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# OAR Box 1313 Prepped by LaTeia Shed



### Document

Number: 

# 88 ) ll-B-6 2

Docket Number: 

# A-88-0 2

Printed 6/12/2008 9:03:31 AM

Sheet 88 of 99

# MRI ® E2

_ 

## A-88-0 2 MIDWES T RESEARC H INSTITUT E "••I - <i-V2

. Suite 35 0 40 1 Harriso n Oak

s Boulevar

d Cary

. N.C

. 2751 3

Date : Februar y

14 , 198 9 (Finalize dMa y

5 , 1989 ) Subject : Californi a Ai r Resource s Boar d(CARB )

Demonstratio nTestin g Projec t Chromiu m Electroplatin g NESHA P EPA Contrac t 68-02-3817 ; ES D Projec t 85/02 a MR I Projec t 7717- K
From : Robi nBarke r To : Andre w

M . Smit h ESD/ISB/SS S (MD-13 ) Unite dState s Environmenta l Protectio nAgenc y Researc hTriangl e Park , N.C . 2771 1

I . Introductio n Th e Californi a Ai r Resource s Boar d(CARB) , i n conjunctio nwit hth e Meta l Finishin g Associatio no f Souther nCalifornia , ha s undertake na progra m t o perform

demonstratio ntest s o n variou s contro l device s t o determin e thei r effectivenes s fo r removin g chromi c aci dmis t generate d fro m har dchromiu

m platin g tanks . Durin g th e wee k o f Januar y 23 , 1989 , CAR B performe demission s test s o n a Monsant o Enviro-Chem fiber-be dmis t eliminator . Thes e emission s test s wer e conducte da t Electroni c Chrome Compan y i n Sant a F e Springs , California . Mr . Andre w M . Smit ho f th e U . S . Environmenta l Protectio nAgenc y (EPA ) an

d Ms . Robi nBarke r o f Midwes t Researc hInstitut e (MRI ) wer e presen t during th e emission s test s t o observ e proces s an

d contro l devic e operation s an d testin g procedures . In addition , EP A

an d MR I personne l visite dtw o othe r facilitie s wher e CAR B plan s t o perform

demonstratio ntest s o n a ventilatio nsyste m an d scrubbe r uni t manufacture db

y CM& E International , a fan/separato r scrubbe r manufacture db

y Tri-Mer , Inc. , an

d a fiber-be dmis t eliminato r manufacture db

y CECO . II . Monsant o Fiber-Be dMis t Eliminator—Electroni c Chrome Company A . Proces s Descriptio n Electroni c Chrom e Compan y i s a mediu

m siz e jo bshoptha t perform s hardchromiu

m platin g o f aircraf t part s an d oi l drillin g equipment . Th e compan y ha s si xhar dchromiu m platin g tank s i n operation . Durin g thi s emissio ntes t program , Tank No . 1 wa s th e onl y tan k tested . Tank No . 1 i s 1. 7 meter s (m ) (5. 5 fee t [ft] ) long , 0.7 6 m (2. 5 ft ) wide , an

d 4. 0 m (13. 0 ft ) dee pan

d hold s approximatel y 4,96 0 liter s (a ) (1,31 0 gallon s [gal] ) o f platin g solution . Th e freeboar dspac e i n th e

/ •P. 3

tank i s 9. 0 t o 10. 0 centimeter s (cm ) (3. 5 t o 4. 0 inche s [in.]) . Th e platin g solutio ncontain s chromi c aci di na concentratio no f abou t 24 0 gram s pe r lite r (g/a ) (3 2 ounce s pe r gallo n[oz/gal]) , an dsulfuri c aci di s use da s a bat hcatalyst . Th e norma l operatin g temperatur e o f th e bat hi s approximatel y 52 ° t o 54° C (125 ° t o 130°F) . A heatin g an

dcoolin g syste m i s installe donth e tan k t o maintai nth e platin g temperatur e withi n th e norma l operatin g range . Th e platin g solutio ni s continuousl y filtered , an

dth e tank i s ai r agitate dt o maintai nunifor m chromi c aci d concentratio nan

dplatin g bat htemperature . Tw o rectifier s ar e usedt o contro l th e curren t i nth e tank . Th e maximu m rate dcurren t an

