s testing , dumm yrod s wer e plate d i n eac ho f th e tanks

. Th e tota l surfac e are a o f th e part s plate d durin g eac hemissio n tes t run i s give n i n Tabl e 7
. Pressur e drop s acros s th e packin g medi a and mes hpad s wer e monitore d durin g eac htes t run . Th e averag e pressur e drop s acros s th e packin g medi a and mes hpad s wer e 0.3 0 kP a (1. 2 in

. w.c. ) and 0.6 0 kP a (2. 3 in

. w.c) , respectively

. 4.1.3.4

. Result s o f Emission s Testing. 1 0 

## Measurement s t o determin e emission s concentration s a t th e inle t t o th e scrubbe r syste mwer e mad e a t tw o locations

. Measurement s take n a t Inle t A represen t emission s vente d fromTank s 1 and 2 , whil e Inle t B reading s measure d emission s vente d fromth e remainin g 4 tanks

. Performanc e dat a fo r th e contro l syste m ar e summarize d i n Table s 8 a and 8b

. Tota l chromiu memission s measure d a t inle t A o f th e contro l devic e average d 13 1 mg/dsc m(0.05 7 gr/dscf) , o r

2 8 

# fi 4 3

## TABL E 8a

. PERFORMANC E DATAFO R TH E PACKED-BE D SCRUBBER/MESH-PAD MIS T ELIMINATO R SYSTE M A T REMC O HYDRAULICS , INC. , WILLITS , CALIFORNI A

(TOTA L CHROMIU

M TES T RESULTS )

Ru n No . 1 2 3 AV G Proces s current, Ah 136,80 0 140,50 0 139,10 0 138,80 0 InletA

Total chromiu

m mg/dscm kg/h rmg/A h 15 0 3.1 6 13 9 10 9 2.3 0 98. 3 13 4 2.9 5 12

7 13 1 2.8 0 12 1 Proces s

current, Ah 229,70 0 221,30 0 213,70 0 225,50 0 InletB

Tota l chromium mg/dscm 1.0 9 1.83 15.6 b 1.4 6 kg/h rmg/A h 0.01 8 0.4 7 0.03 0 0.8 2 0.268 b 7.53 b 0.02 4 0.6 5 Proces s

current, Ah 381,40 0 376,20 0 366,70 0 374,80 0 Outlet

Total chromiur

r mg/dsc m .0.00 6 0.00 3 0.00 9 0.00 6 kg/h r

2.55X10" 4 1.38X10 - 4 3.52X10" 4 2.48xl0" 4 l mg/A h

0.00 4 0.00 2 0.00 6 0.00 4 % Effi
ciency 1 1 99.99 2 99.99 4
99.99 3 "Efficiencie s ar

ecalculated fro

m mass emissio nrates (kg/hr) , an d theaveragei s based o naveragin gefficiencie s foreach run . "DuringRu

n3 a tInletB , i

twas suspected tha

ttheprob ema

y hav econtacte d th educ twall . Therefore , th evalue s obtained fo rRun3 a tInletB werenotuse d to calculateaverages o refficiency .

t o v o 

## TABL E 8b

. PERFORMANC E DATAFOR TH E PACKED-BE D SCRUBBER/MESH-PAD MIS T ELIMINATO R SYSTE M A T REMC O HYDRAULICS , INC. , WILLITS , CALIFORNI A

(HEXAVALEN

T CHROMIUM TES T RESULTS )

Ru n No . 1 2 3 AV G Proces s current, Ah 136,80 0 140,50 0 139,10 0 138,80 0 InletA

Hexavalentchr

c mg/dscm 15 6 11 8 145 14 0 miu

m kg/hrmg/A h 3.2 8 2.5 0 3.1 9 2.9 9 14 4 107 13 8 13 0 Proces s current, Ah 229,70 0 221,30 0 213,70 0 225,50 0 InletB

Hexavalentchromium mg/dscm 1.2 0 1.8 5 16.9 b 1.5 2 kg/h rmg/A h 0.02 0 0.5 2 0.03 1 0.8 3 0.292 b 8.20 b 0.02 5 0.6 8 Proces s

current, Ah 381,40 0 376,20 0 366,70 0 374,80 0 Outlet

Hexavalen tchro

m mg/dsc m 0.00 6 0.00 3 0.00 9 0.00 6 kg/h r 2.35x10" * 1.38X10" 4 3.59X10" 4 2.44X10" 4 tiu

m mg/A h 0.00 4 0.00 2 0.00 6 0.00 4 % Effi
ciency * 99.99 3 99.99 5

99.99 4 "Efficiencie s ar

ecalculated fro

m mass emissio nrates (kg/hr) , an d theaveragei s based o naveragin gefficiencie s fo reach, run . ^DuringRu

n3 a tInletB , itwa s suspected tha tth eprob ema

y hav econtacte d th eductwall . Therefore , th evalue s obtaine d fo rRun3 a tInletB werenotused to calculateaverages o refficiency .P.4 6



## 2.8 0 kg/h r (6.1 8 lb/hr)

. Hexavalen t chromiu memission s a t inle t Aaverage d 14 0 mg/dsc m(0.06 1 gr/dscf) , o r 2.9 9 kg/h r (6.5 9 lb/hr)

. A t th e inle t B location , tota l chromiu memission s average d 1.4 6 mg/dsc m(6.3 8 x IO" 4 

## gr/dscf) , o r 0.02 4 kg/h r (0.05 3 lb/hr)

. Hexavalen t chromiu memission s a t inle t B average d 1.5 2 mg/dsc m

(6.6 6 x IO" 4 

## gr/dscf) , o r 0.02 5 kg/h r (0.05 6 lb/hr)

. Th e relativel yhighinle t loading s observe d durin g thi s tes t ar e mor e tha n likel yattributabl e t o th e larg e tank capacitie s an d th e larg e numbe r o f part s bein g plate d durin g th e test
. Emission s measure d a t th e outle t o f th e packed-be d scrubber/mesh-pa d mis t eliminato r syste maverage d 0.00 6 mg/dsc m (3. 0 x 10" 6 

## gr/dscf ) fo r bot htota l and hexavalen t chromium , o r 2. 5 x 10" 4 

## kg/h r (5. 5 x 10" 4 

## lb/hr ) fo r tota l chromiu mand 2. 4 x 10" 4 

## kg/h r (5. 4 x 10" 4 

## lb/hr ) fo r hexavalen t chromium

. Th e remova l efficienc yo f th e contro l syste maverage d 99.9 9 percent
. Th e averag e tota l curren t applie d t o th e si x electroplatin g tank s durin g outle t testing wa s 374,70 0 Ah

. Therefore , th e proces s emissio n rate , base d o n tota l and hexavalen t chromiu m measurements , wa s 0.00 4 mg/A h(6. 2 x IO" 5 

## gr/Ah)

. 4.1.3. 5 Discussio n o f Packed-Be d Scrubber/Mesh-Pa d Mis t Eliminato r Performance

. A s discusse d i n Sectio n 4.1.3.3 , recirculatio n spray s t o th e composit e mes hpa d wer e shu t down durin g testing t o hel p increas e th e exhaus t rate
. Durin g emission s testin g an d fo r a perio d o f tim e followin g th e tests , onl yperiodi c washdown o f th e composit e mes hpa d wa s used

. Afe w month s afte r th e uni t wa s tested , a n increas e i n pressur e dro p wa s observed , indicating tha t th e composit e mes hpa d wa s plugged

. Th e pa d ha d t o b e take n apar t and cleaned , laye r b ylayer

. Onc e th e uni t wa s pu t bac k o n line , continuou s irrigatio n o f th e composit e mes hpa d wa s initiated , and n o increase s i n pressur e dro p hav e bee n observe d i n th e month s since

. Apparently , th e high-pressur e periodi c spraywa s no t abl e t o penetrat e t o th e fine r layer s i n th e cente r o f th e pad

. Continuou s irrigatio n wit hth e low-pressur e was happear s t o preven t th e buildup o f

3 0



# B 4 5P.4 7



## chromiu mwithi n thes e fine r layers , thu s eliminatin g th e pluggin g problem

. A s show n o n Table s 8 a and 8b , tota l and hexavalen t chromiu m emission s wer e lowe r a t Inle t B , whic hservice s fou r tanks , tha n theywer e a t Inle t A , whic hservice s tw o tanks

