p.1 

OAR Box 1313 

Prepped by LaTeia Shed 

Document Number: 

55) ll-B-29 

Docket Number: 

A-88-02 

Printed 6/12/2008 9:03:29 AM Sheet 55 of 99 
MRI® 

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TL-&-2S A-88-02 

*"-

 J MIDWEST RESEARCH INSTITUTE 

, , , . . -.:-> «-; Suite 3S0 

401 Harrison Oaks Boulevaid 

mmja - a Y -- v - Caiv. N.C. 27513 

fmf l g Tf R ml 

•'I! ! JAN I 8 1991 liij 

Date: August 6, 1987 i r-^/* AI:"* ^\CK'~T 

(Finalized December 28, 1987) Ljdr7l7L±±L^±ii L 

Subject: Summary of Fume Suppressant Cost Data for Decorative Chromium 

Electroplating Model Plants 

Chromium Electroplating NESHAP 

EPA Contract 68-02-3817; ESD Project 85/02a 

MRI Project 7717-K 

From: Robin Barker T& 

To: Andy Smith 

ESD/ISB/SSS (MD-13) 

U. S. Environmental Protection Agency 

Research Triangle Park, N.C. 27711 

I. Introduction 

This memorandum presents annual costs of permanent and temporary 

fume suppressants for the decorative chromium plating model plants. 

Permanent fume suppressants are wetting agents, foam blankets, or a 

combination of a wetting agent and foam blanket that are depleted 

primarily from plating baths by dragout. Temporary fume suppressants are 

mainly foam blankets, but can be wetting agents or a combination of a 

wetting agent and foam blanket that are depleted primarily from 

decomposition of the fume suppressant in the plating bath. 

The annual costs include the material cost of initial makeup and 

maintenance of the fume suppressant in the plating baths. The material 

cost of the chemical fume suppressant is the only component of the 

annualized cost that cannot be considered negligible. All costs are in 

October 1986 dollars. There is no capital investment associated with the 

use of fume suppressants as a control technique. 

II. Decorative Chromium Plating 

A. Information Sources 

Cost data were obtained from five manufacturers of fume 

suppressants. Table 1 presents the manufacturers and the fume suppressant 

brands for which cost data were obtained. 

Cost data for three of the fume suppressant brands listed in Table 1 

were not used in the development of annual costs for the model plants. 

Cost data for Proquel B and Metex® Spray Stop R (manufactured by 

MacDermid, Inc.) were not included in the analysis because these fume 

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suppressants are used as maintenance supplements for Metex® Spray Stop HF 

and are rarely used alone in a decorative chromium plating tank. In addition, cost data for Clepo (manufactured by Frederick Gumrn Chemical 

Company) were not included in the analysis because Clepo is a new fume 

suppressant for which accurate cost data were not available. 

B. Annual Costs of Fume Suppressants 

1. Model tanks. Fume suppressant cost information was obtained for 

two different sizes of model tanks (42 square feet [ft ] of surface area 

and 72 ft of surface area) that are used in the model plants. Table 2 

presents the model tank parameters upon which the fume suppressant cost 

estimates are based. Makeup and maintenance costs of permanent and 

temporary fume suppressants for the 42-ft model tank are presented in 

Tables 3 and 4, respectively. Makeup and maintenance costs of permanent 

and temporary fume suppressants for the 72-ft model tank are presented in 

Tables 5 and 6, respectively. Maintenance cost estimates for the fume 

suppressants were based on an operating time of 2,000 hours per year 

(h/yr) for the 42-ft tank and 6,000 h/yr for the 72-ft tank. 

2. Model plants. The average makeup and maintenance costs of both 

the permanent and temporary fume suppressants for each tank size were used 

to compute the annual costs for the decorative chromium plating model 

plants. The average annual cost of permanent and temporary fume suppressants for each tank size and each model plant are presented in Tables 7 

and 8, respectively. 

