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# OAR Box 

# 1313 Preppedby LaTeiaShed



### Document

Number: 

# 27 ) ll-B- 1

Docket Number: 

# A-88-0 2

Printed 6/12/2008 9:03:28 AM

Sheet 27 of 99$ P. 2 

# M?"i> 2

MIDWES T RESEARC H INSTITUT E

450 5 Creedmoo r Roa

d Raleigh , N.C
. 2761 2 Telephon e (919

) 781-575 0



### Date : Marc h6 , 198 6

(Finalize dMa y

12 , 1986 ) • Subject : Sit e Visit—Dual l Industries , Inc .

Chromiu m Electroplatin g NESHA P li'-i i •-.-. • \ 8 i r 

### Z ; EPA Contrac t 68-02-3817 ; ESE DProjec t 85/02j a ; 

### ' j Jr 

### " j " MR I Projec t 7717- K\ L~—- —

J
v - •-•-•"- « <*••- > nrTKL- T 

### frI . • -—<—- — To : Al Vervaer t

ESED/ISB/SS S (MD-13 ) U . S . Environmenta l Protectio nAgenc y Researc hTriangl e Park , N.C . 2771 1 I . Purpos e Th e purpos e o f thi s sit e visi t wa s t o gathe r backgroun dinformatio n abou t contro l device s manufacture db y Dual l fo r controllin g chromiu m electroplatin g emission s an dt o obtai nname s o f plant s tha t properl y operat e andmaintai nDual l contro l device s tha t coul dserv e a s possibl e tes t candidates . II . Plac e an

dDat e Dual l Industries , Inc . 70 0 Sout hMcMillia nStree t Owosso , Michiga n4886 7 (517 ) 725-818 4 Januar y 8 , 198 6 III . Attendee s Dual ! Industries , Inc . Phi l Welch , Co-owne r Do nStanton , Sale s Manage r U . S . Environmenta l Protectio nAgenc y Al Vervaert , IS B Midwes t Researc hInstitut e Randy Strai t

/ •P. 3

IV . Discussio n
W e arrive da t th e plan t a t 1:3 0 p.m . Th e visi t consiste do f a tou r o f th e manufacturin g facilit y an ddiscussion s abou t contro l device s manufacture db

y Dual l t o contro l chromiu m electroplatin g emission s an d abou t plant s tha t properl y operat e an

dmaintai nDual l contro l device s tha t coul dserv e a s possibl e tes t candidates . A . Genera l Dual l wa s founde di n196 4 an dha s installe dai r pollutio ncontro l system s a t ove r 6,80 0 facilities . A noteboo k o f brochure s describin g th e variou s type s o f contro l equipmen t wa s provided . Dual l manufacture s mis t eliminators , packed-be dwe t scrubbers , an d moistur e extractor s tha t ar e use db y chromiu m plater s t o contro l chromiu m emissions . Thes e contro l device s ar e mad e o f Typ e I o r I I polyviny l chlorid e (PVC ) o r polypropylen e t o protec t agains t corrosio nb y chromi c acid . Typ e I PVC i s use dwhe nfluoride s ar e use da s a catalys t i nth e chromiu m platin g bat hbecaus e fluoride s wil l corrod e Typ e I I PVC . Otherwise , eithe r Typ e I o r I I PVC i s acceptable . Mr . Welc han d Mr . Stanto nbeliev e tha t mos t chromiu m plater s hav e installe dsome typ e o f contro l equipment . B . Contro l Devic e Informatio n 1 . Mis t eliminators . Dual l manufacture s chevron-blad e an dmesh-pa d mis t eliminator s tha t ar e use dt o contro l chromiu m emissions . A

schemati c o f chevro nblade s i s presente di nFigur e 1 . Th e exhaus t ga s i s draw n throug hth e chevro nblade s b y aninduce ddraf t fan . Th e blade s caus e abrup t change s i nth e directio no f th e flow o f th e exhaus t gas , which , i n turn , cause s chromiu

m droplet s t o imping e ont o th e blade s a t th e overlappin g point s o r edges . Th e chevro nblade s shoul db e washe ddow n abou t onc e pe r da y

