I LLI NO I S**NV II** **~ONMENTi\l** P ROTEC TI ON AGENCY P.O . B Oll: 1 9506, SP RINGf i ElD, I lUt>.QlS 62 i 9 -1-9506**I~ ENEE**  CWkl,\NO, DIRE CTOK 217/782-2113 LI FETHIE OPERATING PERHIT
- NESHAP SOURCE PERflITTEE Gr avure Process Company Attn : David Parsi ll 41 79 I-lest Belmont Avenue Chicago , Illinois 60641 Application No. : 9704002) Applicant's Designation: SCSH 4000 Subject : Hard Chrome Electroplating Date I ssu ed : February 13, 2002 Location : 4179 ' dest Belmo nt Avenue, 1.D . No .: 031600GBT Date Received : December 17, 2001 Facility Expiration Date: See condition 1. Chicago, 60541 Permi t i s hereby g ra nted to the above
- designated Permittee to OP ERATE emission source (s) and/or air polluti o n control equipment consisting of two hard chrome elec t roplating tanks each contro lle d by the composite mesh-pad system pursuant to the above-referenced application. This Permit is subject to standard conditions attached hereto and the following special condition (s) : 1a. This Permit shall expire 180 days after the Illinois EPA sends a written request for the renew al of this permit. b. This permit shall terminate if it is withdrawn or is superseded by a revised permi t . 2. Th e hard chromium electroplating t anks are subject to the National Emission Standards for Hazardous Air Pollutants (NESHAP) for chromium emissions, 40 CFR Part 63, Subpart N . The Illinois EPA is administering this regulation in Illinois on beha l f of the United S t ates EPA under a delegation agreement . 3. The conce n tration of total chromium from the electropla t ing operations in the exhaus t gas stream discharged to the atmosphere shall not exceed 0 .03 milligrams per dry sta ndard cubic meter (mg/dscm) pursuant to the standard in 40 CfR 63 . 34.2 (c) (1) (ii) for small existing sources . 4.. The Permittee shall develop and imp l ement work and operatio n al p r actice to minimize chromium emissions which includes the following applicable work practice standards described in 40 CfR 63.342(f) a . A quarterly visual inspectio n of composite mesh pad (CMP) system t o ensure t h ere is proper draina g e , n o c hro mi c acid buildup on the pads, and no evidence of chemical att a c k on the structural integrity of the device. b . A quarterly visual inspection of the back portion of the mesh pad closest to the fan to ensure there is n o breakthrough of chromic acid mist . G W I( GE H. R YAN, G OVER NOfl

, _

. . 

# /Page 2

c. A quarterly visual inspection of duct work from the tank(s) to the control device to ensure there are no leaks. d. Washdown of the composite mesh-pads performed in accordance with manufacturer's recommendations. Sa. The Permittee shall develop and implement an operation and maintenance (0 & M) plan for hard chrome plating tanks which shall include at least the following, pursuant to 40 CFR 63.342(f) (3): i. Description of the control devices and monitoring equipment in use. ii. A checklist to document the operation and maintenance of the equipment. iii. Required operation and maintenance procedures,**pursua~t** to 40 CFR 63.342(f) (Condition 2). iv. Procedure to follow to ensure that equipment or process malfunctions due to poor maintenance or other preventable conditions do not occur. v. Procedure for identifying malfunctions and for implementing corrective actions. b. The Permittee may use any Standard Operating Procedure (SOP) manuals, Occupational Safety and Health Administration (OSHA) plans or other existing plans as part of operation and maintenance plan, as long as they meet all the criteria of Condition S(a). 6. The Permittee shall conduct monitoring of pressure drop across the composite mesh-pad system in accordance with the requirements in 40 CFR 63.343(c) (1). To be in compliance with the standards, the composite mesh-pad system shall be operated within ±1 inch of water column of the pressure drop value established during the initial performance test. 7. The Permittee shall maintain the following records: a. Inspection records for the add-on air pollution control device and monitoring equipment, to document that the inspection and maintenance required by the work practice standards of § 63.342(f) have taken place; b. Records of all maintenance performed on the affected source, the add-on air pollution control device, and monitoring equipment;Page 3
c. Records of the occurrence, duration, and cause (if known) of each malfunction of process, add-on air pollution control, and monitoring equipment; d. Records of actions taken during periods of malfunction when such actions are inconsistent with the operation and maintenance plan; e. Test reports documenting results of all performance tests; f. All measurements as may be necessary to determine the conditions of performance tests; g. Records of monitoring data required by § 63.343(c) that are used to demonstrate compliance with the standard including the date and time the data are collected; h. The specific identification (i.e., the date and time of commencement and completion) of each period of excess emissions, as indicated by monitoring data; i. The total process operating time of the affected source during the reporting period. 8. All records and logs required by this permit shall be retained at a readily accessible location at the source for a period of 5 years in accordance with § 63.10(b) (1) of Subpart A for inspection and copying by the Illinois EPA or USEPA upon request. Any records retained in an electronic format (e.g., computer) shall be capable of being retrieved and printed on paper during normal source office hours so as to be able to respond to the Illinois EPA request for records during the course of a source inspection. 9. If there is an exceedance of the requirements of this permit as determined by the records required by this permit, the Permittee shall submit a report to the Illinois EPA's Compliance Section in Springfield, Illinois within 30 days after the exceedance. The report shall include the emissions released in accordance with the recordkeeping requirements, a copy of the relevant records, and a description of the exceedance or violation and efforts to reduce emissions and future occurrences. 10. Two (2) copies of required reports and notifications concerning equipment operation or repairs, performance testing or a continuous monitoring system shall be sent to: Illinois Environmental Protection Illinois EPA Division of Air pollution Control Compliance Section (#40) P.O. Box 19276 Springfield, Illinois 62794-9276Page 4 and one (1) copy shall be sent to the Illinois EPA's regional office at the following address unless otherwise indicated: Illinois Environmental Protection Illinois EPA Division of Air Pollution Control 9511 West Harrison Des Plaines, Illinois 60016 11. Persons with lifetime operating permit must obtain a revised permit to any of the following changes at the source: a. An increase in emissions above the amount the emission unit or the source is permitted to emit; b. A modification; c. A change in operation that will result in the source's noncompliance with a condition in the existing permit; d. A change in ownership, company name, or address, so that the application or existing permit is no longer accurate. If you have any questions on this permit, please contact Valeriy Brodsky at 217/782-2113.

