OAR Box 1313 

Prepped by LaTeia Shed 

Document Number: 

63) ll-B-37 

Docket Number: 

A-88-02 

Printed 6/12/2008 9:03:30 AM Sheet 63 of 99 

P.1 

- - - • 
P.2 

MRI® 

A-88-02 

MIDWEST RESEARCH INSTITUTE 

IT-fb-"V 7 Suite 350 

401 Harrison Oaks Boulevard 

Cary. N.C. 27513 

Date: May 18, 1988 

(Finalized August 4, 1988) 

Subject: Summary of Fume Suppressant Cost Data for Decorative Chromium 

Electroplating and Chromic Acid Anodizing Model Plants 

Chromium Electroplating NESHAP 

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

MRI Project 7717-K ._.„. 

From: Robin Barker u$ft> >• . *^_ilJ^.-^--'--*(Ki 

To: Andrew Smith , - .. \* ' 

ESD/ISB/SSS (MD-13) 

U. S. Environmental Protection Agency 

Research Triangle Park, N.C. 27711 

I. Introduction 

This memorandum presents annual costs of permanent and temporary 

fume suppressants for the model decorative chromium plating plants and . 

annual costs of permanent fume suppressants for the model chromic acid 

anodizing plants. The annual costs include the material cost of an 

initial makeup addition and maintenance additions of the fume suppressant 

in the plating or anodizing baths. The initial makeup addition is the 

fume suppressant that is added to a plating bath not previously using a 

fume suppressant. Maintenance addition is the fume suppressant added 

periodically after startup to maintain the fume suppressant concentration 

in the bath at the recommended level. All costs are in October 1986 

dollars. There is no capital investment in equipment associated with the 

use of fume suppressants as a control technique. The makeup addition of 

the fume suppressant is not considered a capital cost because it is an 

expendable material and would only last a few days without frequent 

maintenance additions. Permanent fume suppressants are wetting agents, 

foam blankets, or a combination of a wetting agent and foam blanket that 

are depleted primarily by dragout. Temporary fume suppressants are mainly 

foam blankets, but can be wetting agents or a combination of a wetting 

agent and foam blanket that are depleted primarily from decomposition and 

dragout. 

II. Background 

Fume suppressant cost information was obtained from five 

manufacturers of fume suppressants for model tanks used in the decorative 

chromium and chromic acid anodizing model plants. Table 1 presents the 

manufacturers and fume suppressant brands for which cost data were 

obtained. 

/ 
3 

O r t cr 

ro 

c V) 

ro o. 

—la 

3 r t 3 * 

ro 

o 

o 

crt 

<-t* P I 

3 

< 3 n -J 

ro o o PI 

trt 3 -o s: 

coi n 

3 rtW-,13 rtO W Q. r t ro TJ .Q 

O--. —• 

-J 3 CL< < n oi 

-$ —• n* c 

ro c pi to 

-a a. ro c ro -t- a. 

ro a. o Crt -J Pl r t -*. —i 

ro 3 o o a . —i 3 

ri- ro ro 

rf 3-* a 3- ro o -•• Pi 3 

f+IU^- . 3 3 pi 

c-l- pi Pl 

3" —' 3 Q . 

ro << c ro 

-J -i. c c 

ro 3 ro crt 

trt o —i ro *—i to —• Q . 3 pi c co -n 3 a . <T o rf ro pi O -J 

irt a. 3 3 

0.0.0 ) 

Pi —i. ro r t 

-J 3 2 < -•• 

ro ro ro o r t r t —i 3 c 3- ro o 

irt ro x XJ o 

ro @ 3 O-O . Pl 

ro oo 3 pi 

o < *a 3 —• 

3 ro -» c —• 

—i —• Ol PI 

ll -tiD^ Q<< -J O 

Pl TJ -"a Pl O 

•<! crt 

-^. irt 

. 

-j crt o - i 

ro • rt Pi 

—* C r t 

_ l. -j _1 . 

3 ro < 

->• <-> a. ro 3 —' pi nt cr n 

•a -n 

PI 3 oo o lrt ro t r O rt 3 O lrt 3 " 

trt rt*0 rt ro 

C Crt •a o TO -h TJ -ti s: c —I a—.-- . 3 

TT3>< -T(D P) 3 rtf t 

<< O 1 T l O 

_,._..-$ g 

3 crt ro -•• -n a. c o PI ro 3 - j - j 3 3 -•• * a pi ro <-> —• r t •£ 7-r Pl 

-•• r t 

O -ti CD -J . 

3 C C 3 3 3 co 

trt ro 3 C ( T -a crt o PJ • a C 3 * 3 

3 3 Oi 3 " 

ro 3 3 trt 3 C C rt C 

rt pl T. 3"T J 

lrt —i Pl 1 T3 

o ro -j 

-n n n* ro ro 

O OC Crt 

-i crt -j ro to 

rt fD X pi 

3. Crt a. r> 3 

ro ro rt 

rt cr CTT 3 

ro ro •< ct cr 

X O -•• -5 

© PI 3: o pi 

C Pl 3 3 

OO trt O trt Q . 

