p.1 

OAR Box 1313 

Prepped by LaTeia Shed 

Document Number: 

42) ll-B-16 

Docket Number: 

A-88-02 

Printed 6/12/2008 9:03:29 AM Sheet 42 of 99 
$ 

.-<•''' -

Date: December 9, 1986 

(Finalized February 19, 1987) 

pj>_ 

A-88-02 

MIDWEST RESEARCH INSTITU 

4505 Creedmoor Rc 

• \ Raleigh, N.C 276 

\ Telephone (919) 781-5' 

.-<• \ 

V*\ ^ \ \ 

Subject: Site V1s1t~KCH Services, Inc. 

Chromium Electroplating NESHAP 

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

MRI Project 7717-K 

From: Robin Barker 

To: Al Vervaert 

ESED/ISB/SSS (MD-13) 

U. S. Environmental Protection Agency 

Research Triangle Park, N.C. 27711 

I. Purpose 

The purpose of this site visit was to gather background Information 

about mist eliminators manufactured by KCH Services, Inc., for controlling 

emissions of chromic acid mist from chromium electroplating baths. 

II. Place and Date 

KCH Services, Inc. 

Post Office Box 1287 

Forest City, North Carolina 28043 

(704) 245-9836 

November 10, 1986 

III. Attendees 

KCH Services, Inc. 

Ken Hankinson, President/General Manager 

U. S. Environmental Protection Agency 

Al Vervaert, ISB 

Midwest Research Institute 

Robin Barker 

Randy Strait 

/• 
P.3 

IV. Discussion 

The visit began at 9:30 a.m. with a discussion about the basic 

design of KCH's mist eliminators. This was followed by a tour of the 

plant. 

A. General 

KCH Services, Inc., (KCH) manufactures Industrial ventilation and 

air pollution control systems. The systems typically are made of 

polyvinyl chloride (PVC), polypropylene, or other corrosion-resistant 

materials. 

KCH manufactures both packed-bed scrubbers and mist eliminators for 

controlling chromic ad d mist. KCH recommends the use of packed-bed 

scrubbers rather than mist eliminators for controlling chromic acid mist 

from electroplating tanks because scrubbers achieve higher removal 

efficiencies and are easier to maintain. However, mist eliminators are 

purchased by small hard chromium plating job shops because they can be 

purchased for about one-third the cost of scrubbers. Information 

brochures for KCH mist eliminators and scrubbers are presented 1n the 

attachment to this report. 

B. Control Device Information 

1. Chevron-blade mist eliminators. Chevron-blade mist eliminators 

rely on impingement as the principal mechanism for the control of chromic 

acid mist. The mist eliminator is installed in a horizontal section of 

duct, and the contaminated exhaust gas is drawn through the blades by an 

Induced-draft fan. These blades cause the direction of the gas flow to 

change four times at 30-degree angles, which causes chromic ad d mist to 

impinge on the blades. 

There are two types of chevron-blade designs: wave-type and angular 

or overlapping-type. A schematic of the wave-type and overlapping-type 

designs is presented in Figures 1 and 2, respectively. Wave-type blades 

typically are 30.48 centimeters (cm) (12 Inches [in.]) in depth, and 

overlapping-type blades typically are 20.32 cm (8 in.) in depth. The 

center spacing between both types of blades is about 3.18 cm (1.25 in.) 

for both blade designs. At KCH design gas velocities, the wave-type 

design operates at a pressure drop of about 0.06 kPa (0.25 1n. w.c.) of 

water less than the overlapping type design. 

KCH currently uses the wave-type design. Mr. Hankinson stated that 

gas velocities above design could result in reentrainment of the chromic 

acid in the air stream, and gas velocities below design could reduce the 

impingement of the chromic acid on the blades. 