Donald E. Sutton, P.E. Manager, Permit Section Division of Air Pollution

# DES:~~:PSj**H~** cc: Region 1 Control 

# COpy Original Signed 

# b Donald 

# E. Sutt Y 

# on, P,t.July 1,1998 STATE OF ILLINOIS ENVIRONMENTAL PROTECTION AGENCY

DIVISION OF AIR POLLUTION CONTROL P.O. BOX 19506 SPRINGFIELD, IL 62794-9506 

### STANDARD CONDITIONS FOR LIFETIME OPERATING PERMITS

The Illinois Environmental Protection Act [415 I LCS 

### 5/39 (formerly Illinois Revised Statutes, Chapter 111-112, Section 1039)] grants the Illinois Environmental Protection Agency authority to impose conditions on permits which it issues.

1. The issuance of this Permit does not release the Permittee from compliance with state and federal regulations which are part of the Illinois State Implementation Plan, as well as with other applicable statutes and regulations of the United States or the State of Illinois, or with applicable local laws, ordinances and regulations. 2. The Illinois EPA has issued this Permit based upon the information submitted by the Permittee in the permit application. Any misinformation, false statement or misrepresentation in the application shall be grounds for the revocation under 35 III. Adm. Code 201.166. 3. a. The Permittee shall not authorize, cause, direct or allow any modification as defined in 35 III. Adm. Code 201.102, of equipment, operations or practices which are reflected in the permit application as submitted, until the appropriate permit is obtained from the Illinois EPA. b. The Permittee shall obtain a new or revised permit under Section 39.5 of the Act, if the source no longer meets the applicability criteria of 35 III. Adm. Code 201.169 because of changes in emissions units or control equipment. . c. The Permittee shall obtain a revised permit prior to any of the following changes at the source: 

### i. An increase in emissions above the amount the emission unit or the source is permitted to emit; or ii. A modification; or iii. A change in operations that will result in the source's noncompliance with a condition in the existing permit; or iv. A change in ownership, company name, or address, so that the application or existing permit is no longer accurate. 4. a. This Permit only covers emission units and control equipment while physically present at the indicated source location. Unless the Permit specifically provides for equipment relocation, this Permit is void for an item of equipment on the day it is removed from the permitted location, or if all equipment is removed. b. The Permittee shall notify the Illinois EPA in writing to withdraw the Permit if all operations at the source have been permanently discontinued. Printed on Recycled Paper Page 1 of2

## CALCULATION SHEET Facility Gravure Process Company I.D.031600GBT Anal. Eng. VJB Date 02-11-2002 PN 97040023 Rev. Eng. Date Date Rec 12-17-2001 I. The application for the lifetime operating permit. 2. The traveler sheet has no marks. 3. This is existing hard chrome electroplating facility. The operations are subject to NESHAP, Subpart N. Since cumulative rectifiers PTE is less than 60 million amp-hrs/yr they are area source. Emission standard is 0.03 mg/dscm for existing tanks. The company performed the compliance stack test in June of 1997 which demonstrated compliance with NESHAP standards. 4. It is recommended to grant a lifetime operating permit with NESHAP conditions.ST,\TEOF ILLINOI S ENV I RONI'> I ENT ,\L I'ROTECTIO N AGEN C Y D I V I SION OF AIR POLL UT I ON CONTROL 1'. O . BOX 19506 SPR I NGFIELD. ILL I NOIS 6279·V)506
,\ I"' I . I

CAT ION F OR RENEWA L OF AN OPERATlr-.:G PERM I T TOOI)TA[N A Ll FETlr. IE PERMIT !.D . NO . PERMIT NO. OPERATION OF Th.. 

### "'<'><j ".-huoI<N W'",,"'" on.! , ... ._ <1>><10>«**,~** .... our"",,,,,, ..odtt ' 1) lin ,.·lq r..**hoK,odo>",~,"""'.'''''** >wi • .,..... bnos .."... J .dP<">I"" ..odtt '"**IlQ; ~**  ....**~** 11" _""""...,..10_111> . ("""
,.......**""~ III>**  .. ,.r"""",,,,,, nu. r", ... lwbcol :rrv<>' c.l bl' II1c fOOTll 

### _<m<JI' '.... .. FOR ,\GENCV USE ONLY 

# Jlll{,OOGfJT '170'100;.3 /}. '17'0 I**iH~a~r~d,,-~C h",-ro""m~e** **.....: ~I~** **t~r o~p~l~a~t,-,-;** **n~9L**

### _______ (A) DATE (SM .I E AS 9<: ON f' ,\ GE 2) I, . NAME OF OWNER .**2~ .**  NAME OF OI'ERATOR ' G ravure P r ocess Company Gr av ure Process Company Ib STREET ADDRESS O F OWNER; 2n. STREET Al)DRESS O F**p'~f'l k'\?R:**  

### '17 9 H. Be l mont Avenue I .. . Belrr.ont Avenue I, . C I T Y OF OWNER : ::!c. C ITY OF OPE RAT OR: Ch i cago Chicago It! . ST ATE OF OWNER : 

# I" Z IP CODE : 2d. STATE OF OPERATOR : 1 2e

.