dvoltag e fo r bot hrectifier s i s 5,00 0 ampere s an d1 5 volts . Tank No . 1 i s equippe dwit hdouble-side dlatera l hoods , an dth e ventilatio nai r i s ducte dint o a mai nduc t alon g wit hth e ventilatio nai r fro m Tank No . 3 , whic hi s 2. 1 m (7. 0 ft ) long , 0.8 6 m (2. 8 ft ) wide , and 1. 9 m (6. 3 ft ) deep . Th e tota l ventilatio nrat e fo r bot htank s i s 9 9 actua l cubi c meter s pe r minut e ( m /min ) (3,50 0 actua l cubi c fee t pe r minut e [f t /min]) . Figur e 1 present s a schemati c o f th e ventilatio n syste m o nTan k Nos . 1 an

d3 . Emission s fro

m bot hplatin g tank s ar e controlle db

y a doubl e packed-be dscrubbe r locate do nth e roo f o f th e platin g shop . Th e recirculatio nwate r fro m th e scrubbe r i s use d1nbot h tank s a s makeu pfo r platin g solutio nevaporatio nlosses . Twic e a da y a tota l o f approximatel y 19 0 i (5 0 gal ) o f recirculatio nwate r i s draine dt o th e platin g tanks . B . Proces s Operatio nDurin g Testinq 3 Monsant o Enviro-Chem

donate da small , 1 1 m /mi n(40 0 f t /min ) fiber be dmis t eliminato r fo r us e i nth e demonstratio ntest . Th e mai nduc t i n th e ventilatio nsyste m wa s breeche dt o provid e a sli pstream t o b e treate d b y th e fiber-be dmis t eliminator . Figur e 2 present s a schemati c o f th e ventilatio nsystem , sli pstream , an dth e fiber-be dmis t eliminator . Prio r t o the demonstratio ntest , preliminar y testin g wa s conducte da t location s i nthe sli pstrea

m an dmai nventilatio nduc t t o determin e th e representa tivenes s o f th e sli pstrea m wit hrespec t t o ga s velocit y an dtota l chromiu m concentration . Th e preliminar y test s wer e conducte db y Pacifi c Environmenta l Services , Inc. , o f Arcadia , California , a contracto r fo r th e Meta l Finishin g Associatio no f Souther nCalifornia . Th e preliminar y

tes t result s indicat e tha t th e velocit y i nth e sli p strea m (5. 8 meter s pe r second[m/s] ) (18. 9 fee t pe r secon d[ft/s] ) wa s 3 0 percen t lowe r tha nth e velocit y i nth e mai nduc t 8. 3 m/ s (27. 3 ft/s) . Th e hexavalen t chromiu m concentratio nmeasure di nth e sli pstream 6 wa s 0.0035 6 milligram

pe r dr y

standar dcubi c mete r (mg/dscm ) (1.6x10 " grai n pe r dry standar dcubi c foo t [gr/dscf] ) compare d t o a hexavalen t chromiu m concentratio no f 0.0023 9 mg/dsc m (1.0x10 " gr/dscf ) measure di nth e mai n duct . Tes t result s indicat e tha t samplin g a t th e inle t t o th e fibe r be d mis t eliminato r wa s onl y 8 6 percen t isokinetic , whic hdoe s no t fal l withi n th e acceptabl e EP

A rang e fo r isokineti c testin g (9 0 t o 11 0 percent) . Outle t samplin g wa s withi nth e acceptabl e isokineti c rang e a t 10 3 percen t o f isokinetic .

a2^T O SCRUBBE R

LEGEND : A A - Referenc e poin t B B - Referenc e poin t C C - Referenc e poin t

PLATINGTANKNO . 3

PLATINGTANKNO . 1 c o



### Figur e 1 . Schemati c o f ventilatio nsyste m o nTan kNos . 1 an d3 a t Electroni c Chrom e Company .

(v >T O SCRUBBE R

LEGEND : A A - Referenc e poin t BB - Referenc e poin t C C - Referenc e poin t

FLOO R ROOF -

FIBER-BE D MIS T
ELIMINATO R SLI P STREAM

• . A



### U V PARTICULAT E FILTE R

SEA L PO

T



### Figur e 2 . Schemati c o f ventilatio nsystem , sli pstream , an d fiber-be dmis t eliminato r a t Electroni c Chrome Company .

