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# OAR Box 

# 1313 PreppedbyLaTeiaShed



## Document

Number: 

# 61 ) ll-B-3 5
Docket Number: 

# A-88-0 2

Printed 6/12/20089:03:29AM

Sheet 61 of 99P. 2 

# MRI® -nze>-3 S A-88-0 2 MIDWES TRESEARC H INSTITU T

-'•' 1 H.v -Cf

. Oo-v

S I'Oinew r r.-ir vNC
. ::." •

Date : Apri l 18 , 198 8

(Finalized Jun e 30 , 1988 ) Subject : Summar

yo f th e Capita l Cost s Associate d wit hthe Installatio n o f the Trivalen t Chromiu mPlating Proces s a t Existing an d New Decorativ e Chromiu

mElectroplating Plant s Chromiu mElectroplatin g NESHAP EP AContrac t 68-02-3817 ; ES D Projec t 85/02 a MR I Projec t 7717- K
From : Robi n Barke r

Mark McLaughli n To : Andre wSmit h

ESD/ISB/SS S (MD-13 ) U . S
. Environmenta l Protectio n Agency ResearchTriangl e Park , N.C
. 2771 1 L~~-.Z'- Z
I . Introduction Thi s memorandu

mpresent s a mode l plan t analysi s o f th e capita l cost s fo r converting decorativ e chromiu melectroplating mode l plant s fromthe hexavalen t chromiu

mproces s t o th e trivalen t chromiu mproces s an

d incrementa l capita l cost s fo r installing a trivalen t chromiu mproces s instead o f a hexavalen t chromiu mproces s a t newplants
. Als o presente d ar e th e result s o f a preliminaryanalysi s o f the incrementa l annualize d cost s o f trivalen t chromiu mprocesse s ove r the hexavalen t chromiu m process . At present , the hexavalen t proces s i s the predominan t proces s use d in the industry , althoughinteres t i n an d us e o f the trivalen t • chromiu mproces s i s increasing
. Th e trivalen t chromiu mproces s i s reported.t o be technicall ysuperio r an d ha s minima l environmenta l impacts.'" 4 Informatio n obtaine d fro ma vendo r indicate s tha t ther e ar e approximatel y100.electroplating plant s currentl yusin g the trivalen t chromiu mprocess. "
II . Information Source s Cos t dat a fo r convertin g froma hexavalen t chromiu mt o a trivalen t chromiu mproces s wer e obtaine d fromfour manufacturer s of hexavalen t an

d trivalen t chromiu

mplating baths
. "" " Tabl e 1 present s the manufacturer s an d the trivalen t chromiu mproces s trad e name s fo r whic hcos t dat a wer e obtained
. Ther e ar e tw

o type s o f trivalen t chromiu mprocesse s (single-cel l an d double-cell ) currentl ymarketed
. Th e mai n differenc e betwee n the single

an d double-cel l processe s i s tha t th e double-cel l proces s require s a physica l separation o f the anod e fromthe platin g solution
. I

n the

/ •P. 3

double-cel l process , the anode s ar e encase d in anod e boxe s whic har e lined wit ha permeabl e membran e an d contai n a dilut e solutio n o f sulfuri c aci d whic hsurround s the anodes
. I n the single-cel l proces s th e anode s ar e place d in direc t contac t wit hth e plating solution
. Th e single-cel l processe s ar e sol d b yHarshaw/Filtro l Partnershi p an d 0MI m /Udylit e Internationa l Corporation
. The double-cel l processe s ar e sol d b y Frederic k Gum

mChemica l Compan

yan d MacDermid , Inc . Th e capita l cos t estimate s develope d fo r th e mode l plant s ar e representativ e o f eithe r proces s an

d ar e based on a compilatio n o f cos t dat a obtaine d fromth e fou r vendors
. Th e individua l cos t dat a supplie d b, yeachvendo r ar e presente d in Table s 2 an

d 3 fo r the 4 2 squar e fee t [ft' I an d 72-ft ' mode l tanks , respectively
. Al l cost s ar e in Octobe r 198 6 dollars
. Th e vendo r estimate s fo r th e proces s conversio n o f th e 42-ft ' mode l tan k range d from $22,80 0 t o $31,700
. The vendo r estimate s fo r th e proces s conversio n o f th e 72-f t mode l tan k range d fro