## ~~'EC401D_\617 tIl i noi s 

### 606, 1- ,617 t Il i noi 5
),. NAME OF CORPO}t.\TE DIV IS ION OR PLANT : Jb.**ST~EET** I \DDRESS OF EMISS[ON SOURCE : Gr.v, 

### 179 W. Be l mont Avenue ), . CITY OF EMIS SION SOU RCE : Jd .**LOCA~O** WITHIN CITY Je. TOWNS HIP . 

# I Jr. COUNTY: 

# I Jg . ZII' CO I )E : Chicago L1t-IITS .**~** YES D NO Jeffe r son Cook 

### 506,1-,617

4 . ALb**CO~~SI'ONDENCE** TO : (TITLE ANDlOR NA ME OR INDlV [DUAL) 

# ,. YOUR DES IGNA TI ON FOR T ill S API' liCATION : ,., aV I Parsil l - V i ce P re sident 

### SCS H ,000 f> . ADDRESS FOR**CORRES I'O** **NO~NCE:** (C I IECK ONLY ONq 7 . WHO IS 

### nil! I 'ERM I T AI'I'LI CAN T'!



# ,. DOWNER**~** O I' ERAT OR 

# o EMISSION SOURCE D OWNER 

### [lJ**OI'~RA** TOR

T HE UNDERSIGNED HEREBY MAKES APPLICATION FOR ,\ l'ERM I T AND CERTI FIES T I1 ATT II E STATEMENTS**<;Q~TAINED** H ERE IN ARE TRUE AND COR RECT . AND FURTHER C ERTI FIES THAT ALL PREVIOUSL Y SUB MITT ED**NFOR \Ti9~** **"Uif~~** 1:'0 IN nilS AP I 'L[CATION REM,'INS TRUE, CORRECT ,\ND CU RRENT . I1Y AFF IXI NG HI S S IGN, \ TURE IIERETO**II ~**  FUR.:fljllli . : ';t!'!Jt!ES Ttl , T HE IS AUTIIORIZEDTO EXEClfrl! T ill S AI' I ' U C,HIQN. 

## 'rt-.:;;. .**AUT~=N~U:::** (C '\ 7

## 1~G**\** UY

# -.ll~**A-t.-k<li I~ti/o,**  DY 

# \l .

# -"""\,"\l'-~=_

SIGN ,\T URE ,HI: S IGNATURE 

## U .... "CoC-**~** \ :J .&. - DAn :: pavid pars jll**?A ~**  f!>..Io TYP E D O lt PR INTE D NAME OF S I GNER TY I' EDOft I'RINTI;Il

### N'i\r.'I~"**~O~ '.~S~Il~** **N~'~.K'- ---------**  V i ce Pr es ident TI 

### ru : OF SIGN I! R TITLE O F SIGNER {AI Ti l lS FORM IS TO I'ROVIDE T IlE "GENC Y WITII GENERALINFORM ,\TI ON ABOUT TilE**~QUII'MENT** TO UEOPERATED . ( 11 ) I'ROVIDE A DESIGNATION IN IT EM 7 ,\BOVE WBlC Ii YOU WOUI.D LIKE Till:: AGENCY TO USE FOR IDI ! NTlFIC ,\TION OF YOUR EQU IPMENT VO UR IJESIGN ,\TION WILL HE REFERENCED IN CORRESPONDENCE FROM Ti ll S AGENC Y RELATIVE TOTIIIS APPLICATION . YOUR DESIGNATI ON MUST NOT EXCEED TEN (IO)C II ARAC T ERS . (el THIS A!' PLICATION MUS1 · UH S IGNE D IN ACCORDANCE W I l'li JS [LL . AD M . CODE 201 . ISJ OR 201 . 15<) WI II C II STATES : "AL L A I 'f' lI C,\T I ONS AND SU PPLEI> IENTS TlJERCTO S HALL OE S IG NE D OY TI l E OWNER ANDOPEIV\TOR 0 1 ' TilE EMISS ION SOUR<:E OR ,\11t POLLUTION CONTRO L EQU 1f>M ENT,OR THE IR AUTHORIZED AG!;NT. AND S II AI. L IlE ,\CCOMI'ANIED B V EV IDENCE OF AUTIIORITY T O S IGN T ilE ""I'L1C ATION : ' IF TIlE OW NER OR O f' ERAT O R IS A CORPOfMTION, SU C II CORI'O I (ATION MUST 11 ,\V E ON F [LE wlTI! Ti l E AGENCY A CE RTIFlEO CO f'Y O F
,\ RESOLUTION OF T il E CORI'O I {ATION ' S BOARD OF Q!RECTOltS AUTHO RI ZIN G Til E PER SONS S I GN ING T illS APPLICATION T O CAUSE 01( ,\ LLOW T I!E CONSTRUCTI ON OR OPERA T ION OF T il E EQUII'r. IENT TO B E COVERE D BY Til E l'EHMIT . ( 0 ) ALL CURRENT OI'ERATING PERMITS WILL BE IN COR I 'ORATED INTO TilE EXP IRIN G PERMIT UNI.ESS ,\NOTHER O I'ERATING I 'ER MIT NUMBER IS Sf'EC II'I Ei) IN ITE M 9(a ) .