. Thi s ca n b e explaine d b

yth e fac t tha t th e fou r tank s vente d b yInle t B ar e al l circula r tank s wit hdepth s ranging from6 t o 1 8 m(2 0 t o 6 0 ft)

. Inle t Avent s tw o rectangular , horizonta l tanks , eac h approximatel y2 m( 7 ft ) deep

. Mor e chromiu mwil l b e emitte d whe n a par t i s electroplate d i n a shallo whorizonta l tank tha n whe n tha t par t i s electroplate d i n a dee p vertica l tank

. I n a shallo wtank , th e hydroge n ga s i s evolve d close r t o th e surfac e o f th e platin g solutio n an d th e agitatio n effec t i s muc hgreate r tha n wit hth e hydroge n ga s generate d i n a deepe r tank

. 4.1. 4 Discussio n o f Composit e Mes hPad Performance

. Tabl e 9 present s th e performanc e dat a fo r th e composit e mes h pa d system s teste d a t Precisio n Engineering , Monro e Aut o Equipment , and Remc o Hydraulics , Inc
. Agraphica l illustratio n o f th e outle t concentration s fo r eac hplan t i s shown i n Figur e 3

. Th e dat a fromMonro e differentiat e th e test s don e wit ha foa m blanke t presen t i n th e platin g bat hfromth e test s don e withou t a foa mblanke t i n th e bath

. Th e mesh-pa d unit s a t Monro e and Precisio n ar e identica l i n desig n wit hth e exceptio n o f a n improvemen t i n th e sea l systemaround th e pad s i n th e uni t a t Monroe
. Thes e mesh-pa d unit s consis t o f a serie s o f thre e mes h pad s wit hth e composit e pa d a s th e second pa d i n th e contro l system
. Th e ai r pollutio n contro l uni t teste d a t Remc o consiste d
o f a packed-be d scrubbe r followe d b ytw o mes h pads , wit h th e composit e mes hpa d positione d first

. Th e extremel yhig hinle t concentration s measure d a t Remc o resulte d i n a ver yhig hpercen t reductio n fo r th e uni t compare d t o th e percen t reduction s observe d a t Monro e and Precision

. Th e inle t loading a t Precisio n wa s lowe r tha n th e othe r unit s teste d becaus e a moistur e extracto r wa s locate d prio r t o th e inle t tes t location

. Tes t dat a fromanothe r har d chromiu mplatin g facilit y 3 1 

# 4 6

## TABL E 9

. PERFORMANC E DATAFO R COMPOSIT E MESH-PAD MIS T ELIMINATOR S

Plan t Precisio n Monroe , n o foa mblanke t Monroe , wit hfoa

mblanke t Remc o Chromiu m concentration , mq/dscm

. Inle t 0.27 8 0.95 1
0.37 7
73. 2 Outle t

0.01 1 0.01 1
0.00 8
0.00 6 Outle t

proces s emissio n rate , mg/A

h 0.01 4 0.07 9
0.04 1
0.00 4 Curren t

loading , A h 83,50 0 13,60 0
18,10 0
374,80 0 Percen t

reduction , % 

## 95. 9 98. 7
97. 5
99.9 9

O J



## ^ 1P.4 9



### 0.03 OUTLE TCONCENTRATION , MG/DSC M

0.02 5 -

0.02

0.01 5

0.0 1

0.005

-i

_ 

# I I 

# I

_1

_ MONROE-W/

O FB MONROE-W/F B PRECISIO N



### PLAN TNAM E REMC O



## Figur e 3

. Outle t

chromiu mconcentratio ndat afo r composit e mesh-pa dmis t

eliminato r

systems

.

3 3 

# 4 8P.5 0



## indicat e tha t moistur e extractor s ar e capabl e o f removin g approximatel y8 5 percen t o f th e chromiu mmis t enterin g th e device. 1 1 

## Th e tes t dat a presente d ir i Tabl e 9 sugges t tha t th e highe r th e inle t concentration , th e greate r th e percen t reductio n attainabl e and th e lowe r th e proces s emissio n rate
. O n th e othe r hand , regardles s o f th e variation s i n th e inle t loadings , th e outle t concentratio n level s ar e relativel yconstant
. Figur e 4 illustrate s th e lac k o f correlatio n betwee n inle t loading s and outle t concentratio n levels

. Thi s suggest s tha t outle t concentratio n level s ar e a bette r measur e o f th e performanc e o f th e unit s tha n proces s emissio n rate s o r percen t reductions

. Th e relationshi p betwee n inle t loading and percen t reductio n i s show n i n Figure s 5 and 6

. Aregressio n analyse s wa s performe d
o n th e dat a fromMonro e an d Precisio n t o determin e i f a linea r relationshi p existe d betwee n inle t loading s and contro l efficiencies

. Th e correlatio n coefficient s fo r bot hinle t concentratio n and inle t mas s rat e wer e ver ygood : r=0.8 2 and r=0.85 , respectively

. Th e dat a fromRemc o wer e no t include d becaus e o f th e excessivel yhighinle t loadings

. Th e dat a i n Figure s 4 and 5 sugges t tha t a t a n inle t concentratio n o f abou t 1. 2 mg/dscm , o r a mas s emissio n rat e o f 0.0 5 kg/hr , th e dependenc yo n inle t loading s n o longe r exist s and th e percen t reductio n i s a t a relativel yconstan t leve l regardles s o f th e inle t loading

. Thi s phenomen a i s expecte d sinc e 10 0 percen t contro l o r greate r ca n neve r b e achieve d regardles s o f th e inle t loading

. Th e hig hcorrelatio n coefficient s furthe r suppor t th e assumptio n tha t inle t loading s hav e a n effec t o n th e performanc e efficiencie s o f th e contro l systems
. A s show n i n Figur e 4 , outle t concentratio n level s ar e independen t o f inle t loadings , and s o ca n b e use d a s reliabl e indicator s o f contro l devic e performance

. Proces s emissio n rates , mg/Ah , als o ar e no t vali d measure s o f contro l devic e performance

. Inle t loading s t o th e contro l systemar e strongl ydependen t upo n th e amoun t o f curren t applie d t o th e platin g tank(s)

. A s discusse d above , th e outle t 3 4


# 4 9C o

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## ?

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u 0.03 0

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0.00 2 8 1

. 9 0 17 2 8 4 5 0.59 5 0 34 8 0 97 3 0.23 5 0.36 3 1.05 5 0.25 0 0 82 5 Inle t concentrat I on , mg/dsc m



## Figur e 4

. Composit e mesh-pa d mis t eliminato r dat a concentration

. inle t v s outle t

u O l10 2 101- 1 10 0 9 £ 9 8 9 7 9 6 95- | 94 

### % reduction= 3.62*(inletconc , mg/dscm ) + 95.4 6 r= 0.8 1

l-«ci:— ' ' - ' '— • I oT i 0 2 0 3 0 4 0 5 0 6 0 7 0 8 5 5 \ l'.1 I S 1 0 1 5 2 0 2 5 M 3 5 4 0 45 5 0 55 6 0 65.7 b 75 8 0 8 5 9 0 Intel concentration , moMsc m Inle t concentration , mgtiso n 

## Figur e 5
. Composit e mesh-pa d mis t eliminato r dat a - efficienc yversu s inle t concentration

.

0 7 

### % reduction= 76.6*(inle tmas s rate , kg/h ) + 95.7 4 r= 0.8 3

ado s 00 1 061 5 0.02 0.62 s ob s 0.635 00 4 0.645 1 T i W i! i 1

5 S i 4 7s

5 Inie tmas s rale , kg/

h Wetmas s rate, kglh 

## Figur e 6

. Composit e mesh-pa dmis t eliminato r

dat a- efficienc y versu s inle t mas s rate

.P.5 3



## concentratio n level s ar e independen t o f th e inle t loading

. Therefore , i t follow s tha t th e outle t concentration s ar e no t dependen t upo n th e curren t applie d t o th e platin g tank(s)

. Constan t outle t concentration s resul t i n highproces s emissio n rate s fo r operation s wit hlo wcurren t loading s and lo wproces s emissio n rate s fo r operation s wit hhig h curren t loadings

. - Fo r example , a s show

n i n Tabl e 9 , Remc o ha d th e highes t curren t loading o f th e unit s teste d (374,80 0 Ah)

. Thi s hig hcurren t loading produce d th e lowes t proces s emissio n rat e (0.00 4 mg/Ah)

. Monro e (withn o foa m blanket ) ha d th e lowes t curren t loading (13,60 0 .Ah ) and th e highes t proces s emissio n rat e (0.07 9 mg/Ah)