m$46,70 0 t o $58,500
. Thes e narro wrange s in cos t estimate s fo r eachmode l tan k indicat e consistenc yin th e cos t o f the fou r trivalen t chromiu mprocesses . III . Capita l Cost s fo r Existing Facilitie s A . Mode l Tank s Capita l cost,informatiot * wa s obtaine d fo r the two differen t size s o f mode l tank s (4 2 ft " an d 7 2 f t o f surfac e area ) tha t ar e use d i n the mode l plants
. Tabl e 4 present s the mode l tan k parameter s upo n whic hth e capita l cos t estimate s ar e based
. Tabl e 5 present s the capita l cos t associate d wit hthe proces s conversio n fo r eachtan k size
. Th e capita l cos t include s th e direc t cos t o f newequipment , startu p an d installation/modificatio n cost , plu s indirec t costs , taxes , an d freigh t charges
. Th e newequipmen t purchase s consis t o f an ampere-hou r controller(s ) used t o determin e the frequenc yo f chemica l addition s an d t o provid e automati c contro l o f addition s o f require d chemical s t o the bath , a tan k liner , replacemen t anode s an d hangers , an

d anod e boxes
. The purchas e cost s o f chiller s an d filter s als o ar e presente d in Tabl e 5 , bu t thes e items ar e considere d t o be optiona l equipmen t purchases
. Chiller s ar e require d fo r som e operation s wher e part s ar e plate d a t hig hcurren t densitie s an d the productio n loa d i s heav yo r fo r operation s wher e the temperatur e o f th e cooling wate r i s to o hig ht o maintai n the bathwithi n it s norma l operating temperatur e range. 0

- Filter s ar e usuall yrecommende d t o ai d i n the contro l o f plating bathcontaminants
. Th e startu

p (tan k conversion ) cos t include s th e initia l makeu

p cos t o f th e trivalen t chromiu mplating solution , "he initia l makeu p cos t c f the passivatio n solution , an d the disposa l cos t (transportatio n an d treatment ) o f the hexavalen t solution a s hazardou s waste , "^h e passivatio n solutio n i s require d fo r som e double-cel l trivalen t chromiu mprocesse s an

d improve s the corrosio n resistanc e o f the par t following plating
. The capita l cos t o f a passivatio n tan k i s no t included i n the equipmen t cost s becaus e a n existing rins e tan

k can be converte d t o hol d the passivatio n solution
. The cos t t o dispos e o f th e hexavalen t plating solutio n wa s obtaine d fro m Chemica l Wast e Management , Inc. , i n Anaheim , California. 'P. 4

Installation/modificatio n cost s ar e base d on dat a obtaine d fro m actua l operatin g plant s ag d ar e estimate d t o b e 2 0 percen t o f the purchase d equipmen t cost . Installation/modificatio n cost s includ e installatio n o f newequipment , tan k cleaning , an

d an ymodification s t o th e plating line , electrica l supply , o r coolin g system . Indirec t cost s include cost s associate d wit hengineerin g an d supervisio n (I Q percent) , proces s startu

p ( 1 percent) , an

d contingencie s ( 3 percent). ' Taxe s an d freigh t charge s were Q estimate d a t 3 an d 5 percen t o f the bas e equipmen t cost , respectively. '
B . Mode l Plant s Th e capita l cos t informatio n obtaine d fo r eac htan k siz e wa s used t o calculat e th e capita l cost s fo r convertin g thre e mode l plant s o f varying siz e (small , medium , an d large ) fro

mth e hexavalen t t o the trivalen t chromiu mRrocess . Th e smal l an d mediu mmode l plant s consis t o f on e an d tw o 42-ft' 2 mode l tanks , respectively
. Th e larg e mode l plan t consist s o f fiv e 72-f t mode l tanks
. The capita l cos t o f conversio n fo r eachmode l plan t i s presente d in Tabl e 6
. IV . Capita l Cost s fo r NewFacilitie s Th e incrementa l capita l cos t associate d wit hinstallin g the trivalen t chromiu

mproces s instea

d o f th e hexavalen t chromiu mproces s a t a ne wfacilit yi s presente d in Tabl e 7 fo r eac hmode l plant
. The capita l cos t include s th e direc t cos t o f ne wequipment , installation , an d startu

p plu s indirec t costs , taxes , an d freigh t charges
. Th e ne wequipmen t purchase s consis t o f equipmen t tha t i s uniqu e t o the trivalen t chromiu mprocess : an ampere-hou r controller(s ) used t o determin e an

d automaticall ymak e chemica l addition s t o the plating bath , anode boxes , a filte r system , an d chillers
. Th e filte r syste man d chiller s ar e optiona l equipmen t purchases
. Th e incrementa l cos t o f anode s an d hanger s fo r a trivalen t chromiu mbat hove r a hexavalen t chromiu mbat h i s insignifican t an d i s no t included in Tabl e 7
. Th e cos t o f a tan k line r i s no t include d a s a n equipmen t cos t becaus e a tan k line r als o woul d be needed fo r a hexavalen t chromiu mtank
. Th e startu p (platin

g tankfs] ) cos t include s the incrementa l cos t o f th e initia l makeu p solutio n fo r trivalen t chromiu move r hexavalen t chromiu man d th e initia l makeu p cos t o f the passivatio n solution
. Installation cost s ar e base d on dat a obtaine d fro m plants , an