^
U lP. 6

Thre e mass emissio ntes t run s eac hrangin g fro m 6 t o 1 0 hour s i n duratio nwer e conducte d simultaneousl y a t th e inle t an

doutle t o f th e demonstratio ntes t unit . Tan k No . 3 wa s no t operate ddurin g an y o f th e emissio ntests . Tes t port s ar e designate da s letter s A , B , an dC o n Figur e 2 . Th e duc t diamete r a t th e inle t wa s 1 5 c m (6. 0 in. ) an

da t th e outle t locatio nwa s 1 4 c m (5. 5 in.) . Locatio nA wa s use da s th e samplin g port , an dlocatio nB wa s use dt o determin e th e velocit y an dflow characteristic s fo r inle t testing . Ther e wa s approximatel y 0.7 6 m (2. 5 ft ) o f straigh t duc t betwee nth e two locations . Locatio nC wa s use d t o determin e flow

characteristic s a t th e outle t an dt o perform

outle t sampling . Tw o tes t port s wer e use da t th e inle t o f th e contro l devic e a s recommende db

y EP A Metho dI

A fo r samplin g i nduct s les s tha n3 0 c m (1 2 in. ) i ndiameter . Continuou s monitorin g o f th e velocit y wa s desired , s o a velocit y

travers e wa s performe da t th e samplin g por t an da t a por t downstream , t o confir m tha t ther e wa s n o variatio ni nvelocit y betwee nth e tw o points . Durin g testing , th e velocit y wa s monitore dcontinuousl y a t th e downstream

port . Whe nsamplin g wa s completed , anothe r velocit y travers e wa s performe da t bot hport s t o ensur e ther e stil l wa s n o variatio ni nvelocit y betwee nth e two locations . Two tes t ports ar e reconmende dt o minimiz e th e flo w restrictio no f th e ga s stream whe nth e samplin g prob e an

dpito t tub e ar e bot hplace di nth e same port . A filte r wa s locate dupstream fro m th e fiber-be dmis t eliminato r t o remov e an

y particulat e tha t migh t caus e pluggin g i nth e mis t eliminator . Th e glass fiber s i nth e particulat e filte r ar e approximatel y 10 0 micron s (4. 0 thousandth s o f aninc h[mils] ) i ndiameter . Th e pressur e dro pacros s th e filte r wa s 0.2 5 kilopascal s (kPa ) (1. 0 in . w.c) . Particulat e filter s ar e considere dstandar d preventiv e maintenanc e equipmen t befor e fiber-be d mis t eliminator s fo r al l o f Monsant o Enviro-Chem installations . Figur e 3 present s a schemati c o f th e fiber-be dmis t eliminator . Th e mis t eliminato r consist s o f tw o concentri c screen s attache dt o a to pflang e an d a botto m drai nplate . Glas s fibe r i s woun dint o th e annula r spac e betwee n thes e screen s t o for

m a bedwit ha radia l thicknes s o f 5 t o 8 c m ( 2 t o 3 in.) . Th e glas s fiber s i nth e annula r spac e ar e approximatel y 1 0 micron s (0. 4 mil ) i ndiameter , an dth e pressur e dro pacros s th e uni t i s 2. 0 kP a (8. 0 in . o f wate r column) . Th e actua l flowrat e i nth e sli p strea m durin g outle t testin g wa s 8. 0 dr y standar dm

/mi n(28 0 dr y

standar d ft/min) . Th e fiber-be dmis t eliminato r i s equippe dwit htwo spra y nozzles . On e spray

nozzl e i s locate da t th e to po f th e uni t an di s use dt o was h dow nan y larg e particulat e whic hma y clo g th e mis t eliminator , an dth e othe r spra y

nozzl e i s locate da t th e botto m o f th e uni t an

di s use da s a

n aeroso l spra y

t o remov e an

y contaminant s tha t cancrystalliz e i nth e mis t eliminato r an

dcaus e pluggin g o r imprope r drainage . Thes e spra y nozzle s wer e no t operatin g durin g th e emissio ntest s becaus e n o increas e i n pressur e dro pwa s observe dabov e th e desig nleve l whic hwoul dindicate d potentia l plugging . Th e fibe r bedmus t b e replace dwhe nth e desig n pressur e dro pi s exceede db y 0.7 5 t o 1. 0 kP a ( 3 t o 4 in . w.c) .P. 7