t o preven t edg e buildu pan dpossibl e pas s through . Contro l efficiencie s ar e estimate dt o rang e fro m 8 0 t o 8 5 percen t i f th e uni t i s properl y

operate dan

dmaintained . Mr . Stanto nsai dtha t he woul d recommendth e chevron-blad e ove r th e mesh-pa dmis t eliminato r becaus e i t i s easie r t o maintain . Th e mesh-pa dmis t eliminato r contain s a wove nmes hpado nwhic hth e chromiu m particle s impinge . Dependin g o nth e application , th e padca nb e mad e o f variou s type s o f plastic s an dca nbe designe dfo r droplet s o f an y size . Contro l efficiencie s ar e estimate dt o rang e fro m 8 0 t o 8 5 percen t an dpossibl y

upt o 9 0 percent . Dual l recommend s mesh-pa dmis t eliminator s fo r hydrochlori c an

dhydrofluori c aci dmis t bu t no t fo r chromi c aci dmis t becaus e o f thei r tendenc y t o clo g wit hmor e viscou s an dheavie r mists . Installatio nan

doperatin g instruction s fo r Dual l PV C mis t eliminator s ar e presente di nth e attachmen t t o thi s report .P. 4

AIRFLO W DIRECTION OVERLAPPIN G POINT S / v\

Figur e 1 . Schemati c o f chevro nblades ,P. 5

2 . Packed-be dwe t scrubbers . Mr . Stanto nsai dtha t Dual l generall y recommend s a singl e packed-be dscrubbe r fo r th e contro l o f chromiu m emissions . Dual l doe s no t believ e tha t a doubl e packed-be dscrubbe r i s necessar y

becaus e o f th e relativel y hig hsolubilit y

o f hexavalen t chromiu m compound s i nwater . Contro l efficiencie s fo r th e singl e packed-be d scrubbe r ar e estimate dt o rang e fro m 9 8 t o 9 9 percen t i f th e prope r amoun t o f wate r i s used . Installation , operation , an dmaintenanc e instruction s fo r Dual l scrubber s als o ar e presente di nth e attachmen t t o thi s report . Th e scrubbe r shoul dno t hav e t o b e washe ddow nunde r norma l operatin g conditions . However , i f chromiu m deposit s buil dupInsid e th e uni t ove r a perio do f time , th e uni t shoul db e shu t dow nan dchemicall y

cleaned . Many plant s pum

pscrubbe r wate r t o a holdin g tank an drecirculat e th e wate r t o th e scrubber . Mr . Stanto nsai dtha t i t woul db e Importan t t o monito r th e concentratio no f chromi c ad di nth e holdin g tank durin g a tes t becaus e continue drecirculatio no f th e scrubbin g wate r ca nresul t i n th e buildu po f chromi c aci dconcentration s highenoug ht o decreas e th e overal l contro l efficienc y o f th e scrubber . C . Tes t Dat a an

dCandidat e Plant s Dual l ha s a researc han ddevelopmen t laborator y tha t ha s conducte d performanc e test s o f it s scrubber s an dmis t eliminators . Mr . Welc hsai d tha t h e woul drevie w th e tes t dat a an

ddetermin e i f h e coul dreleas e i t fo r revie w

b y EPA . H e als o sai dtha t h e woul dtry t o identif y

plant s tha t ma y b e amiabl e t o a nEPA tes t o f Dual l equipment . Attachmen tattaciimeri L

INDUSTRIES , INC
. P. 6

DUALL PV

C MIS T ELIMINATO

R INSTALLATIO

N AN D OPERATIN

G INSTRUCTION S NO . 121- 8 EL

M 

### TECHNICA L

BULLETI N

1/8 5

Th e Dual l Mis t Eliminato r mus t b e installe d i na horizonta l sectio n o f duct / i.e