d ar e estimate d t o be 1 5 percen t o f th e purchase d equipmen t cost. ' Indirec t cost s wer e based on 1 4 percen t o f the purchase d equipmen t cos t an d includ e cost s associate d wit hengineerin g an d supervision , proces s startuD , an d contingencies. ' Taxe s an d freight,charge s wer e 3 an d 5 percen t o f the bas e equipmen t cost , respectively. "
Abenefi t o f the trivalen t chromiu mproces s i s the eliminatio n o f th e need fo r hexavalen t chromiu mreductio n unit s i n the wastewate r treatmen t system . Th e capita l cos t fo r th e hexavalen t cnromiu mreductio n syste mwa s obtaine d fro ma 198 5 EP

Adocument." ' The capita l cos t o f hexavalen t chromiu

mreduction unit s include s storag e an d fee d systems fo r th e treatmen t reagents , a s wel l a s the cost s fo r hardware , piping ,



### ^3P. 5

4 instrumentation , an d utilit yconnections
. Thes e cos t estimate s als o ar e presente d i

n Tabl e 7
. Th e volume o f proces s wastewate r t o be treate d wa s estimate d fo r eac hmode l plan t base d on informatio n publishe d in the Effluen t Guideline s developmen t document. " Th e smal l mode l plan t wa s assume d t o hav e a batc hsystembecaus e o f it s lo wvolume o f wastewater . The mediu

man d larg e mode l plant s wer e assume d t o b e equippe d wit ha continuou s wastewate r treatmen t system . Treatmen t equipmen t an d ancillar

y items require d strictl yfo r th e reductio n purpose s wer e identifie d an d thei r associate d cost s wer e determined
. Th e cos t o f th e reductio n equipmen t wa s subtracte d fromth e proces s capita l cos t t o achiev e the ne t capita l cos t fo r ne wfacilities
. V . Cas e Studie s Cas e studie s wer e produce d fo r thre e decorativ e chromiu mplating facilitie s tha t ha

d converte d fro

ma hexavalen t chromiu mproces s t o a trivalen t chromiu

mprocess . Tabl e 8 present s a descriptio n o f the plating operatio n agd^he^trivalen t chromiu mproces s operate d a t eacho f the facilities
. ' ' H Tabl e 9 present s the capita l cos t dat a provide d b ythe thre e facilitie s fo r th e conversion^froma hexavalen t chromiu mproces s t o a trivalen t chromiu mprocess . • ' , l Thi s informatio n wa s use d t o confir m o r validat e th e estimatin g procedur e fo r capita l cost s develope d fro mth e vendo r quotations
. Base d o n informatio n obtaine d fro mvendor s an

d confirme d during sit e visit s t o th e thre e trivalen t chromiu mplatin

g facilities , th e capita l cos t of conversio n i s dependen t upo n the siz e o f th e operation , the amoun t an d typ e o f availabl e equipment , an d the configuratio n o f th e existing decorativ e chromiu

mplatin g line
. The capita l cos t dat a obtaine d fro mthe facilitie s visite d wa s use d t o determin e whethe r the capita l cost s estimate d fo r th e mode l plant s ar e representativ e o f wha t existing plant s have incurre d t o conver t fro ma hexavalen t chromiu mproces s t o a trivalen t chromiu mprocess . Tabl e 1 0 present s a compariso n o f th e actua l capita l cos t dat a obtaine d fro

mindustr

yt o th e capita l cos t estimate s develope d fo r the mode l plants
. Plant s 1 an d 2 woul d be classifie d a s smal l operations , an d Plan t 3 woul d be considere d a mediu moperation
. Th e smal l mode l plan t capita l cos t estimat e i s nea r the uppe r en d o f the rang e represente d b y th e cost s submitte d b yPlant s 1 an

d 2
. Plan t 1 operate s a double-cel l trivalen t chromiu

mprocess , an

d Plan t 2 operate s a single-cel l process . The double-cel l proces s i s mor e expensive t o conver t becaus e o f th e need fo r anod e boxe s an

d th e passivatio n solution
. Also , .--Ian t 1 incurred mor e modificatio n cost s than Plan t 2
. Becaus e th e mode l olan t cos t estimate s ar e based on bot hproces s cost s an d th e cos t t o modif yth e plating nne , th e cos t fo r the smal l mode l plan t woul d b e expecte d t o b

e comparaol e t o th e cost s submitte d b yPlan t 1
. The capita l cos t dat a obtaine d fro m Plan t 2 ar e comparabl e t o the capita l cos t estimate d fo r the mediu mmode l plant , even thoug

hth e equipmen t required an d modification s neeae d wer e no t the same .