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# IP. 8

Th e critica l designparameter s fo r fiber-be dmis t eliminator s ar e th e pressur e dro pacros s th e unit , th e collectio nefficienc y required , fibe r diameter , bedthickness , surfac e are a o f th e fiber-bed , an dth e ga s flow rate . Fiber-be dmis t eliminator s manufacture db y Monsant o Enviro Chem ar e designe dfo r specifi c operation s a t a give nplant . Th e demonstratio nuni t wa s designe dfo r a maximu m ga s flo

w rat e o f 1 1 m

/mi n (40 0 f t /min ) a t a pressur e dro po f 2. 0 kP a (8.0 3 in . w.c) . Th e uni t wil l operat e efficientl y

a t ga s flow

rate s u

pt o 1 1 m

/mi n(40 0 f t /min ) i f th e desig npressur e dro pi s no t exceeded . This i s becaus e fiber-be dmis t eliminator s designe dt o remov e particle s b y Brownia ndiffusio nd o no t hav e a lowe r limi t o nga s velocity ; a s velocit y decreases , collectio n efficienc y

o f particle s increases . Durin g tes t runNos . 1 an d2 , two hydrauli c rod s measurin g 11. 0 cm (4. 5 in. ) i ndiamete r an d2. 8 m (9. 0 ft ) i nlengt hwer e plate da t a curren t o f 3,10 0 amperes . Durin g tes t runNo . 3 , on e rol l measurin g 1 5 cm (6. 0 in. ) i ndiamete r an d3. 7 m (12. 0 ft ) i nlengt hwa s plate da t a curren t o f 3,70 0 amperes . Durin g emissio ntesting , onl y on e rectifie r wa s require dt o contro l th e curren t i nth e tank . Th e tank' s ai r agitatio n system an drecirculatio nsyste m wer e no t i noperatio ndurin g testing . A t CARB' s direction , polypropylen e balls wer e adde dt o the platin g tank . Approximatel y

8 0 percen t o f th e tank' s surfac e are a wa s covere db y th e polypropylen e balls . A s observe ddurin g visit s a t othe r facilitie s tha t us e polypropylen e balls , th e balls wer e displace dsevera l inche s awa y from th e cathod e (ite

m plated ) b

y th e hydroge ngase s forme da t th e cathod e durin g period s o f actua l platin g (i.e. , curren t flow) . Othe r observation s mad e durin g testin g tha t caus e concer nove r th e qualit y o r representativenes s o f th e demonstratio ninclude : (1 ) th e tota l ventilatio nrat e fo r Tank s 1 an d3 wa s 9 9 actua l m

/mi n(3,50 0 actua l f t /min) , whic hi s 5 0 percen t les s tha ntha ^ require db y ANS I guideline s fo r tanks baffle donon e sid e (19 0 actua l m /mi n[6,86 0 actua l f t /min]) , an dvisibl e mistin g wa s observe descapin g th e tanks ' ventilatio nsystem ; (2 ) th e part s wer e plate di nth e fron t portio no f th e tank wher e captur e wa s th e leas t efficient ; (3 ) us e o f th e polypropylen e ball s i nth e platin g tan k ma y lowe r contro l efficienc y becaus e o f lo

w inle t loading s o r change s i nth e particl e siz e distribution ; (4 ) th e port s wer e no t seale daroun d th e sampl e prob e durin g testin g t o ensur e tha t no dilutio nai r wa s introduce dt o th e duct ; (5 ) th e poin t i nth e duc t a t whic hth e sli pstream wa s draw

nwa s a nelbo

w wher e cycloni c o r turbulen t flo w wa s likel y

t o exist ; (6 ) th e mete r boxe s fo r th e samplin g train s wer e lef t unmanne d periodicall y

durin g th e tes t runs ; an d(7 ) sampl e recover y wa s no t complete donsit e wher e procedure s coul db e observed ; instead , sampl e train s wer e take nt o a loca l laborator y a t th e en

do f eac hrunwher e th e sample s wer e recovere dan d analyze dfo r th e chromiu m content . III . CM& E Ventilatio nan dScrubbe r System—Electrolyzinq , Inc . A demonstratio ntes t o f th e CM& E ventilatio nan dscrubbe r system

wa s conducte da t Electrolyzing , Inc. , i nLo s Angeles , California , durin g th e wee k o f Januar y