II. 5J :-{lZ42 Prinl ed o n**Rcc~clcd P~pcr**  PAGE I O F! ,\1'(" 2US (Rc' . 2JOO)

# . . AITACHMENTB

# LIuJ~'h 

# IJM U RE C EIVE':;

FE B 2' 5**~~"** NOTI F IC A TIO N OF COMPLI AN CE STATU saowonm ,",,'**p,,,~,** 

## ..· ..**~**

## •. ,,-, Buroau 01 Air . Stale 01 INIno ) ! Applicable Rule: 40 C F R P art '63, Subpart N-National Em ission Standards for C hromium E missions from Hard and Deco rative Chromium E lectroplati n g and Chromium A nodizi ng Tanks 1. Pri nt o r ty p e the fo ll owing for each plant in wh ich c hromium e lect rop lating a nd/o r 

### ch rom iu m anod izing ope rations are performed .

2 . Tank 1 0# 10 1

' U L 

### Qwner/Operato r ___ D

_ a

_ v

_i_

d

_ Pa

_r

_

s

_i

_

I_I_________ 

### T itle Vj ce Pres i den t 

### 4179 W. Belmont Avenue Street Add ress

_ _______________________ _ 

### C i ty 

### Ch i caga 

### State _..:.I.:.L____ ,Zip Cod e 6064 1 - 4617 

### Facility Name Gravure P rocess Company 

### P hone #(773) 777 - 5505 

### Faci lity Con ta ct & 

### T itle __ D :..

a :..

v :...i" d :...:...

P .: a

:.. r;.

s :..

i :..

I :..

1

_ - --' V " i .:

c.:e--'-P:..re:..s:..i :..:d:.:e:..n :.: t '-______ _ 

### Facil ity Address

___ __ 4 _1..: 7 .: 9

_ W

_ , _ B

_e

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_ n

_

t

_ A

_ v

_ e

_ n

_

ue

:...:...__________ _ Ci ty ___ C

_ h

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_

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_ o

______ St ate

_ 1 _L

_____ . Z ip Code 6064 1 -46 1 7 Complete the following table. If additional l ines are needed, make copies of this page. 

### Applicable Type of Control Compliance Test 

### Type and Type of emiss ion control system determinatio n m ethod quant ity of

T ank lim i t tech ni que 

### 10 # method' 

### f o ll owed HA P emitted 2 

### Hard Chrome 0 . 015mq/ 

### Compo s i 

### te "PI 

### erformance EPA/ I EPA Cr O.O)ma/



### Plating dscm Mesh Pa d 5 s . 

### T est ethod 30 A 

### dscm Ha r d Ch r ome 0,015mg/ 

### Co mpos i te GPI 

### Performance EPA/ IEPA C r O.O)m g/ 

### Plating dsc m Mesh Pad 5 s . 

### Tes t ethod 30 A 

### dscm If a perfo rmance test was conducted, submit the tes t report contammg the eleme nts reqUi r ed by 

### 40 CFR 63.344(a). 2

1 f the compliance procedures of 40 C F R 63.344(e) are being followed, attac h the calculations to support the emission li mit expressed in mg/ hr. 

### T ank Type of T a n k 1 0# e m ission limit cont rol tech n ique syste m 

### 10 #

P a g e 1 of 3 determ inatio n m et hod'

; 

### m ethod f ollowed

measurement 3068 

### qu an t ity of H A P 0I 

## / 2.\ 

# //' ;/ 

### NOTIFICATION OF COMPLIANCE STATUS (continued) 3. Complete the

# ~"~Wing table for each control technique used. If additional lines are needed,**mak~** 

### copies of this page. Control Tank • 

### Range of site-specific operating parameter values I 

### system 10#(s)**~uredrop** 

### Velocity pressure Surface tension Foam blanket

10# thickness GPl 

### 101 & ( 

### 2 - 

### l_An.w.c. 

## N/A N/A N/A 102'" 

### --:t-Yin.

11f the applicable monitoring and reporting requirements to demonstrate continuous compliance differ from those in 

### 40 CFR Part 

### 63, Subpart 

### N, attach a description. Parameter value ranges are established through initial performance testing and are those that correspond to emissions at or below the level of the standard{s). CONTROL TECHNIQUE EXAMPLE: Control Tank Range of site-specific operating parameter values 1 

### system 10 #(s) Pressure drop Velocity pressure Surface tension Foam blanket

10# thickness



### 10 1 7 in. w.c. 

### ± 1 in. 

## N/A N/A N/A N/A 2 

## N/A N/A S 45 dynes/cm 

## N/A N/A 3 

## N/A N/A N/A**~1** 

### inch



### . 4. Complete the following if 

### hard chromium electroplating tanks are operated (check the box{es) that apply): [ ] The maximum cumulative potential rectifier capacity of the hard chromium electroplating tanks is greater than or equal to 

### 60 million amp-hrs/year. This was determined by taking the sum of the total installed rectifier capacity (amperes) multiplied by 