# - fP. 6



### VI . Preliminar y

Result s o f th e Annualize dCos t Analysi s Base doninformatio nobtaine ddurin g sit e visit s t o trivalen t chromiu m plants , th e annualize dcos t fo r th e trivalen t chromium proces s i s substantiall y

lowe r tha nth e annualize dcos t fo r th e hexavalen t chromiu m proces s becaus e o f th e reductio ninrejects , increas e inrac kpopulations , an dth e decreas e inwastewate r treatmen t costs . Annualize dcos t dat a fro m thre e plant s tha t wer e visite dan dhadconverte dfrom th e hexavalen t t o trivalen t chromiu

m proces s indicate dtha t th e trivalen t chromium proces s generate da

nannua l cos t saving s o f $14 ? 

### 000/y r t o $153,000/y r fo r smal l an dmedium

operations , respectively."' 1



## OP. 7



### TABL E 1 . LIS T O F MANUFACTURER S WH OPROVIDE DCOS T INFORMATION O N DECORATIV E TRIVALEN T CHROMIUM ELECTROPLATINGPROCESSE S Manufacturer/Locatio nTrivalen t proces s Harshaw/Filtro l Partnership , Cleveland , Ohi o Tri-Chrome'* - LC Plus a 

### OMr/Udylit e Internationa l Corp. , Warren , Mich . Tricrolyte ®III d 

### MacDermid , Inc. , Waterbury , Conn . Trimac TM Cr-III b 

### Frederic kGum

m Chemica l Company , Kearny , N.J . Envirochrome ^Single-cel l process . Double-cel l process .

/P. 8



### TABL E 2
. VENDO R CAPITA L COS T ESTIMATE S FO R CONVERTIN GTH E 42-ft ' MODE L TANK FRO MAHEXAVALEN T CHROMIUMPROCES S T O ATRIVALEN T CHROMIUMPROCES S

Componen t New equipmen t cost s 1 . Anod e boxes , 5 2 . Anode s an dhangars , S 3 . Passivatio ntan k a . Capita l cos t o f tank , S b . Cos t o f initia l makeu p 4 . Tan k1ine r solution , $ 5 . Ampere-hou r mete r o r controlle r 6 . Fi1te r 7 . Chi11e r Subtota l Modificatio ncost s 1 . Tan kcleanina , S 2 . Platin g lin e modification , 5 . Modification s t o electrica l i. Modification s t o coolin g s v 5 . initia l makeu o cos t o f C r Subtota l Installatio ncosts , $ 1 . Labo r cost , 5 2 . Proces s downtime , days ' 3 . Indirec t costs , J Subtota l Tota1 J 5 supply . S ^ stem, r solution , S A a

NA e 3,00 0 N A N A 2,00 0 20 0 7,00 0 N A 12,20 0

f N A N A N A 10,00 0 10,00 0

57 6 3 N A "57 5 22,80 0 Vendo r



### B °

N A 4,60 0 N A N A 2,00 0 N A N A 8.50 0 15,10 0

40 0 3,00 0 N A N A 10.70 0 14,10 0

2,52 0 5 N A 2^52 0 31,70 0 COS T dat a



## c7,20 0 N A 5,00 0 50 0 1,50 0 1,50 0 N A N A 13,70 0

20 0 M A N A N A 11.30 0 i1,30 0

3 6 1 N A 

### 3 5 27,20 0 0 d

13,20 0 N A N A N A N A N A N A N A 13,20 0

N A N A N A N A 14,70 0 14,/0 0

N A N A N A 

### U 27,90 0

a Vendo r A

= Harsnaw/F i I tro l Partnershi p(single-cel l process) . _Vendo r B = OMI/Udylit e Internationa l Corooratio n(single-cel l process) . '"Vendo r C = MacOermid , Incorporate d(double-cel l process) . "'vendo r D= Frederic kGum m Chemic3 l Company

(double-cel l process) . TN A = no t applicaoie . 'Tan kcleanin g cos t i s include di nth e installatio ncost . ^Assume s tan ki s equippe dwit h12-vol t rectifiers . '"'Assume s tan ki s equippe dwit hexterna l shell-and-tub e hea t exchanger s wit hwate r use da s th e .coolant . 'Assume s Dlan t i s converte ddurin g a norma l holida y snutdowno r ove r a nonworkin g weeken d

. ! day = 8-hou r s ni ft . -'Th e tota l capita l cos t provide db y eac hindividua l vendo r i s lowe r thanthe capita l cos t estimate dfo r rh e mode l tank s becaus e vendor s wer e basin g th e estimate s ontnei r trivalen t chromiu m proces s anddi dno t includ e al l o f th e optiona l equipment . Also , th e vendo r aat a wa s no t aiway s complete .