M1st eliminators can be equipped with either a single or a double 

set of blades. KCH typically supplies mist eliminators with only one set 

of blades but will Install an additional set 1f chromic ad d mist breaks 

through the single set. All KCH mist eliminator housings are manufactured 

5L 
Figure 1. Wave-type blade design. 

(* Tl 

J*. 
Figure 2. Overlapping-type blade design, 

^ Tl 

in 
P.6 

so that a second set of blades can be installed if necessary. 

Mr. Hankinson estimates that the addition of a second set of blades adds 

from 20 to 30 percent to the purchase price of the unit. 

The mist eliminators manufactured by KCH are equipped with a spray 

washdown system to clean the blades. KCH recommends washing down the mist 

eliminator once per day to prevent buildup of chromic ad d droplets on the 

blades. Chromic ad d droplets will break through the mist eliminator 1f 

the blades are not washed down frequently. 

2. Packed-bed scrubbers. KCH manufactures single and double 

packed-bed scrubbers for controlling chromic ad d mist. The packed-beds 

are 30.5 cm (12 1n) 1n depth and contain loose propropylene ballast 

saddles. 

C. Test Data and Candidate Plants 

The data from the EPA test program show that a mist eliminator with 

a double set of overlapping-type blades outperforms a mist eliminator with 

a single set of wave-type blades. Mr. Hankinson stated that he believes 

the difference 1n performance was due to the redundancy of two sets of 

blades rather than the blade design. 

KCH recently Installed a mist eliminator with a single set of wavetype blades on a hard chromium electroplating operation at United Metal 

Finishers 1n Greensboro, North Carolina. KCH has agreed to contact United 

Metal Finishers about possible EPA testing. KCH is willing to retrofit 

this unit with a double set of wave-type blades and also with a single set 

of overlapping-type blades to obtain data that could be used to evaluate 

whether the performance of mist eliminators 1s affected by the blade 

design or the redundancy provided by an additional set of blades. 

S 
Attachment 

P.7 

( 

Innovators of corrosion resistant ventilation equipment and related items to 

comply with your pollution control 

needs. 

Special design, space efficiency, and 

great flexibility in your pollution control 

system: We provide it. 

"v. 
P.8 

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USER 

PURCH 

- JOftNO. 

KCH MIST ELIMIPIATOR 

KCH Services. Inc — F-orest City, N. C. 

DATE 

CFM 

*. 

fc.im-mu i IIAI 1 i minim: 

UIMOTI, 

The KCH Chemical Mist EUmiiutor was developed for use on 

moisture-Uden fames containing dissolved chemicals. Contamtnant removal takes place when the fames pass through the PVC 

eliminator Mattes. These blades change the air direction resulting bf entrapment ofthe contaminants on the blades. A spray 

wash down system allows cleaning of the Modes. 

These units are designed for instaUation fn horizontal mn of 

duct 

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H200D 

• DESCRIPTION 

/ •• .,./../.. , ; 7 

H-20Q-Horizontal Flom Fume: 

Scrubber. ThisYfour stage scrubber is 

one of the most popular designs 

available^ This versatile; crossflow 

scrubber is used to remove corrosive 

or noxious fumes' with high 

efficiency. It may be installed with a 

remote recirculation system for'sub^\ 

zero climates* 

Hr2QQB*HYorizonial* Flow Fume. 

SCrUbber. This six stage unit can be 

utilized tx> ensure maximum 

scrubbing efficiency on low soluble. 

fumes. Hard to remove fumes such as 

Nitric.,- Hydrofluoric, and Hydrochloric acids are more efficiently 

scrubbed with this unit.. 

1 

• SCRUBBER OPERA TION 

The removal of contaminants is accompUshed by first slowing-the fumes to a velocity below BOO fpm and 

then passing tne fumes through either four or six stagesof scrubbing. The fumes pass first througha water 

spray during: which some of the larger contaminant particles drop out and the remaining fumes are 

saturated.'The secondstage conaiata of a 12" deeppackofpolypropylene, nonclogging, sphericaltypemasa 

packing which ia kept constantly wet by a continuous spray. The saturated fumea ore impinged upon the 

pachingond the contaminants are absorbed and carried away in the wash water. Thia scrubbing action is 

repeated ih the six-stage unit. 