. However , th e outle t concentratio n level s fo r bot hth e Remc o an d Monro e unit s wer e relativel yconstan t (0.00 6 and 0.01 1 mg/dscm , respectively)

. Thus , proces s emissio n rate s ar e no t reliabl e indicator s o f contro l devic e performance

. Th e dat a presente d i n Figur e 3 and Tabl e 9 migh t sugges t tha t th e uni t a t Remc o represent s a highe r leve l o f contro l tha n th e unit s a t Monro e and Precision

. Th e fines t materia l layer s i n th e composit e mes hpa d a t Remc o wer e wove n wit ha smalle r diamete r fibe r tha n th e materia l use d i n th e composit e pad s i n th e Precisio n an

d Monro e units

. Th e differenc e i n th e fibe r diameter s coul d hav e contribute d t o th e differenc e i n th e performanc e levels

. However , a s note d i n Sectio n 4.1.3.5 , th e uni t a t Remc o develope d a pluggin g proble mafte r a fe wmonth s o f
use . Eve n thoughth e proble mha s bee n corrected , and th e uni t ha s bee n operatin g withou t an yincreas e i n pressur e drop , some concer n stil l exist s regarding th e long termmaintenanc e requirement s fo r thi s unit

. I n addition , th e outle t emissio n level s ar e ver ylowfo r al l th e units , and some dat a overlap exist s betwee n the outle t concentratio n level s measure d a t Remc o and thos e measure d a t Monro e whe n a foa m blanke t wa s presen t i n the platin g bath

. Therefore , th e dat a fromal l thre e composit e mesh-pa d system s teste d wer e determine d t o represen t on e contro l level

.

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0 0 r oP.5 5



## TABL E 10

. CHROMIU

M ELECTROPLATIN

G AND CHROMI C ACI D ANODIZING TAN K SPECIFICATION S A T TH E NAVAL AVIATIONDEPOT ,

ALAMEDA , CALIFORNI A
Type / Dimensions , Capacity , Tank No
. (l,w,d ) , m(ft ) L (gal) a



### 5,00 0 (1,320 ) 5,00 0 (1,320 ) 8,72 0 (2,300 ) 2,62 0 (690 ) 2,62 0 (690 ) 2,62 0 (690 ) 2,62 0 (690 )

8,14 0 (2,150 ) 4,09 0 (1,080 ) 

## Har d chromiu

m 1

2

3

4

5

6

7


## Chromi c aci d

8

9 

## platin a

anodizi n 2.4 ,

(8.0 , 2.4 , (8.0 , 4.3 , (14.0 , 1.8 , (6.0 , 1.8 , (6.0 , 1.8 , (6.0 , 1.8 , (6.0 , q 4.9 , (16.0 , 2.4 , (8.0 , 1.2 , 4.0 , l.:2 , 4.0 , 1.2 , 4.0 , 0.9 , 2.8 , 0.9 , 2.8 , 0.9 , 2.8 , 0.9 , 2.8 ,

1.2 , 4.0 , 1.2 , 4.0 , 1. 8 6.0 ) 1. 8 6.0 ) 1. 8 6.0 ) 1. 8 6.0 ) 1. 8 6.0 ) 1. 8 6.0 ) 1. 8 6.0 )

1. 5 5.0 ) 1. 5 5.0 )

1 

## Assume s a fre e boar d spac e o f 1 5 cm( 6 in. )

3 9


# 5 4P.5 6



## Al l o f th e platin g and anodizin g tank s ar e equippe d wit h heatin g and coolin g system s t o maintai n uniformsolutio n temperatures
. Overhea d hoist s ar e use d t o transpor t part s i n and
ou t o f th e platin g an d anodizin g tanks

. 4.2. 2 Ai r Pollutio n Control. 12 

## ' 1 4 

## Eac ho f th e platin g and anodizin g tank s i s equippe d wit h double-side d draf t hoods

. Thre e identica l contro l system s ar e use d t o contro l chromiu m emission s fromth e platin g and anodizin g tanks

. Eac hcontro l syste mconsist s o f a vertical-flow , singl e packed-be d scrubbe r uni t wit hchevron-blad e mis t eliminator s precedin g and following th e scrubber

. Th e packed-be d scrubber

unit s wer e installe d b yViro n Internationa l Corporation * i n 1990

. Followin g treatmen t i n thes e units , th e ga s stream s ar e ducte d t o fiber-be d mis t eliminators

. Figur e 7 present s a schemati c o f a typica l fiber-be d mis t eliminator

. Thre e o f th e har d chromiu mplatin g tank s ( 1 throug h3 ) ar e commonl yducte d t o on e contro l system
. Th e remainin g fou r platin g tank s ( 4 through7 ) ar e commonl yducte d t o a second contro l system , an

d th e tw o anodizin g tank s ( 8 and 9 ) ar e commonl yducte d to
. a thir d contro l system
. Fo r purpose s o f discussion , th e contro l system s wil l b e designate d a s Lin e G (anodizing tanks) , Lin e L (thre e platin g tanks) , an d Lin e M (fou r platin g tanks)

. Th e ventilatio n rate s fo r Line s G , L , and M ar e 68 0 actua l m 3 

## /mi n (24,00 0 actua l ft 3 

## /min) , 70 0 actua l m 3 

## /mi n (24,80 0 actua l ft 3 

## /min) , an d 40 0 actua l m 3 

## /mi n (14,30 0 actua l ft 3 

## /min) , respectively

. Th e fiber-be d mis t eliminators , manufacture d b yCEC O Filters , Inc
. an

d installe d i n 1990 , ar e locate d o n th e roo f o f th e platin g shop

. Booste r fan s ar e use d followin g eac hpacked

be d scrubbe r t o ai d i n maintainin g th e appropriat e ga s flo wrat e
Mentio n o f trad e name s o r commercia l product s i s no t intende d t o constitut e endorsemen t o r recommendatio n fo r use .

4 0



# 5 5P.5 7



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V"-S-"'
- ' Oli*!.V''*'"''* ' " V" . - a * r 

### Liqui d

Ou t



## Figur e 7
. Schemati c o f a typica l fiber-be d mis t eliminator

. 4 1 

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## (2. 5 gal/hr ) fo r th e large r unit s o n line s G and L , and a t a rat e o f abou t 4. 7 L/hr (1. 3 gal/hr ) fo r th e smalle r uni t o n lin e M
. 4.2. 3 Proces s Condition s Durin g Testing. 1 2 

## 4.2.3. 1 Exhaus t Lin e G
. Fou r four-hou r chromiu m emission s tes t run s wer e performe d a t th e outle t o f th e contro l uni t o n exhaus t lin e G , whic hventilate s tw o chromi c aci d anodizin g tanks

. Durin g th e testing period , on e o f th e tank s containe d fou r aluminu

msheets , eac hwit ha surfac e are a o f 3. 4 m 2 

## (36. 5 ft 2 

## )

. Th e othe r tank containe d on e aluminu m shee t wit ha surfac e are a o f 3. 4 m 2 

## (36. 5 ft 2 

## ) and a ro wo f (unspecified ) parts
. Averag e tota l curren t applie d t o th e tw o anodizin g tank s durin g testin g range d from4,00 0 t o 5,10 0 Ah

. 4.2.3. 2 Exhaus t Lin e L
. Tw o three-hou r and on e four-hou r emissio n tes t run s wer e conducte d a t th e outle t o f th e contro l uni t o n lin e L , whic hventilate s thre e har d chromiu mplatin g tanks

. Durin g th e tests , eac ho f th e tank s containe d fou r part s t o b e electroplated , an d eac hpar t ha d a surfac e are a o f 0. 7 m 2 

## (7. 6 ft 2 

## )

. Averag e tota l curren t applie d t o th e thre e tank s durin g testing range d from29,40 0 t o 42,60 0 Ah

. 4.2.3. 3 Exhaus t Lin e M
. Lin e M pull s ai r fromfou r har d chromiu mplatin g tanks

. On e eight-hou r emissio n tes t ru n wa s performe d a t th e outle t o f th e fiber-be d mis t eliminato r controllin g th e line

. I n addition , tw o four-hou r emissio n tes t
run s wer e performe d simultaneousl ya t th e inle t and outle t o f th e fiber-be d mis t eliminator

. Durin g th e tests , eac htank containe d fou r smal l parts , eac hwit ha surfac e are a o f 0. 1 m 2 