# 7

### TABL E 3
. VENDO R CAPITA L COS T ESTIMATE S FO R CONVERTIN GTH E 72-ft " MODE L

TANK FRO MAHEXAVALEN T CHROMIU MPROCES S T O ATRIVALEN T CHROMIU MPROCES S Vendo r cos t dat a Componen t Ne wequipmen t cost s P. 9

1 . 2 . 5 .

4

. 5 . 6 . 7 . Anod e boxes , S Anode s an d hangars , Passivatio n tan k a
. Ca p i ta I b
. Cos t o f Tan k Iiner , Ampere-hou r F iIte r Ch i Ile r cos t o f tank , J

initia l makeu p solution , S mete r o r controller , 5

Subtota l Modificatio n cost s

3

. 4

. 6

. Subtota l Tan k cleaning , J Platin g lin e modification , S Modification s t o electrica l suppl y Modification s t o coolin g svstem , S Initia l makeu p cos t o fC r 5 9 solution , $
installatio n costs , S 1
. Labo r cost , S/ h 2
. Proces s downtime , 3
. Indirec t costs , 5 Subtota l days ' NAe 8,00 0 N A N A 3,30 0 20 0 10,00 0 N A 21,50 0

f N A N A N A 24,60 0 24,60 0

57 6 3 N A 575 " N

A 7,50 0 N A N A 3,50 0 N A N A 13.00 0 24,00 0

60 0 3,00 0 N A
• N A 28,40 0 32,00 0

2,52 0 5 N A 2752 0 7,20 0

N A 12,00 0 1.20 0 3,00 0 1,50 0 N A N A 24,90 0

20 0 N A N A N A 29,90 0 30,10 0

3 6 1 N A 3 5 19,20 0

N A N A N A N A N A N A N A 19,20 0

N A N A N A N A 38.90 0 38,90 0

N A N A N A " 5
Tot a l J 46,70 0 58,50 0 55,00 0 58,10 0 ^Vendo r A= Harshaw/FiItro l Partnershi p (single-cel l process)
. Vendo r 8 = OMI/Udylit e internationa l Corporatio n (single-cel l process)
. c Vendo r C = MacOermid , Incorporate d (double-cel l process)
. '-Vendor 0 = Frederic k GummChemica i Compan y(double-cel l process)
. e N A= no t applicable
. 'Tank cleanin g cos t i s include d i n Th e installatio n cost . •^Assume s tank i s equippe d wit h12-voi t rectifiers
. Assume s tank i s equippe d wit hexterna l shell-and-tub e hea t exchanger s wit hwate r use d a s th e .coolant
. 'Assume s plan t i s converte d durin g a norma l holida ysnutdow n o r ove r a nonworkin g weeken d

. 1 day= 3-hou r sh i ft
. J Th e tota l caoita l cos t provide d b yeac hindividua l vendo r i s lowe r tha n th e capita l cos t estimate d fo r th e mode l tank s becaus e vendor s wer e basin g the estimate s o n thei r trivalen t chromiumproces s an d di d no t includ e al l o f th e optiona l equipment
. Also , th e vendo r dat a wa s no t alway s complete
.P.1 0



### TABL E 4 . MODE L TAN

KPARAMETER S FORDECORATIVE CHROMIU M PLATINGMODE L TANK S Mode l tan k Mode l tan

kinformatio n4 2 f t 7 2 ft "
Tankdimensions , f t 12.0,3.5,6. 0 12.0,6.0,9. 0 Tankcapacity , ga l 1,73 0 4,58 0



# fP.1 1



### 1 0
TABL E 5 . CAPITAL COS T O F CONVERTINGHEXAVALEN T CHROMIU M PROCES S T O TRIVALEN T CHROMIU

M PROCES S FOREAC HMODE L TAN K Mode l tank Componen t 4 2 ft 2 

### 7 2 ft :


### Startu p(tankconversion ) cos t Initia l trivalen t chromiu m solutio npurchas e 10,00 0 25,00 0 Initia l passivatio nsolutio npurchase a, H

### 50 0 1,20 0 Wast e disposa l cos t o | hexavalen t 3,40 0 7,50 0 chromiu m solution^ ' Subtota l 13,90 0 33,70 0 Purchase dequipmen t cost s Ampere-hou r controller " Tan kliner " Replacemen t anode s an dhangers ' Anod e boxes 0 

### ' " Chiller d 

### » Filter d 

### ' Subtota l 1 0 

### Taxe s an

dfreight* 5 

### ' TOTA L f 9 

### Installation/modificatio n• Indirec t costs^ ' 1 0 1,50 0 2,00 0 3,00 0 7,20 0 8,50 0 7,00 0 29,20 0 2,30 0 31,50 0 6,30 0 4,40 0 1,50 0