After passing through the scrubbing stages the air is mist laden and must then pass through the two atage 

gravity mist eliminator aection. Thia conaiat*ofa drop out area that removes all but the finest mist, then, a 

series of vertically mounted PVC eliminator blades provide four $9° changes in direction ahd efficiently 

eliminates entrained water. 8-'• • • 

Single pack scrubbers have a static pressure drop of 2" and double pitch models-have a static pressure drop 

of3".. • )•... •*. \ 

/ • 
P.10 

tOMNWdn Scrubber/combination. 

frThe true economizer in both space 

tund price, and available in both 

i single and double pack units* The 

\ outlet can be rotated 360° during 

installation before being bolted in a 

fixed position. This vertical flow unit 

also offers an excellent efficiency 

equal to the H-200. 

PT-5aO~Packed 5Tower Fume 

Scrubber. One of the first designs in 

fume scrubbers, this efficient;^ unit 

allows the use of a stach fan or a 

centrifuged design fan. If restricted[. 

floor space is the problem* thePt?600 

often solves it. 

;. These scrubbers may be supplied with water either directly from your supply or from an integral or remote 

'recirculation system supplied with the scrubber. It is generally recommended that a recirculation system 

be used to conserve water except on very low cfm units. The actual fresh water consumption varies from. 

j2nfy .10 to .30 gpm/1000 cfm depending on the contaminant involved. This represents 6% of the water 

weing recirculated. Jfcoldconditions exist a remote recirculation syatemshould be specified for placement 

fn a heated area. KCH Scrubbers come complete with fittings for the additidn of chemicat neutralizers if 

required. A complete metering and pumping system is also available upon request. 

Q>ery KCH Scrubber is shipped complete with an integral coated steel base. No special mounting is 

fequired. Simply connect the duct, the water and power aupply, and the unit is ready for operation. 

alete instaUation and operating inatructiona are supplied with all KCH Scrubbers. \ 

• a • |l ' . . . ". . .' | . . 

i« with till other KCH Products, low maintenance ia a major factor in bur scrubbers. Low maintenance 

^mponents are used throughout and the unit is complete with quick opening access doors for easy 

'apection, •"•••}.••-".'••. . 
p.11 

APPLICATIONS H200 

Acid Fumes 

Plating Fumes 

Cleaning Fumes 

Lab Fumes 

Anodizing Fumes 

H200D OMNI OMNI D PT500 PT500D 

Pickling Fumes 

Rust-Proofing Fumes 

Die-Casting Fumes 

Stripping Fumes 

Etching Fumes 

Bright Dip Fumes 

•ADVANTAGES 

Low cost. 

High efficiency on soluble fumes. 

High efficiency on low soluble fumes 

with addition of chemical neutralizers. 

Low maintenance. 

Low water consumption. 

Low static pressure drop. 

100% corrosion resistant 

•ADVANTAGES 

Lowest overall purchase and installation cost. 

High efficiency on soluble fumes. 

High efficiency on low soluble fumes with 

addition of chemical neutralizers. 

Low maintenance: 

Low water consumption. 

Low static pressure drop. 

100% corrosion resistant. 

•ADVANTAGES 

Highest efficiency on all fumes. 

Moderately priced. 

Low maintenance. 

Low water consumption. 

Low static pressure drop. 

100% corrosion resistant. 

•ADVANTAGES 

Low cost. 

High efficiency on soluble fumes. 

High efficiency on low soluble fumes with 

addition of chemical neutralizers. 

Low maintenance. 

Low water consumption. 

Low static pressure drop. 