## (1. 5 ft 2 

## )

. Curren t applie d t o th e fou r tank s durin g inle t testin g range d from37,40 0 t o 37,60 0 Ah

. Th e curren t range d from37,40 0 t o 37,60 0 A

h fo r th e outle t tes t run s tha t wer e conducte d i n conjunctio n wit hth e inle t runs . Th e curren t applie d t o th e tank durin g th e eight-hou r run a t th e outle t wa s 75,10 0 Ah

. 4.2. 4 Result s o f Emission s Testing. 1 2 

## Tabl e 1 1 present s th e performanc e dat a fo r eac ho f th e fiber-be d mis t eliminato r scrubbe r system s teste d a t th e Nava l Aviatio n Depot
. Emission s measure d a t th e outle t o f th e fiber

4 3


# 5 8Ru n No . TABL E 11 . PERFORMANC E DAT A FO RTHREE SCRUBBER/FIBER-BE D MIS T ELIMINATO RSYSTEM S A T TH E NAVA L AVIATIO N DEPOT , ALAMEDA , CAUFORNIA. 1 1
Inlettota l chromium emissions " Outlettota l chromium emission s Proces s current, Ah mg/dscm

(IO' 3 ) kg/h r

(IO' 3 ) mg/A h

(IO" 3) Proces s

current, Ah mg/dscm

(IO- 3 ) kg/h r mg/A h

(IO- 3 )

< 0.00 4
< 0.00 4
< 0.00 5 <0.00 5

< 0.00 5

<0.00 7 0.01 9 <0.00 5 <0.01 0

0.01 1

< 0.00 4

< 0.00 3 <0.00 6 (IO" 3 )

<4. 1 <4. 4 <3. 9 <4. 2 <4. 1

<0. 7 <1. 9 <0. 4 <I. O

1. 2 <0. 4 <0. 3 <0. 6 % Effi
ciency 0

rf*- 1 2 3 4 AV G

1 2 3 AV G

1 2 3 AV G 37,60 0 140

37,40 0 20 0 37,50 0 170 4.1 4 5.3 1 4.7 3 Exhaus tLineG

.

i J L 2 < 2 < 4: 32 M 75,10 0 44 0 37,60 0 56 7 37,40 0 50 4 50,00 0

3,99 0 3,99 0 5,10 0 5,10 0 4,54 0 ExhaustLineL

29,40 0 29,40 0 42,60 0 33,80 0 ExhaustLineM 0.08 3 0.08 6 0.10 4 0.10 9 0.09 5

0.12 7 0.37 4 0.09 7 0.19 9

0.35 8 0.11 2 0.09 9 0.19 0 99. 9 99. 9 99. 9

a Eac h emissio ncontrol system control s aventilatio nexhaustline . LineG exhausts emission s fro m chromi caci d anodizin gtanks ; line s L an d G each exhaustemission s fro m har d chromium platin gtanks . ''N o inlettestin gwa s performe d o nthecontrol units forline s G o rL . Forlin eM , tw o emissio ntestruns wereconducte d betwee nthepacked
bed scrubberan

d th efiber-bed misteliminator . c Efficiencie s ar

ecalculated fro

m mass emissio nrate

s (kg/hr) , an

d theaveragei s based o naveragingefficiencie s foreac h run .



## soP.6 1



## be d mis t eliminato r systemcontrolling exhaus t lin e G average d 9. 5 x IO" 5 

## mg/dsc m

(4. 2 x IO" 8 

## gr/dscf) , o r <0. 5 x IO" 5 

## kg/h r (<1. 1 x IO" 5 

## lb/hr)

. Th e averag e tota l curren t applie d t o th e anodizin g tank s exhauste d t o lin e G wa s 4,54 0 .Ah , resultin g i n a tota l chromiu

m proces s emissio n rat e o f <4. l x 1 0 mg/A h (<6. 3 x IO" 5 

## gr/Ah)

. N o inle t measurement s wer e mad e a t lj.n e G and , therefore , n o remova l efficiencie s coul d b e determined

. A t th e outle t o f th e contro l systemfo r lin e L , emission s average d 2. 0 x 10" 4 

## mg/dsc m (8. 7 x IO" 8 

## gr/dscf) , o r <1. 0 x IO" 5 

## kg/h r (<2. 2 x IO" 5 

## lb/hr)

. Th e averag e tota l curren t applie d t o th e tank s exhauste d b ylin e L wa s 33,80 0 Ah

. Therefore , th e tota l chromiu mproces s emissio n rat e fromth e contro l syste mwa s <1. 0 x IO" 3 

## mg/A h(<1. 5 x IO" 5 

## gr/Ah)

. A s wit hlin e G , ther e wa s n o inle t testing performed

. Fo r lin e M , emission s wer e measure d betwee n th e packed-be d scrubbe r and th e fiber-be d mis t eliminator

. Thes e measurement s ar e representativ e o f inle t condition s fo r th e fiber-be d mis t eliminato r and average d 0.1 7 mg/dsc m(7. 4 x IO" 5 

## gr/dscf) , o r 4.7 3 x IO" 3 

## kg/h r (10. 4 x IO" 3 

## lb/hr)

. Emission s measure d a t the outle t o f th e fiber-be d mis t eliminato r average d 1. 9 x IO" 4 

## mg/dsc m(8. 3 x IO" 8 

## gr/dscf) , o r <0. 6 x IO" 5 

## kg/h r (<1. 3 x IO" 5 

## lb/hr)

. Th e remova l efficienc yo f th e fiber-be d mis t eliminato r average d 99. 9 percent
. Th e averag e tota l curren t applie d t o th e tank s service d b yLin e M durin g outle t testin g wa s 50,00 0 Ah

. Therefore , th e outle t tota l chromiu mproces s emissio n rat e wa s <6. 0 x IO' 4 

## mg/A h(<9. 3 x IO" 6 

## gr/Ah)

. 4.2. 5 Discussio n o f Fiber-Be d Mis t Eliminato r Performance

. Ther e wer e n o advers e operationa l factor s identifie d durin g emission s testing o f th e fiber-be d mis t eliminator s a t th e Alamed a Facility

. Th e contro l device s performe d well , and th e emissio n testing demonstrate d tha t fiber-be d mis t eliminator s ar e capabl e o f achievin g outle t chromiu mconcentration s o f 3. 7 x 10" 4 

## mg/dsc m(1. 6 x 10" 7 

## gr/dscf ) o r less

. Figur e 8 i s a graphica l presentatio n o f th e outle t chromiu m concentratio n level s measure d fromeac ho f th e thre e fiber-be d 4 5 

# 6 0P.6 2



### OUTLE TCONCENTRATION , MG/DSC M (1E-04)

2 -



# " a

I . I i 

### LINE M LINE L LINE G



## Figur e 8

. Fiber-be d mis t eliminato r outle t concentrations ,

4 6


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• H J J A d ) TJ - r l 0) V J d )
a * C Q V J O J J (t f A

- H 

### E - r l r H Q J
J J C Q

• H 

### E TJ d ) J J (t f O O wi d) V H (t f
>- , J J - r l r H • r l C J rt f U H
0 1

• H 43 J J J J (t f
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### E

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### E TJ C D 4 3 i V J d ) 4 3

- H U H r

-P.6 4



### OUTLE TCONCENTRATION

. MG/DSC M (1E-4)



# I

LINE M LINE L LINE G



## Figur e 9

. Fiber-be d mis t eliminato r outle t concentration s

withou t hightes t values

.