The methodology for the cost calculations also is shown in Tables 7 

and 8. The annual cost of fume suppressants was calculated by multiplying 

the number of tanks in each model plant by the makeup and maintenance 

costs of fume suppressant use associated with that size tank. The maintenance cost for each model plant includes an operating time adjustment 

factor. The operating time adjustment factor accounts for the difference 

between the operating time of the model tanks upon which the cost data 

were based and the operating time for the model plant. The small model 

plant operates 2,000 h/yr, the medium model plant operates 4,000 h/yr, and 

the large model plant operates 6,240 h/yr. 

<Z~ 
TABLE 1. LIST OF MANUFACTURERS WHO PROVIDED COST INFORMATION ON 

INDIVIDUAL FUME SUPPRESSANTS 

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Manufacturer/brands Type of fume suppressant 

MacDermid, Inc. 

Proquel B 

Metex® Spray Stop HF 

Metex® Spray Stop R 

OMI"/Udylite International Corp. 

Zero-MistTM 

Zero-MistTM HT 

Zero-MistTM HT-2 

Foam Lok® L 

Harshaw/Filtrol Partnership 

MSP-1 

MSP-2 

MSP-ST 

M&T Chemicals'* 

a b Temporary/foam blanket . 

Permanent/combination0 

Permanent/combination 

Permanent/wetting agente 

Permanent/foam blanket 

Permanent/combination 

Temporary/foam blanket 

Permanent/combination 

Permanent/comb ination 

Permanent/wetting agent 

Fumetrol' 

Fumetrol' 

Fumetrol' 

Fumetrol' 

Fumetrol' 

103 

104 

205 

208 

210 

Frederick Gumrn Chemical Company' 

Clepo 

Temporary/foam blanket 

Temporary/foam blanket 

Permanent/combination 

Permanent/combination 

Permanent/comb i nat ion 

Permanent/foam blanket 

aTemporary fume suppressants are depleted mainly (80 percent) from 

decomposition of the fume suppressant. 

Foam blankets produce a layer of foam on the surface of the plating 

solution to entrap chromic acid mist. 

cPermanent fume suppressants are depleted mainly (80 to 90 percent) from 

.dragout of the fume suppressant. 

Combination fume suppressants are a combination of wetting agents and 

foam blankets. 

eWetting agents reduce the amount of chromic acid mist by lowering the 

surface tension of the bath. 
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TABLE 2. PARAMETERS FOR DECORATIVE CHROMIUM 

PLATING MODEL TANKS 

Model tank information 

Tank dimensions, ft 

Tank capacity, gal 

Operating voltage, volts 

Operating current, amperes 

Current density, amp/ft 

Time electrodes are energized, % 

Temperature, °F 

Chromic acid concentration, oz/gal 

Chromic acid: sulfuric acid ratio 

Operating time, hours/year 

Model 

42-ft2 

12.0, 3.5, 6.0 

1,730 

6-7.5 

2,000-4,000 

72-360 

80 

100-115 

35-40 

170:1 

2,000 

tank 

12.0, 

72-ft2 

6.0, 9.0 

4,580 

16 

6,000 

72-360 

80 

100-115 

35-40 

170:1 

6,000 

r 
TABLE 3. PERMANENT FUME SUPPRESSANT MAKEUP AND MAINTENANCE COST DATA FOR THE 

42-ft DECORATIVE CHROMIUM PLATING MODEL TANK 

Manufacturer/ 

fume suppressant brand 

M&T 

FumetrolTM 205b 

FumetrolTM 208c 

FumetrolTM 210c 

Purchase cost, 

$/gal or $/lb 

32.78 

68.38 

59.12 

Initial 

makeup, 

gal or lb 

5.00 

2.50 

2.50 

Makeup 

cost, $ 

163.90 

170.95 

147.80 

Tank 

maintenance 

consumption, 

gal or lb 

58.00 

23.00 

23.00 

Maintenance 

cost, $/yra 

1,901 

1,572 

1,360 

MacDermid 

Metex® Spray Stop HFb 23.50 

Udylite 

Zero-Mist" 