100% corrosion resistant. 

spray booth shields 

P.O BOX 1287 • FOREST CITY. NC 28043 • PHONE (704) 245-9836 

© KCH, 1982 

/o 
KCH FUME SCRUBBERS 

Average Removal Efficiencies 

P.12 

MODEL • 

CONTAMINANTS 

Acetic Acid CH^COOH 

Alkaline Cleaners 

Aluminum Bright Dip* 

Amines 

Anodizing 

Aqua Regia 

Boric Acid 

Caustic Cleaners 

Caustic Soda 

Chlorine 

Chromic Acid Plating 

Copper Chloride 

Cyanide Plating Solutions 

Ferric Chloride 

Ferric Nitrate 

Ferrous Chloride 

Ferrous Sulfate 

Fluosilicic Acid 

Hydrochloric Acid 

Hydrocyanic Acid 

Hydrofluoric Acid 

Hydrofluosilicic 

Hydrogen Peroxide 

Hydrogen Sulfide 

Mercaptans 

Nickel Chloride 

Nickel Sulfate 

Nitric Acid 

Nitrogen Dioxide 

Nitric-Hydrofluoric Acid 

Perchloric Acid 

Phosphate Salt Bath 

Phosphoric Acid 

Potassium Dichromate 

Selenuim Sulfide 

Sodium Chloride 

Sodium Fluoride 

Sodium Glutenate 

Sodium Hydroxide 

Sulfur Dioxide 

Sulfuric Acid Pickle 

Tin Chlorides 

Zinc Chloride 

Zinc Nitrate 

Zinc Sulfate 

Four 

STAGE 

H-200 

PT-500 

OMNI 

% 

95-99 

95-99 

80-85 

90-97 

96-99 

75-80 

85-95 

98-99 

98-99 

80-85 

98-99 

75-80 

97-99 

80-85 

95-98 

90-95 

94-97 

95-98 

80-85 

85-95 

85-95 

94-98 

85-95 

70-75 

80-85 

80-85 

80-85 

75-85 

45-50 

72-80 

85-95 

96-99 

96-99 

95-98 

95-98 

95-98 

90-95 

95-98 

98-99 

70-75 

96-98 

75-80 

75-80 

95-98 

95-98 

Six 

STAGE 

H-200D 

PT-500D 

OMNI-D 

% 

98-99 

98-99 

85-90 

97-99 

98-99 

80-85 

97-99 

99 

99 

85-90 

99 

80-85 

99 

85-88 

98-99 

95-98 

96-98 

98-99 

85-90 

98-99 

97-99 

98-99 

97-99 

75-80 

85-90 

85-90 

85-90 

85-90 

50-60 

85-90 

97-99 

98-99 

98-99 

98-99 

98-99 

95-99 

95-98 

95-99 

99 

75-80 

99 

81-85 

80-85 

98-99 

98-99 

Four 

STAGE 

Six 

STAGE 

With Chemical 

Neutralizer 

(pH Control) 

% 

80-85 

85-90 

85-90 

90-95 

85-90 

90-95 

90-95 

90-95 

65-70 

80-85 

85-90 

% 

85-90 

90-95 

90-95 

95-99 

95-98 

95-98 

95-98 

95-98 

70-75 

85-90 

90-95 

"Thaaa afftcianciaa ara for tha combinad nHrk and phoaphortc fuma. Tha afficiancy for tha NO2 portion of tha fuma onty wtll ba liatad abova. 

•Tha abova afftcianciaa ara intandod aa rapraaanting avaraoa vatuaa. Spaciflc combtnationa and concantrattona of fumaa may raautt tn a atgtnWcant -atrtatton from tna 

Th«rafora no guarantaaa ara tmptiad. 