30 , 1989 . Th e facilit y i s a smal l jo

bsho ptha t perform s hardchromiu

m platin g o f aircraf t parts . Th e platin g tank use db y CAR B i n


# 7P. 9

8 th e demonstratio ntes t i s approximatel y 2. 4 m (8. 0 ft ) long , 0.8 4 m (2.7 5 ft ) wide, , an

d 0.6 1 m

(2. 0 ft ) dee p an

d hold s approximatel y 95 0 i (25 0 gal ) o f platin g solution . Th e platin g tank i s equippe d wit ha rectifier rate d a t 1,50 0 ampere s an d 1 2 volts . Durin g th e demonstratio n test , th e platin g tank wa s schedule d t o be operate d a t 1,00 0 amperes . I n addition , polypropylen e ball s wer e use d onth e surfac e o f th e platin g solution . Th e ventilatio nsystem o nth e tank consist s o f a tota l enclosin g hoo

d tha t ha s slidin g sid e panel s t o allo w fo r th e placemen t o f part s i nan

d ou t o f th e tank . Th e ventilatio nrat e durin g testin g wa s expecte d t o rang e fro m 2. 8 t o 3. 4 actua l m /mi n(10 0 t o 12 0 actua l ft/min) . Ther e i s approximatel y 2 3 t o 3 1 m

(7 5 t o 10 0 ft ) o f flexibl e hos e betwee nth e hoo d an d contro l device . Th e inle t samplin g locatio nwa s i na sectio no f duc t approximatel y 1. 5 m (5. 5 ft ) upstream

o f th e contro l device , an

d th e outle t samplin g locatio nwa s i nth e stac k approximatel y 1. 5 m (5. 0 ft ) downstream o f th e contro l device . IV . Tri-Me r Fan/Separato r an d CEC O Fiber-Be d Mis t Eliminato r Chroma ! Platin g Company On e demonstratio ntes t eac hwil l be conducte d o na Tri-Me r fan/separato r an

d a CEC O fiber-be d mis t eliminato r a t Chroma l Platin g Company i nLo s Angeles , California , durin g Februar y 1989 . Th e facilit y i s a mediu m siz e jobsho p tha t perform s hard chromiu m platin g fo r th e aircraf t industry . A full-scal e Tri-Me r fan/separato r uni t wil l b e installe d an

d teste d o nplatin g Tan k No . 1 . A smal l CEC O filte r wil l b e evaluate d o na sli p strea m pulle d fro

m th e mai nexhaus t duc t o nplatin g Tan k No . 2 . Tan k No . 1 i s 1. 5 m (5. 0 ft ) long , 0.9 1 m (3. 0 ft ) wide , an

d 1. 5 m (5. 0 ft ) dee p an

d hold s approximatel y 1,89 0 «

, (50 0 gal ) o f platin g solution . Tank No . 2 i s 1. 8 m (6. 0 ft ) long , 2. 1 m (7. 0 ft ) wide , an

d 2. 4 m (8. 0 ft ) dee p an

d hold s 8,93 0 i

(2,36 0 gal ) o f platin g solution . Th e chromi c aci d concentratio ni nbot hplatin g bath s i s 24 0 g/j , (3 2 oz/gal) , an

d sulfuri c aci d i s use d a s a bat hcatalyst . Durin g testing , Tan k Nos . 1 an d 2 wil l be operatin g a t abou t 1,50 0 an d 5,00 0 amperes , respectively . Th e norma l operatin g temperatur e fo r th e platin g bath s i s abou t 49° C (120°F) . Al l o f th e platin g tank s i n th e sho p ar e ducte d togethe r o nth e roo f an d vente d t o a packed-be d scrubber . T o accomodat e testing , th e duc t fro m Tan k No . 1 wil l b e disconnecte d fro

m th e mai ntrun k lin e an d th e airflo w

wil l b e redirecte d t o th e Tri-Me r scrubber , whic hha s it s ow nfa nsystem . Th e desig nairflow fo r th e Tri-Me r scrubbe r i s 8 5 actua l m /mi n(3,00 0 actua l f t /min) . T o allow th e CEC O filte r t o be teste d withi nit s desig nflow rat e range , a sli p strea

m wil l b e pulle d fro

m a sectio no f straigh t duc t use d t o ven t Tank No . 2 .



# 7