Zero-Mist" 

Zero-Mist" 

HTU , 

HT-2f 

25.00 

21.00 

22.00 

8.5 

5.10 

2.50 

6.80 

199.75 

127.50 

52.20 

149.60 

44.00 

24.00 

36.00 

24.00 

1,031 

600 

756 

528 

Harshaw/Filtrol 

MSP-STC 

MSPMSPl

l 

49.00 

53.50 

56.50 

3.46 

3.46 

3.46 

169.54 

185.11 

195.49 

12.30 

12.30 

12.30 

600 

660 

690 

AVERAGE 156.00 970 

^Maintenance costs are based on a tank operating time of 2,000 hours per year. 

Cost data and solution makeup and maintenance additions are in pounds. 

Cost data and solution makeup and maintenance additions are in gallons. 

K XI 

0> 
TABLE 4. TEMPORARY FUME SUPPRESSANT MAKEUP AND MAINTENANCE COST DATA FOR THE 

42-ft DECORATIVE CHROMIUM PLATING MODEL TANK 

Manufacturer/ 

fume suppressant brand 

M&T 

FumetrolTM 103 

FumetrolTM 104 

Udylite 

Foam-Lok® L 

AVERAGE 

Purchase cost, 

$/gal 

19.31 

22.31 

13.00 

Initial 

makeup, 

gal 

0.63 

0.42 

1.70 

Makeup 

cost, $ 

12.17 

9.37 

22.10 

15.00 

Tank 

maintenance 

consumption, 

gal 

70.00 

70.00 

30.00 

Maintenance 

cost, $/yra 

1,351 

1,560 

390 

1,100 

Maintenance costs are based on a tank operating time of 2,000 hours per year. 

^ 
TABLE 5. PERMANENT FUME SUPPRESSANT MAKEUP AND MAINTENANCE COST DATA FOR THE 

72-ft DECORATIVE CHROMIUM PLATING MODEL TANK 

Manufacturer/ 

fume suppressant brand Purchase cost, 

$/gal or $/lb 

Initial 

makeup, 

gal or lb 

Makeup 

cost, $ 

Tank 

maintenance 

consumption, 

gal or lb 

Maintenance 

cost, $/yra 

M&T 

Fumetrol' 

Fumetrol' 

Fumetrol' 

205D 

208c 

210c 

32.78 

68.38 

59.12 

14.00 

6.90 

6.90 

458.92 

471.82 

407.93 

157.00 

62.00 

62.00 

5,146 

4,239 

3,665 

MacDermid 

Metex® Spray Stop HFL 23.50 22.90 538.15 238.00 5,593 

Udylite 

Zero-MistTMu 

Zero-MistTM HTb 

Zero-MistTM HT-2b 

Harshaw/Filtrol 

MSP-STC 

MSP-1C 

MSP-2C 

25.00 

21.00 

22.00 

49.00 

53.50 

56.50 

13.50 

6.80 

18.00 

9.16 

9.16 

9.16 

337.50 

142.80 

396.00 

448.84 

490.06 

517.54 

90.00 

108.00 

60.00 

97.60 

97.60 

97.60 

2,250 

2,268 

1,320 

4,780 

5,220 

5,510 

AVERAGE 420.00 4,000 

^Maintenance costs are based on a tank operating time of 6,000 hours per year. 

Cost data and solution makeup and maintenance additions are in pounds. 

cCost data and solution makeup and maintenance additions are in gallons. 

^ 

00 
TABLE 6. TEMPORARY FUME SUPPRESSANT MAKEUP AND MAINTENANCE COST DATA FOR THE 

72-ft DECORATIVE CHROMIUM PLATING MODEL TANK 

Manufacturer/ 

fume suppressant brand 

M&T 

FumetrolTM 103 

FumetrolTM 104 

Udylite 

Foam-Lok® L 

AVERAGE 

Purchase cost, 

$/gal 

19.31 

22.31 

13.00 

Initial 

makeup, 

gal 

1.69 

1.15 

4.00 

Makeup 

cost, $ 

32.63 

25.66 

52.00 

37.00 

Tank 

maintenance 

consumption, 

gal 

189.00 

189.00 

90.00 

Maintenance 

cost, $/yra 

3,649 

4,216 

1,170 

3,012 

Maintenance costs are based on a tank operating time of 6,000 hours per year. 