### 8.400 hours/year and by 

### 0.7 for each tank. 

### [xl The maximum cumulative potential rectifier capacity of the hard chromium electroplating tanks is less than 

### 60 million amp-hrs/year. This was determined by taking the sum of the total installed rectifier capacity (amperes) multiplied by 

### 8,400 hours/year and by 

### 0.7 for each tank. [ ] Records show that the facility's previous annual actual rectifier capacity of the hard chromium electroplating tanks was less than 

### 60 million amp-hrs/year. If so, submit the records that support this rectifier capacity for any 1,2 month period preceding the compliance dates, or submit a description of how operations will change to meet this rectifier capacity limit. For new sources, the capacity can be that projected for the first 12-month period of tank operation. [ ] The facility has accepted or will accept a Federally-enforceable limit of 

### 60 million amphrs/year on the maximum cumulative potential rectifier capacity of the hard chromium electroplating tanks. Page 2 

### ot3

### • 

### ,
NOTIFICATION OF COMPLIANCE STATUS (continued) 5. Check one of the following boxes that describes the fac,ility's compliance status: 

### [>I The facility is in compliance with the provisions of 40 CFR Part 63, Subpart N. [ ] The facility is not in compliance with the provisions of 40 CFR Part 63, Subpart N. 

### 6. Print or Type the name and title of the Responsible Official for the plant (facility): 

### Dav i d Pa rs ill Vice President (NAME) (TITLE) A Responsible Official can 

### be: • The president. vice-president, secretary. or treasurer of the company that owns the plant; • The owner of the plant; . • The plant manager. engineer or supervisor; • A governmental official if the plant is owned by the Federal, State, City, or County government; or • A ranking military officer if the plant is located on a military base. I Certify That An Operation And Maintenance Plan Has Been Completed And The Plan And Other WorJs.(ractice Standards of**~R** 

### 63.342(f) Are Being Followed.

# ~.~ 

# ?**~~«** 2/22/99 (Signature of Responsible Official) (Date) I Certify That The Information Contained In This Report Is Accurate And True To The Best Of 

### My Knowledge.

# ~~ 

# 2**~~** 2/22/99 (Signature of Responsible Official) (Date)

Page 3 of3

# • TESTING - CONSULTING 

### Iuly 2. 1997 

# I, . • •11 Daniel J. BeD Engineering Servlca. 3158 South Kolin Avonue Chicago IL 60623-4889**Phone;~2~24D8** FAX: n3-254-6661 

### STATE OF ILLINOIS ',-.''':''EhTAL 

### PROTECTION AGEt\ Illinois Environmental Protection Agency Division of Air Pollution Control Eisenhower Tower 

## l &.: eEl 

## V E ff': .t. l'i.:." 

## ,JUL 

# 14 1997 BUREAU OF 

### AIR 1701 First Avenue Maywood IL 60153 

### ;IV OF AIR POLLUTION 

# cr"Tnn. Dear Sir or Madam: 

### FIELD OPERATIONS SECTl\,:: Please find enclosed a chromium emission stack test report prepared for our client: Gravure Process 4179 West Belmont Avenue Chicago IL 60641 lD. No.: 031600GBT The stack test was performed Iune 11. 1997. If there should be any questions. please do not hesitate to call.

db:DB CN06083b Respectfully Submitted.

# ~/¥ SCIENTIFIC CONTROL LABORATORIES. INC.

### •

TESTIN G - CON SU L. TIN G 

### Report To: Gravure Process 4179 W. Belmont. Chicago IL 60641 ATrN: Mr. Dave Parsill Project Type: Stack Test Analysis for Chromium Emissions 

### IDENTIFICATION OF MATERIAL: DuIeIJ. BeD EnliaeerIDc Sen'lca 3158 S. Kob A "Co CaJaco IL 60623 41189 Plaoae:**T73-2S4-2~** FAX: 'T7l-2SU661 

### Report Date: 06130/97 

### Project Number: 06-083 Project Inception:06/11/97

Four (4) sample bottles, from 306A air testing, identified below: 

### PROCEDURE: Gravure Process manufactures printing rolls. Part of this process involves electroplating of hard chromium. The facility has two hard chromium electroplating tanks, a large 

### tank of 600 gallons identified as L and a smaller tank of 350 gallons identified as M. It is rare that both of these tanks are operated at the same time. However, in order to demonstrate compliance under maximum operating conditions, both tanks were electroplating throughout testing. The biggest rolls available at the job shop were chromium plated in these two 

### timks. Tank M contained a roll with a surface area of approximately 18,600 square inches. This roll was being electroplated throughout the entire day of testing at 900 amps. The rectifier for this tank has a maximum capacity of 2500 amps. Tank L contained several rolls throughout the testing, with surface areas ranging from 39,340 in. 2 

### and 49,860 in. 2• 

### The rectifier to this 

### tank was operated at 1700-2000 amps. The rectifier for this 

### tank has a maximum capacity of 3000 amps. This workload represents the maximum operating conditions and therefore the

.emission results should be representative of maximum conditions. An 

### attachment shows the specific tank and rectifier operating parameters that were recorded during the performance test. The test was performed on June 11, 1997 by Mr. Daniel J. Bell, Mr. David Caskey, and Ms. Joetie HilI of Scientific Control Laboratories. An 

### IEPA official was not present. All analyses were performed in accordance with the EPA1IEPA approved test procedures as specified in 40 CFR, part 63, Method 306A. Scientific Control Labs, Inc., is a certified laboratory for analysis of potable water (lEPA Cert. #100183), and a certified laboratory for wastewater analysis (State of Washington Cert. #CI65, State of Wisconsin DNR #998091930). This means we have a quality control program in effect and that this quality control program is monitored and reviewed annually by the certifying agencies.
Note: It is our policy to keep copiea o( RpOrts (or Iix moDthL The da1a i. kept OD file (or up to thrn yean. Sample. (d' Ipplicable) are kept (or tlmc _IlL Sample. that are Uzardou. will be nturaed to the clieDL Ir this policy pote•• difficulty. plcuc CODtact UI to make other am.DaemeDlL Irrcprac:luccd. our RpOrt. mUll be rcprac:luced completely. ADY waauthorized alteratioD of this report iDYalidI1et the CODteD1.