3,30 0 8,00 0 7,20 0 13,00 0 10,00 0 43,00 0 3,40 0 46,40 0 9,30 0 6,50 0 

### Tota l cost h

### 56,10 0 95,90 0 ^Passivatio n solutio n i s require d fo r som e trivalen t chromiu mprocesses . b 

### Wast e disposa l cost s includ e treatmen t and transportation
. Th e treatmen t cos t wa s estimate d t o b e S80.0 0 pe r 55-gallo n drumand th e transportatio n cos t wa s S845.0 0 pe r truckloa d (8 0 drums)
. An yfractio n o f a load wa s coste d ou t a s a ful l load
. ^Anod e boxe s ar e require d fo r al l double-cel l processes . Optiona l equipment
. e 

### Taxe s and freigh t ar e estimate d t o b e 3 an d 5 percen t o f th e bas e equipmen t cost , respectively
. Installation/modificatio n cost s ar e estimate d t o b e 2 0 percen t o f th e purchase d equipmen t costs . ^Indirec t cost s includ e cost s associate d wit hengineerin g and supervision , proces s startup , an

d contingencie s and ar e estimate d t o b e 1 4 percen t o f th e purchase d equipmen t cost . Th e tota l capita l cos t i s no t solel yattributabl e t o ai r pollutio n contro l bu t als o t o proces s improvement
.

t&P.1 2



### TABL E 6
.

Componen t 1 1

CAPITA L COS T O F CONVERTIN GHEXAVALEN T CHROMIUMPROCES S T O TRIVALEN T CHROMIU MPROCES S FO R EAC H MODE L PLAN T Mode l plant s • Smal l Medium Larg e Mode l tank s Numbe r o f tank s Surfac e are a o f tanks , f t Startu p (tank conversion ) cost a 

### Initia l trivalen t chromium solutio n purchas e Initia l pa§sivatio n solutio n purchas e Wast e disposa l cost 3 

### o f hexavalen t chromiumsolutio n Subtota l Purchase d equipmen t cos t Ampere-hou r mete r Tank line r Replacement^anode s and hanger s Anod e boxe s Chiller** ' Filter 0 

### ' Subtota l Taxe s and freight 0 , 

### TOTA L
r l a 

### Installation/modificatio n ' 1 4 2

10,00 0 

### 50 0 3,40 0 2

4 2

20,00 0 1,00 0 6,80 0 5

7 2

125,00 0 6,00 0 37,50 0



### Indirec t cost s e , i o 

### 13,90 0

1,50 0 2,00 0 3,00 0 7,20 0 8,50 0 7,00 0 29,20 0 2,30 0 31,50 0 6,30 0 4,40 0 27,80 0

3,00 0 4,00 0 6,00 0 14,40 0 17,00 0 14,00 0 58,40 0 4,60 0 63,10 0 12,60 0 8,80 0 168,50 0

7,50 0 16,50 0 40,00 0 36,00 0 65,00 0 50,00 0 215,00 0 17,00 0 232,00 0 46,50 0 32,50 0 Tota l cos t 56,10 0 112,20 0 479,50 0

a 

### Startu p cost s includ e th e initia l makeu p o f th e trivalen t chromiumsolu

tio n and th e disposa l cos t o f th e hexavalen t chromiumplatin g solution. Optiona l equipment
. c 

### Taxe s and freigh t ar e estimate d t o b e 3 an d 5 percen t o f th e bas e .equipmen t cost , respectively
. a 

### Insta11ation/modificatio n cost s ar e base d o n 2 0 percen t o f purchase d equipmen t costs . e 

### Indirec t cost s includ e cost s associate d wit hengineerin g an d supervision , proces s startup , and contingencie s and ar e estimate d t o b e 1 4 percen t o f the purchase d equipmen t cost . 

## f Th e tota l capita l cos t i s no t solel yattributabl e t o ai r pollutio n contro l bu t als o t o proces s improvement
.



## tlP.1 3



### 1 2
TABL E 7
. INCREMENTA L CAPITA L COS T ASSOCIATE D WIT H INSTALLIN GATRIVALEN T CHROMIU MPROCES S INSTEAD O F AHEXAVALEN T CHROMIU MPROCES S A T NE W PLANT S Mode l plant s Componen t Smal l MediumLarg e Mode l tank s Numbe r o f tank s Surfac e are a o f tanks , ft " Startu p Cost s Startu p (platin g tank(s) ) cost*' 1 

### Initia l passivatio n solutio n ' Subtota l Purchase d equipmen t cos t Ampere-hou r controlle r Anod e boxes 0 

### ' * Chillers'? ' Filter 0 

### ' Subtota l 1 0 

### Taxe s an d freight e 

### ' TOTA L g 

### Installatio n ' 1 0 

### Indirec t costs^ ' 

### 1 4 2
2,80 0 

### 50 0 3,30 0
1,50 0 7,20 0 8,50 0 7,00 0 24,20 0 2,00 0 26,20 0 4,00 0 3,70 0 

### 2

4 2
5,50 0 1,00 0 6,50 0
3,00 0 14,40 0 17,00 0 14,00 0 48,40 0 3,90 0 52,30 0 7,80 0 7,30 0 