4 8


# S 6 3C D

0 1 V J d ) 4 3 4 3 

# 2 u C Q TJ d J 4 3 i TJ d ) X V rt f 

### a d ) 0 1 C D 4 3 I H

a 0 1 V J C D 4 3 4 3 

# 2 V Ui TJ d J 4 3 1 TJ d J X O (t f 

### a U H 0 g r o < D V J J J C Q C 3 O T J 4 3 U

- H 4 3 

### z

a

. c n TJ d ) 4 3
V J d J 4 3 •ri U H
< D 4 3 J J O J J O l A

- H TJ (t f O wi J J C D wi A •r l Q J 43 J J d ) O A TJ Q J V J
>. wi J J A (t f O •r l U H •r l A t n • H C Q J J O A O T J C Q V H O TJ A d J > J J 0 1 O 2

• t n A r H 

### a

•P
. • U , ' 0 1 J J

- H A A C D 4 3 J J U H O

> i C J A C D TJ A 0 J J J Q J 4 3 J J C Q d ) 0 1 (t f d l V J U d) TJ d l xi J J U H O d J t n rt f J J 01 J J C O V J -r l U H 0) 4 3 J J C Q (t f 0 1 V J O J J (t f A •r l E •r l wi C D J J C Q -r l E T > C D Xi 1 V J C D 4 3 -r l U H

* 0 A d) g g O 

### o d > V J c n -r l J J H

• t n A wi 

### a o J J 

### s u A C D TJ A Q J J J U •ri d) xi J J U H 

### o d J C Q A rt f U d) 4 3 E C D J J 0 1 > i C O wi 

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### a A T J d ) r- H wi rt f J J C Q A -r l C D 4 3 d ) U *
• H > Q J TJ O l A

- H V H d J J J wi
• H U H d ) 0 1 V H (t f 

### o o rt f J J rt f 4 3 J J TJ d ) TJ A 0 ) E g O C J C D V J J J (t f

. A J J
m g d J r H a Q O V H 

### a wi (t f A O

- H J J (t f V J d J 

### a O TJ A (t f O i A
• H O i O l A r H 

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- H U H d )
•A J J U H 

### o t n A •r l O l O l A r H 

### a U H 

### o J j r H A 0 1 d ) V H (t f
c n rt f d ) C O •r l V J rt f

> i rr t E 0 1 J J r H A 0 1 d J 

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### o •ri Ui Ui •ri E W U H 

### o 

# fc
rr t g g " 3 C O

r o • ' * d ) 4 3 J J U H 

### o r-i r-i (t f
V J O U H C O A O -r l J J rt f V H J J A d ) O A O O A O
• H 0 1 0 1 •r l E C D 

### B A
• H E O V J '4 3 O J J 0 1 rH J J A O 0 ) 4 3 EH i g 

## 3
• H E 

### o V J 4 3 C J J J C D r H J J A O 0 ) O l rt f V J d ) > rt f d J Xi J J 0 1 (t f

r H r H ( D > 0 1 rt f

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a

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### a
r H rt f 

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>. 4 3 T J C D > C D •r l 4 3 O (t f C O A O -r l J J rt f V J J J A d ) C J A O O T J C D J J 0 1 C D J J
m g d ) J J C O >, 0 1 TJ rt f 

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### o a E 

### o V C D 4 3 H

a o r H d) V H A O l

- H fa A -r l TJ d J J J A d ) 0 1 d ) V H 

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-*•>

. O l E
cr . o o • o U H 

### o 0 1 A 

### o

- H J J rt f U J J A d ) o A O O J J d ) r H J J A O Q J t n (t f V H d l > (t f TJ d l > d > •ri Xi V rt f d ) r H 

## • a a rt f 

### o 0 ) V J rt f 0 1 V J O J J rt f A -r l E

- H r H 0 ) J J 0 1 -r l E TJ 0 ) 4 3 1 V J d l 4 3 -r l fa

.

. — U H O 0 1 TJ "v
. V J O l
r o i o H X •t f o o • o *- * 1 o r H X ^ O o • o — E 

### o C D TJ "->
. 

## s * E H O O O • o U H O C O A O •ri J J rt f V J J J A d J u A O V J J d ) r H J J A O O l A -r l > d ) -r l 4 3 o rt f U H O V J O U H A O -r l J J rt f V J J J A d ) U A O U g A -r l E O V J 4 3 U J J d J wi J J A O d) t n rt f V H 0 ) > rt f d J 4 3 H

a
, . , U H O 0 1 TJ

•>>
. V H t n i n E O C O TJ ^ 

### S 1 E »t f C N o

a o 0 1
• H 0 1 V J d ) 4 3 4 3 

# 2 o 0 1 TJ d J 4 3 1 TJ < D X 

### u rt f 

### a wi (t f A O -r l J J
• H T J (t f V J J J J J c n -r l E 0 ) 43 J J U H 

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a

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- H 4* ! Q ) 4 3 J J 0 J J Q ) H 4 3 rt f J J A 4 3

- H 

### u J J J J (t f 01

- H C Q V J 0 J J (t f A
• H £
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### o C J 0 1 TJ C D 4 3 V J d ) a Q
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### a 4 3 0 1 C D E d ) 4 3 J J U H 

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• H J J (t f V J 1 O J J i rt f C D V J (t f d) O (t f U H V J A 0 1 d ) 4 3 J J

a

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a

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o o H E 

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### B 

## 3 r H O > d ) £ A r H O > 1 

### o J J 1 (t f di V J (t f C D O (t f U H V J A 0 1 wi (t f o

- H 

# R J J rt f d ) > rt f 4 3 0 1 TJ C D 4 3 V J 0 ) 4 3 -r l fa

C N

a

_ r o j J U H \ C N J J U H O O 0 0 i O J J i rt f C D V J (t f 0 ) O (t f U H V J A 0 1 ( D 4 3 E H

r o

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a

. o H

— - r o E C N E
o C D r o » i n r o U H O 

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- H J J (t f V J 0 J J C O cn E 0 V H U H 01 0) O i A rt f V J O i A •r l X O rt f 

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### B 

## 3 wi 0 > i n H

. _- ^ r o J J U H \ C N J J U H i n •t f O J J
o r* i

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### g P 0 U H V J d) 

### a 0) 43 J J

a

. o H
< D V J A O i •r t fa A •r l 

# 8 o 43 0 1 0 1 < U H 0 d l 

### u A rt f g 

### p O U H V H d > 

### a Q ) 4 3 J J A (t f 43 J J V J d ) J J J J d ) 4 3
> , wi J J A (t f U
• H UH •r l A t n •r H Ui C O
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• H UH U H 0 d i 

### o A rt f g H O UH V J O J 

### a V J 0 ) Xi O l -r l 4 3 C D 43 E H

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### a i 43 0 1 C D E C D J J

- H 0 1 O 9 4 E 0 C J I rt f C D V J (t f d) U (t f U H V J A 0 1 V H 0 ) 4 3 t n •r l 4 3 0 ) 43 J J O J J 0 1 r H 4 3 (t f J J A 4 3 -r l V H J J J J (t f O 0 1 r H (t f 0 1
• H 0 1 V J O J J (t f A

- H E
• H r H d ) J J 0 1 •r l E C D V J (t f 0 1 TJ d J 43 V J d) 4 3
• H U H
V H O U H 0 1 O
• H J J (t f V J d J 43 J J

• a Q J > O 43 (t f 

### c 5 o 43 0 1 0 1 <

a 0 1 

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### g p r H O > 1 

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• H U H

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a * 

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• 

### c n T J (t f 

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# g < d J V J d ) C J A (t f A 0 ) J J A -r t rr t g J J A 0 J t n A

- H V J J J C Q C D U O E d J > rt f 43 C O V J O J J rt f A

- H E
• H r H d J J J 0 1 -r l E T J d J 43 a.

•t fP.6 6



### 0.03

0.02 5

0.02

0.01 5

0.0 1

0.005 OUTLE TCONCENTRATION , MG/DSC M

A > TRADrriONA L SCRUBBER S B - COMPOSIT E MES H PA D •MONRO E W/ O FOA M BLANKE

T C
. COMPOSIT E MES H PA D - MONRO E W/FOA M BLANKE T D
. COMPOSIT E MES H PA O •PRECISIO N ENGINEERIN G E •COMPOSIT E MES H PAD - REMCO HYDRAULIC S F M
. FIBER-BE D MISTELIMINATO R - ALAMEDA/UN E M F L •FIBER-BE D MISTELIMINATO R •ALAMEDA/UN E L FG •FIBER-BE D MISTELIMINATO R - ALAMEOA/LIN E G



## -©

- -©

- -©

- B D E

PLAN T COD E F

M F L F G

Figur e 10

. Performanc e dat a fo r mis t eliminato r systems ,

5 0


# 6 5

## cr >

>. wi A O
< D 0 1 A V J O U H TJ d ) TJ A d l g g O O d ) V H 0 ) V H (t f TJ A (t f C Q g 0 ) J J 0 1 > 1 C O T J rt f 

### a 1 4 3 0 1 C D E C D J J • r l 0 1 O 

## 2* E 

### o o A rt f 4 3 J J O J 0 1 V J rt f O O
<

• d l C J - r l > d J TJ
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r- H (t f A • r l U H V J O