### Page Two
RESULTS: The samples were analyzed by graphite furnace at omic absorption for detection of total chromium .

SAMPLE t.D. TEST CONC. 1 TEST TRIAL # 1 0.019 mg/L 611 1 / 97 TEST TRIAL #2 0.032 mg/L 6111197 TEST TRIAL #) O.oJ8 mg/L 6/11197



### . BLANK 0.00) mg/L AnalyzodbySCL 'As calcul:ued by SCL 

### (see attached) ) As calculated by Set (see anacbed) ACTUAL EMTSSION L IMW [JItHSSTON 1 0.0029 mg/dscm 0.0) mg/dscm 0 .0054 mg/dscm 0.03 m&!dscm 0 .0065 mgldscm 0.03 mgldscm 

### NA NA



### The sampling ports were already installed in th e stack. These sampling test pcrts were located in a duct after the blower with diameter of 16 inches. The length of this straight duct section is 66 inches. The ports are located 54 inches (3.4 due: diameters) downstream from a minor flow disturbance (a change from a rectangular to a circular duct immediately following the blower) and 12 inches (0.75 duct diameters) from the top of this duct. This samp ling location does meet the min imum criteria of 2.0/0.5 duct diameters for an acceptab le sampl ing po int as specified in sect ion 2.1 of US EPA Method 1 (40CFR Pan 60, Appendix A) . See the attached diagram for a description of the sampling location and the specific sampling points. The presence of cyclonic flow was checked at each sampling location and the average ang le of misalignment was found to be 

### 9.r. Since the average ang le of misalignment is less than 20 degrees, the amount of cyclonic flow is acceptable. The pressure drop across the pollution control devive was 2.1 in. of water column pressure throughout the day of testing. Leak tests were conducted before and after each test run and found to be less than 0.2 Umin. The vacuum pressure of the sampling pump was 22" of mercury.

Nole: II is our polit}' I/) keep eopiu o( ttporU (or six mooths. The dall is kept 00 file for up t o**th~e** yean.**~Iu** (if applicablc) are kepi (or thtte weeks. Samplu thlt U'C hl.Z.lrdous will bc**~tumcd** \0 thc clieoL I(this policy POKI I dimtulty. plcue coollet UIII:! makc other Irn n8emcnt.s. If ttproduced. our "'port.**mu~** be**~roduccd** com pletely . An y unauthorized IhrrlLioo of this n:port il1vt.1id&1n the coo\cnL

# ~ C=k.CRATCRIC•• INC. 

### Page Three


### SUPPLEMENTAL CALCULATIONS FOR GRAVURE PROCESS Equation (taken from Method 306A, FR 

### 1125/95, Pg. 4992):


## Where: Ccr = 

### <Mal (T m

### + 460) 

### (499.8)(Y

### J(V J(Pbar ) 

### Cer =Conccntration in stack gas in mgldscm Mer=Amount of Cr in sample from stack sampling in micrograms Till =Dry gas meter temperature, 

### Of YIII 

### =Dry gas meter correction factor VIII 

### =Dry gas meter volume in 

## ftl P

bar 

### =Barometric pressure in inches of Hg

Gravure Process Results Trial ##1: 

### (360 ml in test trial #1 sample) 0.019-0.003 mgIL = 

### 0.016 mgIL Mer = (0.016 mgIL)x(0.360 L) 

# = 0.0058 mg x 1000 micrograms/mg 

### = S.76 micrograms Till = 

### 9S.6 

### Of Y III 

### =1.009 (see calculation below) v VIII 

### =(1.985 m')(3S.3 ftl/m')

### ~ 70.07 

## ft' Pbar 

### = 30.72 -_. - Ccr = 

### (S.76) (9S.6 

## + 460) 

# = 0.0029 mg/dscm ../ (499.8)(1.009)(70.07)(30.72) Gravure Process Trial #2: (370 ml in test trial #2 sample) 0.032-0.003 mgIL = 0.029 mgIL Mer = (0.029 mgIL)x(0.370 L) 

## = 0.0107 mg x 1000 micrograms/mg 

# = 10.73 micrograms Till = 84.9 

### OF YIII 

### =1.009 (see calculation below) VIII 

### =(1.992 m3 

### )(3S.3 ftl/m3) 

### =00.32 ftl.. .", 

### Pilar = 30.72
-- Note: It is our poliq' to keep copiel of reports for lix mOllths. The data is kept OD file for up 10 three yean. Sample. 