### 5

7 2

27,50 0 6,00 0 33,50 0
7,50 0 36,00 0 65,00 0 50,00 0 158,50 0 12,70 0 171,20 0 25,70 0 24,00 0
Tota l cos t

U1 1 Wastewate r treatmen t cos t saving s ' Ne t cost k 37,20 0 -18,000 ' 19,20 0 73,90 0

-27,000 J ' 46,90 0 254,40 0

-38,000 j 216,40 0 

### Startup cos t fo r ne wplant s woul d onl yconsis t o f th e incrementa l cos t o f th e trivalen t chromiu mbat hsolutio n ove r th e hexavalen t chromiumbat h solution
. Th e cos t differentia l betwee n th e trivalen t chromiumplatin g solutio n and th e hexavalen t platin g solutio n i s $1.6 0 pe r gallo n o f platin g solutio n fo r th e smal l an d mediummode l plant s an d $1.2 0 pe r .gallo n fo r th e larg e mode l plant. " ^Passivatio n solutio n i s require d fo r som e trivalen t chromium processes . SAnod e boxe s ar e require d fo r al l double-cel l processes . ^Optiona l equipment
. Taxe s and freigh t ar e base d o n 3 and 5 percen t o f th e bas e equipmen t f 

### cost , respectively
. ^Installatio n cost s ar e base d o n 1 5 percen t o f th e purchase d equipmen t costs , "indirec t cost s includ e cost s associate d wit hengineerin g an d supervision , proces s startup , and contingencie s and ar e base d o n 1 4 percen t o f th e .purchase d equipmen t costs . "Represent s th e capita l cos t o f a hexavalen t chromiu mreductio n uni t fo r •the wastewate r volum e associate d wit heac hmode l plant
. •Batchprocess . ^Continuou s process . Th e tota l capita l cos t i s no t solel yattributabl e t o ai r pollutio n contro l bu t als o t o proces s improvement
.



### /<XTABL E 8
. PLAN T PARAMETER S FO

R THE TRIVALEN

T CHROMIU

M FACILITIE S THAT PROVIDE D COS T DAT A

Plan t informatio n Plan t 1 Plan t 2 Plan t 3

No . o f plating line s o r tank s 1 Dimension s o f tanks , f t 12 , 3.0 , 6. 0

Tan k capacity , ga l

Trivalen t chromiu

mproces s an d typ e
(Single-cel l process ) Operating time , h/y r 1,48 0

Trimac' " C r II I MacDermid , Inc .



### 4,00 0 1 4.6 , 3.8 , 5. 5
65 0 Tricrolyte w

### II I OMr/Udylit e Intl

. Corp

. (Double-cel l process )

2,88 0 2 @ 16.5 , 3.8 , 7. 2 10.0 , 2.5 , 5. 5 2 @ 3,14 0 93 5 Tri-Chrome- * L C Plu s Harshaw/Filtro l Parternshi p (Single-cel l process )
2,70 0

### 1 4

TABL E 9
. CAPITA L COS T FO R CONVERTIN GFRO MAHEXAVALEN T PROCES S T O A TRIVALEN T CHROMIUMPROCES S FO R TH E TRIVALEN T CHROMIUMPLATIN GFACILITIE S
Plan t cos t dat a Componen t Ne w equipmen t cost s 1 . Anod e boxe s Anode s an dhangar s Passivatio ntan k a . Capita l cos t o f tank , S b . Cos t o f initia l makeu psolution , 5 Tan kIiner , S Ampere-hou r mete r o r controller , 5 F iIter , S Chille r o r coolin g coils , J Platin g tank , $ Rectifiers , $ Automati c D H andtemperatur e controllers , i 2 . 3 .

4 . 5 . 6 . 7 . 8 . 9 . 10 . 15,86 0 2,89 5

1 ,40 0 65 0 N A

• ,20 0 3,80 0 N A 6,15 0 N A 2,02 5 NA a

1,80 0

N A N A N A N A 5,00 0 4,20 0 N A 15,00 0 N A N

A 17,80 0

N A N A 3,00 0 2,20 0 N A 31,40 0 N A 39,60 0 N A Subtota l 33.98 0 26,00 0 94,00 0
Modificatio ncost s 1 . 2 . 3 . 4 . 5 . 6 . Subtota l Tan kcleaning , S Platin g lin e modification , S Modification s t o electrica l supply , 5 Modification s t o coolin g system , $ Disposa l o f Cr + ° solution , S Initia l cos t o f C r solutio nmakeup , 3 2,00 0 2,17 0 10 0 40 0 9,45 0 13,80 0 N

A N A N A N A N A 4,50 0 N A N A N A N A N A 24,50 0 27,92 0 4,50 0 24,50 0
installatio ncosts , S 5,16 0 N A N

A

TotaI ' 67,10 0 30,50 0 118,50 0
d N A = no t applicable . Number s wer e rounde dt o neares t S100 .