. ai r enter s a t on e sid e an d exit s a t th e opposit e side

. Th e eliminato r wil l normall yrequir e transi

tion s t o adap t t o you r duct
. Th e inle t an d outle t ar e stan

dar d wit h 1-%"

flange s whic h shoul d b e drille d t o matc h th e configuratio n o n you r transition s o r a minimu mo f 5/16 " hole s a t 4 ' c c . A

n aci d resistan t masti c o r foa mtyp e gaske t materia l shoul d b e use d t o sea l th e flanges
. Th e eliminato r i s complet e wit h a n integra l stee l base
. Thi s bas e shoul d b e securel yattache d t o you r platformo r floor
. Afte r prope r connectio n t o th e duct / th e sprayWashdown inle t i s connecte d t o a fres h wate r suppl ywit h a valv e i n th e line

. Th e purpos e o f thi s lin e i s fo r periodi c washdown o f th e interio r o f th e mis t eliminator

. Th e frequenc yo f th e wash

dow n proces s wil l varywit h th e typ e o f mis t bein g removed
. O n a n average / operatio n o f th e sprayfo r te n minutes / onc e a dayshoul d b e adequate
. I f th e uni t i s t o b e installe d i n a n are a subjec t t o freezing temperatures / precautio n shoul d b e take n t o preven t freeze-u p o f th e fres h water.line

. Th e drai n shoul d the n b e connecte d t o you r wast e drain

. A goos e nec k tra p shoul d b e installe d i n th e drai n lin e oj r th e en d o f th e drai n shoul d b e submerge d i n liqui d t o preven t ai r enterin g thi s line

. Thi s lin e wil l receiv e a continua l drain

ag e fro mth e mis t bein g remove d a s wel l a s th e wate r an d contaminant s fro

mth e periodi c washdown
.


# Tfua££
INDUSTRIES , INC
. Mai n Office : OWOMO , M l 46867-076 9 (517) 725416 4 TELEX 22-653 2 Fontst City , N C 26043-100 0 (704) 245472 5 TELEX 60-221 0 

### -SP. 7

INDUSTRIES , INC
. DUAL L SCRUBBER S INSTALLATION / OPERATIO N & MAINTENANC E INSTRUCTION S 121- 3 

### TECHNICA L

BULLETI N

1/8 5

AI RFLO W -•= • "--77" . Unit s ar e designed t o be o nthe " suctio

nside o f th

e fan . Ai r flo

w throug

hunit s mus t b

e i nth e directionindicated . To o larg e a deviationfro m th e desig nflo w (CFM ) vil l affec t th e efficiency

o f th e scrubber . Othe r design s are avail able / however / extr a specia l equipmen t wil l b e required . SUPPORTIN

G TH E UNI T Th e scrubbe r rest s o na stee l channe l bas e makin g th e uni t self-supporting . Thi s stee l bas e ma y b e suspended fro

m overhead structur e o r tes t o

nan y medi a suitabl e t b suppor t th e unit' s weight . CONNECTIO

N T O VENTILATIO

N DUC T T o eliminat e th e possibilit yo f vate r runnin g dovn th e duct / ther e shoul d b e a minimu mo f 4 ft
. o f horizonta l duc t befor e th e scrubbe r inle t transition

. Thi s shoul d b e slope d slightl ytoward s th e botto mo f th e scrubber
. Th e flange s shoul d b e fiel d drille d o n approximatel y4"-5 " centers
. A sof t foa

mtyp e chemicall ycompatibl e gaske t materia l o r caulkin g i s recommende d betwee n th e .scrubber...flange an d th e duc t flange
. I f possible / caulkin g insid e th e scrubbe r o n botto man

d hal f wayu

p th e side s i s recommende d befor e th e duc t i s attached
. ELECTRICA

L CONNECTIO

N Prope r electrica l connectio n complyin g wit h loca l code s shoul d b e mad e t o th e pum p motor
. UNIT S WIT H INTERNAL RECIRCULATIO NSYSTE M Unit s shoul d b e installe d i n heate d area s o r protecte d from freezing

. Fres h wate r mus t b e supplie d b yconnectin g th e suppl ylin e t o th e flowmete r provided