## car IPplicable) are kept for three _oks. Samples that are hllZaldous will be returJIed 10 the cliellL If this poliq' pose. a difficulty. pleuc: contact UI to tub other anusemOllts. If reproduced. our report. must be reproduced completely. ADy unauthorized altenlioll ofthis report invalidate. the coDtenL

### Page Four
Ccr 

### = 

### (10,73) (84,9 

## + 460) 

### = 0.0054 

### mg/dscm v 

### (499.8)( 1.009)(70.32)(30.42) Gravure Process Results Trial ##3: 

### (368 ml in test trial #3 sample) 0.038-0.003 mgIL = 0.035 mgIL Mer 

### = (0.035 mgIL)x(0.368 L) 

### = 0.0129 mg x 1000 micrograms/mg**~** 

### 12.88 micrograms Till = 71.2 

### OF YIII =1.009 (see calculation below).--_, VIII =(1.917 m3 )(35.3 ft'/m3) 

### =',67.67 

### ft') '"'" P bar 

### =30.65 . - .. Cer 

# = 02,88) (71,2 

## + 460) = 0.0065 

### mgldscm v 

### (499.8)(1.009)(67.67)(30.65) 

### Quality Control Data: Sample: Duplicate: Spike: 

## LFB: LRB: 19.63 ppb 20.44 ppb = relative percent difference = 

### 4.13 

### % 39.74 ppb 

# = 101.0% spike recovery 9.49 ppb 

# = 94.9% recovery <1.0 ppb = < minimum detection limit 

### Calculation for Post Test Gas Meter Calibration: The meter was run for 6 minutes with a critical orifice that allows 0.75 cfm. The meter recorded a volume of 4.7703 

## ftl. The average temperature was 85.5 and the barometric pressure was 30.42 in. of mercury. To correct to standard conditions:

where: Vm(JId) = (KI)(VaJ 

# ...e- + (6H113,6from EPA Method 5 Till
Note: It i. our policy 10 keep I:opici or reports ror lix moath .. The daIa i. kept 00 file Cor up 10 three yean. Samples OC applil:able) ani kept Cor three weeks. Samples that are hazardous wil1 be retumed 10 the ctieaL IC this policy pose•• difficulty. plcuc**c:o~** UI 10 make other arrangements. It reproduced. our report, must be reproduced completely. Any unauthorized alteration 

### ot this report iavalida1c. the COlltcllL

### Page Five

K, 

# = 17.64 VfA 

### = 

### volume of gas recorded from post test in fe p .. 

## = barometric pressure in inches of mercury**~** 

### = 

### average pressure differential across the orifice in inches of water provided on orifice calibration sheet T fA = 

### temperature in degrees R
VIII(IId) 

### = £17.64)(4.7703)[ 30.42 

## + £1 .8/13.6)] 85.5 

## + 460 VmJ.IId) 

### = 

### 4.7130 

## rt'
To calculate the standard volume of air passed through the critical orifice:**V~IId)** 

### = 

### K' where: K' = 

### factor from orifice calibration sheet provided with critical orifice by manufacturer p .. = 

### barometric pressure in inches of mercury, from orifice calibration sheet provided 

### with critical orifice by manufacturer 

## e = 

### time in minutes, from orifice calibration sheet provided with critical orifice by manufacturer T unb 

### = 

### temperature in degrees R, from orifice calibration sheet provided with critical orifice by manufacturer**V~std)** 

# = 0.5933 (29.72)(6) 

### 1"541**V~Sld)** 

### = 

### 4.5486 

## ftl

NOIe: It is our policy 10 keep copies of repons for six mODths. The data is kept OD file for up to thm years. Samples (ifapplicable) are kept for three weeks. Samples that are hazardous will be retumed 10 the clicat. If this policy poses. diffieulcy. please coDlaCl us to mate other ImDBcmeats. If reproduced. our report, must be reproduced completely. ADY uDauthorized alteratioD of this report invalidates tho cODteat.

# ~(c- .

# ~~~c~J:,**CCNTRCJ)~DRATD"IE** •• INg.


### the Y value for the post test is then: Page Six



### YaI(lftcr tal) 

### = _ 

### 4.5486 4.7130 Y_(afta' lat) 

### = 

### 0.9651**~-** 

### 0.965 = 

### 1.009 -As 

### provided on the meter calibration sheet provided with the meter by the manufacturer Since the Y value is between 0.95 and 1.05, the gas meter is acceptable.


### CONCLUSION: This report was prepared to demonstrate compliance with the National Emissions Standard for Hazardous Air Pollutants (NESHAP). The results of this performance test indicate that Gravure Process meets the emission limit of 0.03 mgldscm. Ongoing compliance will be demonstrated by recording the pressure drop across the composite mesh pad system. Gravure Process will be considered to be in compliance as long as the pressure drop remains within =1.0 inch of water pressure of the value recorded during the performance testing (i.e., 2.1 in.). These measurements will be recorded daily.

Nole: It is our policy 10 keep copies of repons for six moDths. The data is kept OD file for up 10 dim: yeUl. Samples (ar IpJlIiClblc) lit kept for dlreo weeki. Samples dill arc Iaazardous wiD be rctunled 10 abe ctieat. Ir Ibis poUcy polCl • difficulty, plcuc coalll:l ualo IDIkc odler amDgemcDts. IfRProduccd. our report, mull be RProduced completely. ADy UIWldlorized IltcratiOD of dIiI report iDvaIidItct die CODleDL