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## 1 5

TABL E 10 . COMPARISON OF PLAN T CAPITAL COS T DAT A AN D MODE L PLANT CAPITAL COS T DATA Plan t Tota l capita l cost , $ Plan t dat a Plan t 1 (small ) 67,10 0 Plan t 2 (small ) 30,50 0 Plan t 3 (medium ) 118,50 0 Mode l plan t dat a Smal l 56,10 0 Medium 112,20 0 Larg e 479,50 0



## /S*P.1 7



### 1 6
VII . Reference s 1 . Cos t Enclosur e fo r Decorativ e Chromium Electroplatin g Processes : Harshaw/Filtro l Partnership . Prepare dfo r U . S . Environmenta l Protectio nAgency , Researc hTriangl e Park , Nort hCarolina . Jun e 22 , 1987 . p . 4 . 2 . Cos t Enclosur e fo r Decorativ e Chromium Electroplatin g Processes : OMI/Udylit e Internationa l Corporation . Prepare dfo r U . S . Environmenta l Protectio nAgency , Researc hTriangl e Park , Nort h Carolina . Jun e 5 , 1987 . p . 4 . 3 . Cos t Enclosur e fo r Decorativ e Chromium Electroplatin g Processes : Frederic kGum

m Chemica l Company , Inc . Prepare dfo r U . S . Environmenta l Protectio nAgency , Researc hTriangl e Park , Nort h Carolina . Jun e 22 , 1987 . p . 4 . 4 . Cos t Enclosur e fo r Decorativ e Chromium Electroplatin g Processes : MacDermid , Inc . Prepare dfo r U . S . Environmenta l Protectio nAgency , Researc hTriangl e Park , Nort hCarolina . Jun e 18 , 1987 . p . 4 . 5 . Telecon . Barker , R. , MRI , t o Masarik , D. , Harshaw/Filtro l Partnership , Cleveland , Ohio . Septembe r 16 , 1987 . Informatio non installatio nan

dmodificatio ncost s associate dwit hthe trivalen t chromium

proces s conversion . 6 . Telecon . Barker , R. , MRI , t o Masarik , D. , Harshaw/Filtro l Partnership , Cleveland , Ohio . Decembe r 10 , 1987 . Informatio no n chiller s an

dampere-hour s meter s fo r trivalen t chromiu m plating . 7 . Telecon . Barker , R. , MRI , t o Cepla , A. , OMF/Udylit e Internationa l Corporation , Warren , Michigan . Decembe r 14 , 1987 . Informatio non chille r requirement s fo r trivalen t chromium plating . 8 . Telecon . Barker , R. , MRI , t o Gloverner , S. , Chemica l Wast e Management , Anaheim , California . Septembe r 16 , 1987 . Informatio n abou t hexavalen t chromiu m platin g solutio ndisposa l costs . 9 . Memo fro

m Barker , R. , MRI , t o Smith , Andrew , EPA/ISB . Marc h7 , 1988 . Tri prepor t fo r Universa l Gy m an dNissa nCompany , Cedar s Rapids , Iowa . 10 . Neveril , R . 8. , Gard , Inc . Capita l an dOperatin g Cost s o f Selecte d Ai r Pollutio nContro l Systems . Prepare dfo r U . S . Environmenta l Protectio nAgency , Researc hTriangl e Park , Nort hCarolina . Publicatio nNo . EPA-450/5-30-002 . Decembe r 1977 . p . 3-3 . 11 . Environmenta l Pollutio nContro l Alternatives : Reducin g Wate r Pollutio nContro l Cost s i nthe Electroplatin g Industry . U . S . Environmenta l Protectio nAgency , Washington , D.C . EP A Publication : 625/5-85/016 . Septembe r 1985 . p . 7 .



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### 1 7 12 . Developmen t Documen t fo r Effluen t Limitation s Guideline s an d Standard s fo r th e Meta l Finishin g Industry . U . S . Environmenta l Protectio nAgency , Washington , D.C . EPA Publication : 440-1-80-091A . Jun e 1980 . p . V-12 . 13 . Memo from

Barker , R. , MRI , t o Smith , Andrew , EPA/ISB . Marc h7 , 1988 . Tri prepor t fo r Lufki nRule , Apex , Nort hCarolina . 14 . Memo from

Barker , R. , MRI , t o Smith , Andrew , EPA/ISB . Marc h7 , 1988 . Tri prepor t fo r Plan t ABC , Southeaster nUnite dStates . Attachmen t

/ /