. Thi s flowmete r i s mounte d o n th e sid e o f th e scrubber
. Th e make-up wate r lin e shoul d b e valve d t o provid e a maximu mo f 5 % o f th e recirculatio n rat e a s show n o n th e sid e o f th e scrubber
. CAUTION : Th e scrubbe r drai n i s connecte d t o customer' s wast e drai n line

. I f thi s lin e mus t g o t o a sump / i t mus t b e submerge d 6"-8 n belo w th e lowes t expecte d level / o r a plumber' s "P " trap installed

. Thi s wil l preven t ai r fro m flowin g int o th e drai n lin e and interferin g wit h prope r drainag e o f th e scrubber
. Liqui d build-up i n th e scrubbe r ca n interfer e seriousl ywit h th e prope r operatio n o f th e scrubber
. 

# T)ua£C
INDUSTRIES , INC
. Mai n Of f Ica : Owoaao , M l 46667-076 9 (517) 725416 4 TELE X 22-653 2 Foraa t City , N C 26043-100 0 (704) 245472 5 TELEX 00-221 0P. 8

INDUSTRIES , INC
. DUALL SCRUBBER S INSTALLATION / OPERATIN G & MAINTENANC E INSTRUCTION S 121- 5 

### TECHNICA L

BULLETI N

drain . Pum

p moto r shoul d b

e interlocked vit hfa nto provid e approximatel y

tv o (2 ) minute s pum

p operationbefor e fa nma y b e started . Pump s shoul d no t be started unti l th e scrubbe r bas e o r remot e recirculationtan k ar e filled t o th e overflo

v level . Durin

g th e earl y

break-i nperiod / th e pum p packin

g glan d shoul d be checked fo r prope r veeping . I f incorrect / chec k pum

p manufacturer' s instruction s for correctionproce dure . 8 . CHEMICA

L ADDITION S I nsom e cases / liqui d causti c (sodiu m hydroxid e solution ) or a naci d solutionma y b e metered int o th

e recirculationsys te m t o increas e scrubbe r efficiency . A threaded couplin

g i s provided inth

e side o f th

e self-containe d recirculatio n scrubber s fo

r introductiono f thi s chemica l addition . Chemica l additionfo r scrubber s provided vit hremot e recirculationtank s i s mad e b y addin g th e solution t o th

e recirculationtank . Whenusin g soli d caustic / car e shoul d b e taken i

nmixin

g t o assur e tha t n o soli d materia l i s pumpe d int o th

e scrubbe r o

r recirculation tan k vhichma

y caus e a build-up . Th e p H o f th

e recirculationtan k shoul d b e maintaine d ina rang e tha t wi-1 1 achieve th

e desired scrubbe r efficiency whil e preventin

g th e appearanc e o f a build-u p o nth e packing . A

p H contro l packag e ma y b e purchased fro

m Dual l t o provid e a chemica l fee d pum p an d p H contro l t o maintai nth e recirculationsolutio ni nth e satisfactor yrange . 9
. PERIODI C MAINTENANC E SCHEDUL E Inspectio n door s ar e provide d i n al l scrubbe r unit s fo r periodi c inspection

. Periodi c inspectio n o n a monthl ybasi s i s suggested
. Thi s inspectio n shoul d includ e th e following : A
. Chec k spraynozzle s wit h th e pum p an d fa n i n operation

. Al l nozzle s shoul d produc e a ful l 36 0 spraypattern
. I f an ynozzle s ar e foun d t o b e sprayin g incorrectly / th e pum p shoul d b e stopped / th e heade r pip e removed / an d eac h nozzl e cleane d individually

. Whe n th e cleane d heade r syste mha s bee n replaced / th e pum p ma yb e re started
. B
. Chec k th e fac e o f th e scrubbe r an d th e spraynozzle s fo r ari yindicatio n o f a build-up o f solids

. I f a surfac e build-up ha s occurred / i t ma yb e remove d b

ysprayin g th e pac k wit h high pressur e water / b ychemica l treatmen t o f 1/8 5

INDUSTRIES , INC
. Mai n Offlea : Owoaao , M l 46667-076 9 (517 ) 725416 4 TELEX 22453 2 Foraat City , N C 26043-100 0 (704)245472 6 - TELEX 60-221 0 

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