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a * O rt f 

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a C D

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. 0 1

r H O V H J J A 

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d l 4 3 J J U H 

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### o 4 3 0 1

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- H 

## e

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• H 

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a t n A

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### a

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# 2 C J C Q C D 4 3 E H

• c n A O •r t J J rt f V J d l 

### a O
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### B 

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### o V J 4 3 C J TJ V J (t f 4 3 A •ri
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J J •ri S TJ d l J J (t f

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### a E

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# 8 0 1 4 3
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### a O t n A • r l J J (t f r-i 

### a o V J J J C J Q J wi d l E 

### o V H U H C Q A O

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• H V J J J J J (t f
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J J A d l U V H d l 

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a O V a. U H O
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a

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• H J J (t f r H 

### a E 

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0 1 d J

- H t n O r H 

### o A 4 3 C J Q J J J
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> d) A
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— *

a 0 1 t n A

- H T J (t f O r H
J J d l wi A - r l A - r l
>-
. J J - r l r-i - r l 43 (t f

- H V H (t f > d J 43 J J V H O U H

J J A A O C J C J rt f O J J i n

## TABL E 12

. PARAMETER S FO R TH E HARD CHROMIU M ELECTROPLATIN

G MODE L PLANT S

OS ^ 2 Mode l operation Plan tSiz e Smal l Mediu m Large Operatingtime , hr/y r Percen ttimeelectrode s energized , percent Tota l ampere-hours peryear , Ah/y r 2,00 0 7 0
5. 0 x10 6 3,50 0 7 0
4 2 xIO

6 6,00 0

8 0
16 0 xIO

6

Numbero f

tank s Tan kdimension s (l,w,d) , m (ft)

Ventilatio nrat

epertank, m J/mi n(fr/min )

Uncontrolle d hexavalentchromium emissio nrate , kg/y r(lb/yr ) Numbero f

operations nationwid e 1 3.6 , 1.1 , 1. 8 (12.0 , 3.5 , 6.0 )

29 7 (10,500 )

5 0 (110 ) 1,080 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 )

5 7 (2,000 ) 2 @ 17 0 (6,000 ) 53 1 (18,750 )
42 0 (926 )
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i nP.7 0



## TABL E 13

. HEXAVALENT CHROMIU M EMISSIONESTIMATE S ASSOCIATE D WIT H TH E US E O F PACKED-BE D SCRUBBER S AND NE W EMISSIONCONTRO L TECHNOLOGIE S A T HARD CHROMIU M ELECTROPLATIN

G MODE L PLANT S

Emissio nestimates , kg/y r(lb/yr ) Smal l Medium Large Uncontrolle d Singl epacked-bed scrubber * Mis teliminato rwith mes h pad s inserie s Packed-bed scrubber/mesh-pad mist
L

. eliminato rsystem " Fiber-bed mis teliminato r 50(110 ) 0.5(1.1 ) 0.10(0.22 ) 0.10(0.22 )

0.1 0 (0.22 ) 42 0 (926 ) 4. 2 (9.3 ) 0.84(1.85 ) 0.84(1.85 )
0.84(1.85 ) 1,600(3,530 ) 1 6 (35.3 ) 3.2 0 (7.06 ) 3.2 0 (7.06 )

3.2 0 (7.06 )

a Singl e packed-bed scrubbertha treduces uncontrolled emission s by 9 9 percent. "-"Ne wcontrol technology tha treduces uncontrolled emission s by 99. 8 percent.



### 5 4


# 1 6 U

## TABL E 14

. ANNUA L ENERGY REQUIREMENT S ATTRIBUTABL E T O TH E US E O F PACKED-BE D SCRUBBER S AND NE W EMISSIONCONTRO L TECHNOLOGIE S A T HAR D CHROMIU M PLATIN G MODE L PLANT S

Small Medium Larg e

u . Operatingparameter s Tota l ventilatio nrate , m/mi n(ft J/min ) Operatingtime , hr/y r Basiccaptur

esvste m Numbero f

fans Individua l fa nsizes , h p Total fa nsize , h p Electrica l use , kWh/y r Control Devic e Packed-bed scnibbe r Numbero f

control device s Individua l fa nsizes , h p Tota l fa nsize , h p Increas einenergy requiremen tove rbasiccaptur

esystem t

o operat efans , h p Individua l pum p sizes , hp Tota l pum p size , hp Tota l additiona

l energy requirement, h

p Increas ei nelectrical us eoverbasi ccapturesyste m alone , kWh/yr * Misteliminato rwit

h mesh pads inserie s Numbero f

control device s Individua l fa nsizes , hp Tota l fa nsize , hp Increas einenergy requiremen tove rbasi ccaptur

esystem t

o operatefans , h

p Increas einelectrical us eove rbasi ccaptur esyste m alone , kWh/yr 8 

### 34 0 (12,000 ) 2,00 0



### 1 1 0 1 0 14,90 0



### 1 1 5 1 5 

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### 1 2 5 2 5 1 5 22,40 0 

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### 1 4 0 4 0 104,40 0



### I 6 0 6 0 2 0 

### 3. 0 3. 0 2 3 60,10 0



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### 2 2 @ 4 0 8 0 358,10 0



### 2 2 ®6 0 / 12 0 

### ^4 0 2 ®3. 0 

### 6. 0 4 6 205,90 0



### 2 2 ®

### 10 0 20 0 12 0 537,10 0 (continued )



## o

## TABL E14

. (continued )

Smal l Medium Large

i n cr » Packed-bed scrubber/mesh-pad misteliminato rsvstem

Numbero f

control device s Individua l fa nsizes , hp Total fa nsizes , h p Increas einenergy requiremen tove rbasiccaptur

esystem t

o operat efans , h p Individua l pum p sizes , h p Total pum

p size , h p Total additiona

l energy requirement, h

p Increas ei nelectrical us eove rbasi ccaptur esystem alone , kWh/yr 8 Fiber-bed misteliminato r Numbero f

control device s Individual fa

nsizes , h p Total fa nsize , h p Increas einenergy requiremen tove rbasi csyste m to operat efans , h p Increas einelectrical us eove rbasi ccaptur esystem alone , kWh/yr * 

### 1 3 0 3 0 2 0 

### 3 3 2 3 34,30 0



### 1 4 0 4 0 3 0 44,80 0 

### 1

10 0 10 0 6 0 

### 7. 5 7. 5 67. 5 176,20 0



### 1 12 5 12 5 8 5 221,90 0 

### 2

2 ®

### 10 0 20 0 12 0 2 ®

### 7. 5 1 5 

### 13 5 604,30 0



### 2 2 ®12 5 

### 25 0 17 0 760,90 0

aNumber s wer erounde

d to th enearest10 0 kWh .P.7 3



## 37. 3 MWh/y r fo r the smal l mode l plan t t o 89 5 MWh/y r fo r th e larg e mode l plant

. Thi s rang e represent s a n increas e o f approximatel y 15 0 percen t ove r th e uncontrolle d leve l an d approximatel y5 2 t o 5 9 percen t ove r th e energ yrequire d t o operat e a typica l packed

be d scrubber

. Th e tota l energ

yrequire d t o operat e a packed-bed

_ scrubber/mesh-pa d mis t eliminato r system range s from

49. 2 MWh/y r fo r th e smal l mode l plan t t o 96 2 MWh/y r fo r th e larg e mode l plant

. Thi s i s a n increas e o f approximatel y17 0 t o 23 0 percen t compare d t o th e uncontrolle d leve l and approximatel y7 1 t o 10 0 percen t compare d t o usin g a typica l packed-be d scrubber

. Fo r fiber-be d mis t eliminators , th e tota l energy requirement s rang e from 59. 7 MWh/y r fo r th e smal l har d chromiu m platin g mode l plan t t o 1,12 0 MWh/y r fo r th e larg e mode l plant

. Thi s i s a n increas e o f approximatel y21 0 t o 30 0 percen t ove r th e uncontrolle d (basi c captur e systemalone ) leve l and approximatel y 9 8 t o 14 0 percen t ove r th e energ yrequirement s fo r operatin g a typica l packed-be d scrubber

. 5. 3 Wastewate r Impact s Us e o f eac ho f th e thre e ne wemissio n contro l technologie s fo r har d chromiu

mplatin g operation s result s i n th e generatio n o f wastewate r tha t require s reuse , treatment , o r disposal

. However , base d o n availabl e information , i t i s assume d tha t al l wastewate r generate d b

yth e contro l device s ca n b e draine d t o th e platin g tank s t o mak e up fo r evaporatio n losses , a s i s typicall yth e practic e wit hothe r contro l technologie s currentl yuse d i n th e industry