# ~/ .

# ~**~~iuJ;.l·- CaNTRa~~.aRATC:U"E**  •• 'NC. 

### Page Seven
I certify that the above results are. to the best of my knowledge. true and accurate.



### Daniel 1. 

### Bell CERTIFICATION: 

### The above statements and report were subscribed and sworn to before 

### ltat" this

DB:db 

### CN05519a

Nolc: It is our policy 10 keep copies of RpoIU for six months. The dala is kept on file for up 10 thEft years. Samples (if If'pliClble) an: kept ror thEft weeks. Sampleslhat an: hazardous will be returned to the clienl Ifthis policy posos a difficulty, please COlltact us 10 make other amIIsements. Ir reproduced. our Rport, must be reproduced completely. Any unauthorized allcmion or this IqIOrt iDvalidaie. the conlcDl

### Federal Kegister I 

### VoL 

## ao. No. 16 I 

### Wednesday. January 25. 1995 I 

### Rules and Reguiations 4989 

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# or SAMPUNC POINTS

GRAVURE PROCESS 4179 

## w .**BE~ONT** AVENUE CHICAGO IL 60641 

### 1.0. N O

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### CONTAINER (t) 2 

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## voe Vlitl!l (ot) ,.",. (9) Vials (5) Ouall (10) Olher 

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_. _____ ._--L. __ . __ .. _ ... __**~_.** _._. __. .J..-ot--.L-__________________________________l !m3lks: Oat_ , Tlrne Reelewd by. (Signalure)

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## APR- 8-87 TUE 3:18 PM ErA AIR PERMIT FAX NO.**21752~:02S** 

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### due' rc:c::t i rKf capeii)' (ampcra) . ion ofparts plataJ AppJk:ab1e tlDbdon liMil 

# I Compliance dak' 101 Hard_pi"".. /011 / /91 10. 1XJO PUIUU 40'H'gdnw InJ", 

### 1 0 I li a rd chrome 

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## en. 

## ,i.}.f7 (c) (1)..liotifKIIion of CoDJWakla Of lU:cutstNdioa f.ona l'DUSI.be submkted. 

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## Otamu.. anodima IInb**~** tn.5 f9 1 For IW',.,tuks ( iL. tanks b .. Kb cx:artuction or ru;:omInJdiolt commeaccd &ftcr IVI6o'Q] ) : If initial )UrtIP occurnd bctwtal IlJlISNl IWId II2SI'9S 

# '" Ill.1 f 9. <Ii Ifhtiuu startlp**~** .net" 11116195 => upon stuItUp

## APR- 8-37 TUE 3:19 PM**~?A** 

## AIR PERMIT ?AX NO. 2175245023

A. Complete the CoUowinl tabJe fl:Ir aD decarldvt 

### chromium electropladB& tankI usinl • trivalent 

### c:ta.maa bath. If

aciditioaalllnes are ncaded. naMe copi. ofdUa pap. . Noc.: Jf 1M vMkftI GIvontiwn t.dI ffIIIa.JIIII iDoorpofiM ........... dill I11III IIlUbject 10 die _ NIDdanIa _ ....... far •**~"** cbrvnalum badllllina a aw.Io cl4111111&io&. .tllde II daa c-. ClDlftIll_ Qy.dan n ___ " .
TaIc.ID. StIrtW dIIIIe I of
.... plllad date3 '."**~ ~** .. : 

## .. .: . :.--:;:!:: 

## ·0·.... : ... . " 

## .. 101
. "UIJ0/91..**"~.** : 

### .. , 

# . !Sz".: ... NIA NIA N/A 

### N/A

, , 

### • I Pursuant 10 40 

## en 63.341 ( c ) ( 2 ). a**N~** ofCanslruc:lian at**~GIion** 

### fonn anal be wbnUued 

### In 

### additiOfl to this 

### form for 

### a111«ected 

### tIDb with 1ft iDitillltllWp daI after JIIIU8Y 2!f. 

### 1"" : CoMPLlAJlCCl DAn: 

# -

For 

### clstbtllIIlIcs (I,.., IUD wi1b iDitiaJ IIInUp CIa 

### or before 12116193 ): Hud cbramium plZlliDI tmb**~** 1125197 

### Decaratiw 

### chnmliam 

## plllizls'" 

# .. 1Il5196 Chnnniam anoctizinS1lDU**~** l/2m7 : For 

### newbUlu (i.e .. amJcs forwblc:b CODIII'IICIion OI'l'IICCIIUInIcdaa cammIIlced dIr 12116193):, Ifinltw stanUp occumd betwcca 12116193 ancllJ25J9.5 ::ao 11l.5l9.5 IfiaitiaJ Ita1:up occwmS after 1211619'**~** 1I'pGIIa1a'p

• B. Will a trivUac chromiwn pI'OCOss tbat iItoorpot'lJf. (I 

### WfIlItt6."" be UIOd 10 comply wtdI lb. nilfor wIric:b tbi.t (orm 11 

### btifta compJ8I.ed1 

## s.. 40 CFIt 63.342 ( • ). eYES tiNO 

## P.14

NoIe: lIa**~CIIII'OIftI_** pIocea dut 1Daorpof_ ......... ItMd. 

### -.I, II)' 112SIN,_ .................... ...... or ... """cIIronsn.n Jll'C*ltif II .....**"qwwor~"** ....30...,..,.................. I I_

.........PfOC'IIIoo OIIIIIpI'1Iridl
... 1IIIdf
........

## ftIPIIIdIII.... • ......... ,.,.,., (I )(S .. C. frD¥ido Ibe Ifsl otbcb compcmtIHI tbat comprUe dle1rlYlltat cbroalillnl 

### bIIa. WIllI ..

# Wtasaa ......., idemifted: 

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