p.1 

OAR Box 1313 

Preppedby LaTeiaShed 

Document Number: 

11) l-B-4 

Docket Number: 

A-88-02 

Printed 6/12/2008 9:03:27 AM Sheet 11 of 99 
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Rl® A-88-0^ 

MIDWEST RESEARCH INSTITUTE 

13Z-6)- 4 450 5 Creedmoor Road 

Raleigh, N.C. 27612 

Telephone (919) 781-5750 

Date: March 29, 1985 

(Finalized April 19, 1985) 

I E COPY 

FINAL 

Subject: Site Visit—T&S Brass and Bronze Works 

Survey of Chromium Emission Sources—Chromium Plating 

EPA Contract 68-02-3817; ESEO Project 85/02 

MRI Project 7711-L 

From: Barb Duletsky &"#> 

To: Al Vervaert 

ESED/ISB/SSS (MD-13) 

U. S. Environmental Protection Agency 

Research Triangle Park, N.C. 27711 

I. Purpose 

The purpose of this site visit was to gather background information 

on the chromium plating operation at the subject plant and to determine the 

suitability of the plant for chromium emissions testing. 

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II. Place and Date 

T&S Brass and Bronze Works 

Route 4 

Old Buncombe Road 

Travelers Rest, S.C. 29690 

(803) 834-4102 

March 7, 1985 

III. Attendees 

T&S Brass and Bronze Works 

Jim Anderson, Vice President of Manufacturing 

Dick Goughnouer, Manufacturing Manager 

Cliff Theisen, Vice President 

Midwest Research Institute (MRI) 

Barb Duletsky 

Charles Hester 

IV. Discussion 

We arrived at the plant at 2:20 p.m. and were escorted to a 

conference room. After discussing the purpose of our visit with the three 

attendees from T&S Brass and Bronze Works (T&S), we were provided with 

general information about the chromium plating operation at the plant. 

/ 

Principal Laboratories 425 Volker Boulevard, Kansas City, Missouri 64110 
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Following the discussion, Mr. Goughnouer showed us the chromium plating 

operation and the associated control device. 

A. General 

T&S is a large faucet manufacturer, competing with companies such as 

American Standard, Kohler, and Crane. T&S has operated the plant in 

Travelers Rest for 7 years, having moved from a previous location in New 

York. 

B. Process 

The decorative plating line consists of a series of dip tanks 

containing nickel plating solution, chromium plating solution, and various 

cleaning and rinsing solutions. The line is serviced by an automatic hoist 

that transfers the racks of faucet parts to each tank in sequence. It 

takes 45 minutes for each rack of parts to complete the plating cycle. The 

plating sequence is staggered so that a rack comes off the line every 5 or 

6 minutes. 

There is one chromium plating tank on the line. The tank measures 

8 feet (ft) in length, 3% ft in width, 5 ft in depth, and holds 

1,000 gallons of plating solution. The solution is composed of a 

proprietary mixture called Chromatex, manufactured by McDermitt. The 

mixture contains a high ratio of chromic acid to sulfuric acid (higher than 

the conventional 100:1 ratio) and a small amount of fluoride. The exact 

proportion, of constituents is considered by McDermitt to be a trade 

secret. T&S uses an average of 250 pounds of Chromatex each month. 

Typically, parts remain in the chromium plating tank for 1^ minutes, 

receiving a plate thickness of 2 to 2% mil. The temperature of the 

solution is regulated by a steam heating system and 1s normally maintained 

at 110° to 112°F. The electrodes 1n the tank are energized by a single 

transformer/rectifier set. Although the voltage and current settings are 

highly variable, the average operating values are 5 volts (V) and 2,400 to 

2,500 amperes (A). During the visit the tank was operating at 3V and 

1,300A. The current required in the tank depends on the total surface area 

of parts to be plated. There is a chart in the plating area that indicates 

the best electrical settings for racks of parts of various shapes. 

C. Control 

T&S uses a demisting agent in the chromium plating solution called 

Fumetrol 205T, which is supplied by M&T Chemicals. The agent creates a 

layer of foam on the surface of the solution to inhibit the release of 

hydrogen gas bubbles. 