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TABLE 7. AVERAGE ANNUAL COST OF PERMANENT FUME SUPPRESSANTS 

FOR DECORATIVE CHROMIUM PLATING MODEL PLANTS 

Model plants 

Small Medium Large 

A. Model tank data 

1. Surface area of tank, ft 

2. Average makeup cost of fume 

suppressant, $ 

3. Average maintenance cost of fume 

suppressant, $/yr 

4. Operating time basis, h/yr 

B. Model plant data 

1. No. of model tanks 

2. Operating hours, h/yr 

3. Makeup cost of fume suppressant, $a 

(A2xBl) 

4. Maintenance cost of fume suppressant3 

a. Operating time factor 

(B2->A4) 

b. Maintenance cost, $/yra 

(A3xBlxB4a) 

5. Annual cost of fume suppressant, $/yra 1,130 

(B3+B4b) 

aCost data were rounded to the nearest $10. 

42 

156 

970 

2,000 

1 

2,000 

160 

42 

156 

970 

2,000 

3 

4,000 

470 

72 

420 

4,000 

6,000 

5 

6,240 

2,100 

1.0 

970 

130 

2.0 

5,820 

6,290 

1.04 

20,800 

22,900 

<? 
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10 

TABLE 8. AVERAGE ANNUAL COST OF TEMPORARY FUME SUPPRESSANTS 

FOR DECORATIVE CHROMIUM PLATING MODEL PLANTS 

Model plants 

Small Medium Large 

A. Model tank data 

2 

1. Surface area of tank, ft 

2. Average makeup cost of fume 

suppressant, $ 

3. Average maintenance cost of fume 

suppressant, $/yr 

4. Operating time basis, h/yr 

B. Model plant data 

1. No. of tanks 

2. Operating hours, h/yr 

3. Makeup cost of fume suppressant, $a 

(A2xBl) 

4. Maintenance cost of fume suppressant3 

42 

15 

1,100 

2,000 

1 

2,000 

20 

42 

15 

1,100 

2,000 

3 

4,000 

50 

72 

37 

3,012 

6,000 

5 

6,240 

190 

5. 

a. Operating time factor 

(B2-A4) 

b. Maintenance cost, $/yr

 a 

(A3xBlxB4a) 

Annual cost of fume suppressant, $/yra 

(B3+B4b) 

1.0 

1,100 

1,120 

2.0 

6,600 

6,650 

1.04 

15,660 

15,850 

aCost data were rounded to the nearest $10. 

W 
P.12 

11 

III. References 

1. Cost Enclosure for Fume Suppressant Vendors: MacDermid, Inc. 

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

Park, North Carolina. February 20, 1987. p. 2-3. 

2. Cost Enclosure for Fume Suppressant Vendors: OMI/Udylite 

International Corporation. Prepared for U. S. Environmental 

Protection Agency, Research Triangle Park, North Carolina. 

February 26, 1987. p. 2-3. 

3. Cost Enclosure for Fume Suppressant Vendors: Harshaw/Filtrol 

Partnership. Prepared for U. S. Environmental Protection Agency, 

Research Triangle Park, North Carolina. January 20, 1987. p. 2-3. 

4. Cost Enclosure for Fume Suppressant Vendors: M&T Chemicals. Prepared 

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

North Carolina. January 20, 1987. p. 2-3. 

5. Cost Enclosure for Fume Suppressant Vendors: Frederick Gumm Chemical 

Company, Inc. Prepared for U. S. Environmental Protection Agency, 

Research Triangle Park, North Carolina. February 9, 1987. p. 2-3. 

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