. 5. 4 Soli d Wast e Impact s On e potentia l sourc e o f soli d wast e fromhar d chromiu m platin g operation s i s th e sludg e produce d bywastewate r treatmen t operations

. A s note d i n the previou s section , wastewate r generate d b

yth e thre e ne wcontro l technologie s fo r har d chromiu m platin g i s assume d t o b e recirculate d and reuse d i n th e process . Thi s recirculatio n minimize s th e wastewate r treatmen t throughput ,

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• H

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M H o J J A d l V V J d l 

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### o V J 

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### E O O rt f

• a C O A O - r l J J (t f wi A C J r H (t f O
J J u rt f 

### a E

- H
J J C D O O
M H O " • Q J V J O M H Qi U di xi b>

• wi rt f - r l V J d ) J J rt f g T J (t f 

### a i 43 01

w 

### E T J A (t f C n A
• H X V rt f 

### a T J d > 43 V 4 O M H T J d i g 

### 3 C O C O rt f
C Q (t f 3 T J d l C Q 0 1 A V Ui - r l T J C Q C D E 

### 3 r H O > d > J J 01 (t f 3 T J •ri wi O Ui Qi xi J J

•. J J A - r l O 

### a T J A (t f J J C O
wi (t f C J

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i n

• T J d ) > wi (t f 43 d l 43

> i rr t 

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## TABL E 15

. SOLI D WAST E IMPACT S ASSOCIATE D WIT H TH E US E O F PACKE D -

BE D SCRUBBER S AN

D NE W EMISSIONCONTRO L TECHNOLOGIE S A T HARD CHROMIU

M ELECTROPLATIN

G MODE L PLANT S P.7 5

Har d chromium platin gmodel plant s Smal l

0.8 2 (29 ) 1 0 0.0 8 (2.8 )

0.9 5 (34 ) 5 0.19(6.7 )

2. 3 (81 ) 1. 1 (39 ) 1 0 5 0.4 5 (16 )

2. 1 (74 ) 5 0.42(15 ) Medium

2. 1 (74 ) 1 0 0.2 1 (7.4 )

2. 6 (92 ) 5 0.5 2 (18 )

6. 7 (237 ) 3.3(117 ) 1 0 5 1.3(46 )

6. 4 (226 ) 5 1.3 (46 ) Larg

e
4.2(148 ) 1 0 0.4 2 (15 )

5. 2 (184 ) 5 1.0(35 )

1 3 (459 ) 6. 7 (237 ) 1 0 5 2. 6 (92 )

1 3 (459 ) 5 2. 6 (92 ) Singl epacked-bed scrubber s 3 3 Tota l volum eo f

packingmaterial , m (fr ) Frequenc y o f replacement, yr Annualized volume , m 3 /y r(ft/yr )

Mis teliminators with mes h pad s i nserie s Tota l volum eo f

mesh pa d material , nr(ft 3 ) Frequenc y o f replacement, y r Annualized volume , nr/y r(fr/yr )

Packed-bed scrubbers/mesh-pad mis teliminato rsvstem s Tota l volum e o f

packin g material , n r



### (ft 3 

### ) 3 Tota l volum eo f

mesh pa d material , m 3 (ft3 ) Frequenc y o f replacemento f

packingmaterial , y r Frequenc y o f replacemento f

mesh pads , y r Annualized tota

l volum eo f

material , m 3 /y r(fr/yr )

Fiber-bed mis teliminators Total volum eo f

packingmaterial , m (fr ) Frequenc y o f replacement, y r Annualized volume , nr/y r(fr/yr )

--Base d o napacking-bed dept h o f 0. 9 m ( 3 ft)



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v o iT5-s 3 

## TABL E 16

. CAPITAL COST S O F SINGL E PACKED-BE D SCRUBBER S AND NE W CONTRO L TECHNOLOGIE S FOR NE W AND EXISTIN G HAR D CHROMIUM ELECTROPLATING MODE L PLANT S (NOVEMBE R 198 8 DOLLARS) 5 

## ' 1 6 

## " 1 8

Model plan

tsiz e Small Medium Large

Control technolog y Ne w Existin g Ne w Existin g Ne w Existin g Singl epacked-bed scrubber Mesh-pad misteliminato rwit h mesh pads inserie s Packed-bed scrubber/mesh-pad misteliminato rsystem Fiber-bed misteliminato r 36,70 0 27,20 0

58,10 0

114,60 0 45,90 0

34,00 0

72,60 0

126,10 0 74,20 0

71,80 0

97,80 0

228,60 0 92,80 0

89,80 0

122,20 0

251,50 0 148,40 0

143,60 0

195,60 0

502,80 0 185,50 0

179,50 0

244,50 0

688,30 0
a- *

^ 1 ^ 1

## TABL E 17

. NE T ANNUALIZE D COST S O F SINGL E PACKED-BE D SCRUBBER S AND NE W CONTRO L TECHNOLOGIE S FOR NE W AND EXISTIN G HAR D CHROMIU

M ELECTROPLATING MODE L PLANT S (NOVEMBE R 198 8 DOLLARS) 5 

## ' 16 

## " 1 8

Control technology Singl epacked-bed scnibbe r Mesh-pad mis teliminato rwith mes h pads inserie s New 9,70 0 13,50 0 Smal

l

Existin g 11,10 0 14,90 0 Model plan tsiz e Medium

Ne w 18,60 0 32,80 0 Existin g

21,50 0 36,40 0 Ne w

38,80 0 76,70 0 Larce

Existin g

44,60 0 84,10 0

Packed-bed scrubber/mesh-pad misteliminato rsystem 

### 17,00 0 19,30 0 31,80 0 35,70 0 72,10 0 80,00 0

o- * N J Fiber-bed misteliminato r 28,90 0 30,70 0 66,20 0 69,80 0 149,20 0 156,30 0

o o

## compare d t o th e capita l cost s o f singl e packed-be d scrubber s

installe d a t ne wo r existing plants

. A s show n i n Tabl e 17 , th e ne t annualize d cost s o f ..operatin g thi s contro l technolog yar e $13,50 0 t o $76,70 0 fo r ne wplants , an d $14,90 0 t o $84,10 0 fo r existing mode l plants

. Fo r ne w plants , th e cost s ar e 4 0 t o 10 0 percen t highe r tha n th e cost s o f operating singl e packed-be d scrubbers ; fo r existin g plants , th e cost s ar e 3 0 t o 9 0 percen t higher

. 5.5. 2 Packed-Be d Scrubber/Mesh-Pa d Mis t Eliminato r System
. A s shown i n Tabl e 16 , capita l cost s o f installin g packed-be d scrubber/mesh-pa d mis t eliminato r system s ar e $58,10 0 t o $195,60 0 fo r ne wmode l plants , and $72,60 0 t o $244,50 0 fo r existin g mode l plants

. Thes e cost s ar e from3 0 t o 6 0 percen t highe r tha n th e capita l cost s associate d wit hth e installatio n o f singl e packed

be d scrubber s a t thes e mode l plants

. Tabl e 1 7 show s tha t th e ne t annualize d cost s o f operatin g packed-be d scrubber/mesh-pa d mis t eliminato r system s rang e from $17,00 0 t o $72,10 0 fo r ne wmode l plants , and $19,30 0 t o $80,00 0 fo r existin g mode l plants

. Fo r ne wplants , th e operatin g cost s ar e 7 0 t o 9 0 percen t mor e tha n th e cost s associate d wit hth e us e o f singl e packed-be d scrubbers

. Fo r existin g plants , th e operatin g cost s ar e 7 0 t o 8 0 percen t higher

. 5.5. 3 Fiber-Be d Mis t Eliminators

. A s show n i n Tabl e 16 , th e mode l plan t capita l cost s o f fiber-be d mis t eliminator s fo r ne wplant s ar e approximatel y $114,60 0 t o $457,100

. Thi s i s approximatel y21 0 percen t mor e tha n th e capita l cost s o f $36,70 0 t o $148,40 0 fo r singl e packed

be d scrubbers

. Fo r existing plants , singl e packed-be d scrubbe r capita l cost s rang e from $45,90 0 t o $185,500 , and fiber-be d mis t eliminato r cost s ar e $126,10 0 t o $502,800 , a differenc e o f abou t 17 0 percent
. Tabl e 1 7 show s tha t th e ne t annualize d cost s fo r singl e packed-be d scrubber s a t ne wplant s rang e from$9,70 0 t o $38,800