The chromium plating tank has two side-draft hoods along the 8-foot 

length of the tank. An induced draft fan draws emissions from the tank 

through a circular duct to a fume scrubber mounted on the roof. The 

scrubber is manufactured by Duall, Model No. 101-F, and has a design gas 

flow rate of 8,000 standard cubic feet per minute (scfm). The flow rate of 
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the scrubbing liquid through the system is 24 gallons per minute (gpm). 

The treated emissions are exhausted through the fan and a 3-foot high stack 

before exiting to the atmosphere. A diagram of the control system, which 

also treats emissions from a small nickel strip tank, 1s presented 1n 

Figure 1. A description of the fume scrubber has been supplied by Duall 

Industries, Inc. and is included as Attachment A. 

The fume scrubber was installed when the plant was built in 1978. 

The reason for installing the system was to reduce chromium air emissions 

to a level that would comply with State and local standards. The company 

also installed an extensive wastewater treatment system to treat the 

various types of metal finishing wastes generated at the site. Currently, 

the plant treats the 24 gpm flow of scrubbing water used in the Duall 

scrubbber with the other wastewater from the chromium plating process. 

D. Conclusions 

T&S is a captive plater performing decorative chromium plating of 

nickel-plated brass faucet parts. Emissions from the chromium plating tank 

are controlled by a demisting agent, side draft hoods, and a fume scrubber. 

There were no visible emissions from the scrubber stack the day of the 

visit. Inlet and outlet testing of the scrubber is feasible, however, 

ports would need to be installed. Plant personnel are not opposed to a 

test being performed at this site. Test data from this plant could be used 

to determine both the emissions from an automated decorative chromium 

plating tank controlled by a demisting agent and the performance of a fume 

scrubber in controlling those emissions. 

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8,000 

scfm It 

DUALL 

# 101-F 

SCRUBBER 

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DIRECTION 

OF RACKS 

Figure 1. Emissions control system on chromium plating tank. 

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Attachment A 

Z>utt£l INDUSTRIES 

PVC Constructed, 100% Corrosion Free 

FUME SCRUBBERS 

FW-300 Vertical Pack with Blower 

5 00 TO 1 2,000 C.F.M. . . plus multiple installations 

This packed tower type scrubber is not only a space saver, 

it's also a true economy model. It incorporates a built-in 

rugged fan with convenient exterior, belt driven, TEFCBB 

motor. During installation, the horizontal air discharge can 

be swivelled 360° before sealing into permanent position. 

Efficiency is equal to the F-101 and the PT-500. Compact-

ness and versatility make it an unusually popular model. 

This FW-300 saves three ways ... in initial cost, installation, 

and in space. Also avaiiabie with double pack. 

F-101 Horizontal Single Filter Pack 

5 00 TO OVER 60,000 C.F.M. . . plus multiple installations 

Being our most popular scrubber design, this compact 100% 

corrosion resistant P.V.C. unit has proven its efficiency in 

46 states. The Duall F-101 incorporates high efficiency, low 

maintenance filter media and the open orifice type spray 

nozzles, forthe assurance of a thoroughly saturated collection 

chamber. Our mist eliminator outlet section gives four air 

direction changes to properly remove the entrained moisture. 

Where a horizontal installation is preferred, the F-101 should 

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F-101-D Horizontal Double Filter Pack 

5 00 TO OVER 60,000 C.F.M. . . plus multiple installations 

An extra heavy duty scrubber for real ''tuffies". It incorpo-

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scrubbing .. . plus an effective mist eliminator at the air out-

let. Serious concentrations of rough fumes, such as nitric, 

hydrofluoric, and hydrochloric acid are double scrubbed 

through six stages for maximum efficiency. For such problems in your plant, use this high efficiency fume scrubber, at only a small increase in price. 

PT-500 Vertical Pack 

5 00 TO OVER 30,000 C.F.M. . .plus multiple installations 

The upright PT-500 is the space saver. This scrubber is a 

vertical packed tower type designed to fit into restricted 

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equal to the F-101, and also 100% corrosion-free. Air flow is up through a thoroughly water saturated bed of filter media. 

The mist eliminator pack near the top outlet assures properly 

dried air. If space is your problem, take a good look at the 

PT-500. Also available with double pack. 

"DuaCC 

x. 

INDUSTRIES, INC. 

700 S. McMillan Street, Owosso. Michigan 48867. Ph. (517) 725-8184