/ / 
P.13 

FUME, SCRUBBER 

MAINTENANCE 

PI.mtn? • Fflitnem.icMMJ . TM-MS-MU 

SCRUBBERS, INSTALLATION, OPERATION, AND MAINTENANCE INSTRUCTIONS 

1. AIR FLOW 

Units are normally designed to be on the suction side of the fan. Air 

flow through units must be in the direction indicated. Too large a deviation from the designed CFM will affect the efficiency of the scrubber 

2. SUPPORTING THE UNIT 

The scrubber rests on a steel channel base making the unit self-supporting. This steel base may be suspended from overhead structure or rest 

on any media suitable to support the units weight. 

3. CONNECTION TO VENTILATION DUCT 

To eliminate the possibility of water running down the duct, there -

should be a minimum A ft. of horizontal duct before the scrubber transition. This should be sloped slightly towards the bottom of the scrubber. The flanges should be field drilled on approximately V-5" centers 

A soft foam type chemically compatible gasket material is recommended 

between the scrubber flange and the duct flange. 

4. ELECTRICAL CONNECTION 

Proper electrical connection complying with local codes should be made 

to the pump motor. 

5. UNITS WITH INTERNAL RECIRCULATION SYSTEM 

These units should be installed in heated areas or protected from freezing. Fresh water supply line is connected directly to the street elbow 

of the flowmeter, if one is provided. It should be vaived to continuously provide a maximum of 5% of the recirculation rate as shown on the 

side of the scrubber. The scrubber drain is connected to customer's 

waste drain line. If this line must go to a sump, it must be submerged 

6"-8" below the lowest expected liquid level, or a plumber's "P" trap 

should be installed. This will prevent air from interfering with the 

operation of the scrubber and its overflow. Before Start-up, shut the 

waste drain and fill to the overflow thru the flowmeter, if supplied. 

Additional water can be introduced thru'the inspection doors. When water level reaches overflow level, operation of pump and fan may begin. 

6. UNITS DESIGNED WITH REMOTE RECIRCULATION TANK AND PUMP 

A recirculation tank is required and should have an adequately sized 

overflow and waste drain. This tank will allow a self-draining scrubber to be placed outside. The scrubber must be elevated for easy drain 

return to the recirculation tank. The scrubber drain pipe must be submerged 6"-8" below the lowest expected liquid level in the tank and on 

the opposite side from the pump. The pipe end should be cut on a 60° 

angle with the long opening facing the tanks side. For information on 

start-up and make-up water, please see Section 5 above. 

Form SI-1 1981 O copy-rlghUd 

- Continued On Next Page - / 2 
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INSTALLATION AND 

SERVICE NATIONWIDE 

After the system has been 

designed and manufactured, our experts will 

guide every part into place. 

KCH provides engineering, installation, and 

technical service nationwide. Once the 

nature, of the problem has been outlined, our 

engineers begin on the physical problems: 

space, locations, and energy demands. Finally the KCH system ideal for your situation 

will be designed, manufactured, shipped, 

assembled, and installed by KCH's own people. 

TECHNICAL SERVICE AFTER START-CIP 

IF YOQ NEED CONTINUING TECHNICAL AND MECHANICAL 

ASSISTANCE, PREVENTIVE MAINTENANCE INSPECTIONS, 

SPARE PARTS .. . WE PROVIDE IT. 

Centrifugal fans 

Fume washers 

Hoods 

DuctFittings 

Mist eliminators 

Moisture extractors 

Stack caps 

Tanks and tank liners 

and all types of special 

fabrications such as . . . 

materials handling duct 

plating racks and baskets 

electrical insulators 

protective wall coverings 

current blocks 

tank guards 

grilles 

cleaning/plating consoles 

semi-enclosed lab ventilation 

consoles 

abrasion-resistant shields 

spray booth shields 

Machined parts 

stock items: 

PVC sheet, rod. pipe. 

nuts, bolts and fittings 

Polypropylene 

Polyethylene 

Odor control systems 

P.O. BOX 1287 • FOREST CITT. M.C. 2M43 • 704/245-MM 

KCH, 1982 

£0