. Ne t annualize d cost s fo r fiber-be d mis t eliminator s i n thes e sam e plant s ar e $28,90 0 t o $149,200 , a n increas e o f abou t 20 0 t o 6 3 

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## TABL E 18

. ESTIMATE D PERCENT CHANG E I NHAR D CHROMIUM ELECTROPLATIN G COS T O F THRE E EN

D PRODUCT S ATTRIBUTABL E T O VARIOU S CONTRO L TECHNOLOGIE S (198 8 DOLLARS) 1 9

Percen tpric eincrease , %

Control technolog y Automobile s model plan

tsiz e small medium large Industria l rolls 1 1 mode l plan tsiz e small medium larg e Hydrauliccylinders"-
- mode l plan tsiz e small mediu

m larg e

a. a. Compositemesh-pa d mist eliminato r Packed-bed scrubber/mesh-pad mis teliminato rsystem Fiber-bed mis teliminato r Singl epacked-bed scrubber 12. 5 3. 9 3. 4 10.9-18. 3 3.3-5. 6 2.1-3. 5 18.0-36. 0 5.6-11. 1 3.5-7. 1

16. 1 3. 8 3. 2 14.1-23. 6 3.3-5. 5 2.0-3. 4 23.5-46. 4 5.5-10. 9 3.4-6. 8

25. 9 7. 3 6. 1 22.7-38. 1 6.3-10. 5 3.8-6. 3 37.4-74. 9 10.5-21. 0 6.3-12. 6 9. 4 2. 4 2. 0 8.3-13. 9 2.1-3. 5 1.2-2. 1 13.6-27. 3 3.5-6. 9 2.1-4. 1 "Ranges includ epercen

tincreases inelectroplatin gcost s a t$0.009/cn rto $0.06/cm 2($0.06/in. 2to $0.40/in.*' ) Range s includ epercen

tincreases inelectroplatin gcost s a t$0.005/cm 2to $0.009/cm 2($0.03/in
. t o $0.06/in
. )

O OP.8 3



## 2 percen t fo r larg e plant s t o 2 7 percen t fo r smal l plants

. Estimate s o f th e change s i n fina l produc t price s attributabl e t o increase s i n electroplatin g cost s whe n ne w contro l technologie s ar e use d ar e presente d i n Tabl e 19

. Th e fina l product s ar e har d chromium-plate d part s fo r a representativ e automobil e and a typica l backho e usin g hard

chromium

- electroplate d hydrauli c cylinders

. A s state d i n Tabl e 19 , pric e increase s fo r industria l rol l end product s ca n no t b e easil yestimate d becaus e o f thei r wid e diversity

. However , fo r mos t industria l rolls , th e cos t o f electroplatin g i s les s tha n 1 0 percen t o f th e fina l produc t price , and us e o f th e ne wcontro l technologie s woul d increas e th e pric e o f th e en d product s b

yles s tha n 1 percent. 1 9 

## 6. 0 CONCLUSIONS/SUMMARY I n term s o f performance , composit e mesh-pa d system s and fiber-be d mis t eliminator s achieve d highe r performanc e level s tha n thos e achieve d b ypacked-be d scrubbers

. Th e performanc e level s fo r fiber-be d mis t eliminator s wer e highe r tha n thos e fo r composit e mesh-pa d systems
. However , th e economi c impact s associate d wit hth e us e o f fiber-be d mis t eliminator s ar e muc h greate r tha n th e impact s attributabl e t o th e us e o f eithe r composit e mesh-pa d system s o r traditiona l packed-be d scrubbers

. Furthermore , th e economi c impact s presente d fo r fiber-be d mis t eliminator s wer e base d onl yo n cost s o f th e fiber-be d mis t eliminato r itself

. A s discusse d i n Sectio n 4.3 , th e relativel y hig hperformanc e leve l o f th e fiber-be d mis t eliminato r wa s due , i n part , t o th e inle t load reductio n attributabl e t o th e us e o f th e coars e contro l systemupstream o f th e fiber-be d mis t eliminator

. I f th e cost s fo r th e upstreamcontro l syste mwer e include d i n th e cos t o f contro l fo r fiber-be d mis t eliminators , th e economi c impac t woul d b e eve n greater , particularl yfo r smal l businesses

. Th e economi c impact s fo r composit e mesh-pa d system s ar e no t significantl ydifferen t tha n thos e fo r traditiona l packed-be d scrubbers

.

6 7 

# 8 2

## TABL E 19

. ESTIMATE D CHANG E I NPRIC E O F FINA L PRODUCT S ATTRIBUTABL E T O TH E INCREAS E I NHAR D CHROMIU M ELECTROPLATIN

G COST S WHE NUSIN

G VARIOU S CONTRO L TECHNOLOGIE S (198 8 DOLLARS) 1 9

c n o o Estimated priceincrease , $

Contro l technolog y Automobiles " mode l plan tsiz e small mediu

m large Industria l rolls 0 mode l plan tsiz e smal l medium large Hydrauliccylinders
- backhoe 0 model plan

tsiz e small mediu

m large Compositemesh-pa

d mis t eliminato r Packed-bed scrubber/mesh-pad mis teliminato rsyste m Fiber-bed misteliminato r Singl epacked-bed scrubber 13.2 2 4.0 9 2.6 1

17.0 4 4.0 2 2.5 0

27.4 8 7.7 0 4.6 8 10.0 0 2.5 4 1.5 2 24.8 0

31.9 7 7.5 9

7.4 6 4.8 1

4.6 0

51.5 5 14.2 9 8.6 2 18.7 6 4.7 1 2.8 0
"Price increases ar

ebased o narepresentativeautomobile , theOidsmobil eCutlass/Ciera(si xmode l years inth e1980's) . ''Amounto f

priceincreas eforfina

l product s cannotb ereadily estimated forindustria l rolls . Th eelectroplatin gcos ta s apercentag eo f thepriceo f

thefina l produc tca ndiffe rforroll s wit

h theexac

tsameplatingcost s becaus eo f variations inroll thicknes s (notplatin g thickness ) priorto platin go rinthequalit y o f thesteel substrate . Industria l roll s themselve s ar

ea nintermediate , rathertha nafinal , product. c Fina l produc

tcost s ar ebased o narepresentativebackhoewit h 1 1 hydrauliccylinder s an d alis tpric

eo f $37,000
.

G OP.8 5

1 mt

.-imf

"



## Th e composit e mesh-pa d system s ar e economicall yviabl e contro l option s fo r al l size s o f har d chromiu melectroplatin g operations , a s indicate d b yth e increase d us e o f thes e systems
. Th e us e o f fiber-be d mis t eliminators , o n th e othe r hand , i s limite d t o a few , ver ylarg e har d chromiu melectroplatin g operations

. I t appear s that , o f th e tw o ne wemissio n .contro l techniques , composit e mesh-pa d system s represen t th e mor e reasonabl e approac ht o controlling emission s o f chromi c aci d mis t fromal l har d chromiu m plating'operations

. 7. 0 REFERENCE S 1

. CEC O Aeroso l Fibe r Be d Filter s an d System s fo r th e Collectio n o r Recoveryo f Mist s an d Valuabl e Solids

. Produc t Informatio n Brochure

. 1987

. CEC O Filters , Inc. , Conshohocken , Pennsylvania , p . 2

. 2

. Mem o fromBarker , R. , MRI , t o Smith , A. , EPA:ISB
. Novembe r 12 , 1990

. Repor t o f meetin g wit hKimre , Inc. , Ma y10 , 1990

. 3

. Holmes , T.L
. an d G.K
. Chen

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. 6 9 

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## 9

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mfro m Barker , R. , MRI , t o Smith , A. , EPA/ISB

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. Memorandu

mfrom Barker , R. , an

d Shrager , S. , MRI , t o Vervaert , A. , EPA/ISB

. Summaryo f Packed-Be d Scrubber/Mesh

Pa d Mis t Eliminato r Syste mCos t Dat a fo r th e Har d Chromiu m Electroplatin g Mode l Plants

. February1 , 1991

.

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## 19

. Mem o wit hattachmen t fro mWatkins , T. , EPA/SDB , t o Barker , R. , MRI
. Apri l 15 , 1992

. Transmitta l of ' economi c analysi s document , Economi c Impac t Assessmen t o f Emergin g Technologie s fo r Controlling Chromiu mEmission s from Chromiu mElectroplating Operations

.

7 1 

# § 8 6