—io ro J-TTJ roa« c/i 

--.-a 3 • 

ro -j ->• 

a. ro n 

Crt Pl I—I 

a- co —i 3 

i< p, 3 o pi 

-s ro PI <T -J —J << 3- 3 C. -" 

ro -•• 0 1/1 

00 crt Q. crt r t 

cr ro <• <r ro 

0 0 . 

3" rt O Q.TJ T- •—i Q . 

-•• 3 Q. 

VI Pl TJ - • 

3 pl r t 

n o. 3 —• 

O *< o 

3 tTw 3 

-a 3- . 

pi ro *s 

3 ro << -« 

ro 

C 3 Pl -". 

IT 3 O rt 3 

TI ro • PJ 

-—• —1 

Pl T| Pl 

3 S O O-

o. ro -j —1 

-$ ro 

PI ro 

-1 •—• 

ro 

3 T> 

o 

-. 

3 Pi 

o 

3 

cn 

O 

c 

-t 

n 

ro 

crt 

1—1 

I—l H H 

. 

O 

ro 

n 0 

-. Ot r t 

mml. 

K 

ro 

0 3

-

- j 

0 

3 

mJ. 

c 3 TJ —J Pi 

c-t ^ a 

3 

.Q 

crt rt ro O -ti O 

c 3- —no c zr 

TJ ro ro ro 3 ro 

•a 0 -$ ro 3 -IT - ft p -,* 

ro ro -$ ct vt 0 

c/i -j 0 -!• c pi —1 

crt 3 —• 3 -o —• ro 

pi pi c< CO TJ 3 

3 3 trt -j ro T J 

IT ro -,* ct n —• 0 

crt 3 crt -•• c/i ro -$ 

r t* 3 crt n pi 

s: ro pi c-t -j 

Ol T> •£ «• 3 -J •< 

trt c 3- rt O 

3 -1. P) aI T l 

» ra n*o <•< c 

o. 3--o ro trt 3 

«-J. trt ro 3 —>• ro 

C C -•• pi Q. Crt 

Crt TJ trt 1 O trt 

rt-TJ crt -l rt- c 

ro -J Q. Vt 3"TJ 

o. ro ro rt pi TJ 

w -a 0 crt ct -j 

cr w ro c ro 

Pl Ol 3 o-to O trt 

0 3 a. ro co 0 w 

ro rt ro ro n pi a. trt 3 p> crt c 3 *» r t rt -% rt O 3 Crt irt crt 3 r t O O 

3 -3 -. rt ->* pi 

rt ro ro 3" 3 -> 

3- 0 pi ro 

ro n *o o. rt ct0 ro 0 zr a. 

-« crt -j 3 a. ro ro 

ro rt pi -i. -j -a 

< rt 3 pi -a — 

- 1. o_ -J. pi IQ —1 ro 

trt pi 3 3 O pi r t 

ro rfcQ rt C rt 0) 

d. pi rt -J. Q . 

C) Tia, 3 

3 -ti c pi co er 

0 0 -» n -E «< Q.-1 -Ir+TI T 

ro ro 0 -!• pi o** 

—' rf 3 -$ O rt* O 

ro rf 3- 3- r f 

rt 3 » rf . 3-

pi -a ZT -,. 

3 0 Pi Crt O. 

«•-. H3 1-1 -J 

01 zr a. 3 Pi 

0 -» ro 0 ro -tno 

TJ << -J 3"TJ 0 0 

ro ro ro ro -j c 

-J -h -ti 3 3 3 r t 

PI c 0 —<• Q. Pl 

rt 3 -i n ro rt pi 

_i. ro ro PI 3 —^ 3 

3 •» —• rt O Q. 

CO 3 —• O rt* r f -J . 3 T i 3 * 

-,* 7c -jr o 3 ro 0 

ro 3 Crt 

. 

3 

O 

Q.TJ CO r f 

PI -t ro PI 

O. rt O O 3 

ro — j 

(tTJ(Ddirt<rtP3rt-1Pi 1 

-jp130003-303-roo.r o 

ro-»ro-<ai —irooo.ro<o. < 

pi-opi -Tn » taw rt o-ro —•• —•• -"• 

O C trt 

O 1 Crt • 

rt -1 rt ro TJ 

P> - J. _J. ro 

3 to 0 O- -. 

7C 

0 T J 

ro 

-•• 3 "J 3 

3 0) pi pl 

Ol —-*cO 3 

—• or o —' r t C 3 

1 "< O rtr t 

Pi f f T

3 rf ->* T , 

a-Ja 

3 CO r t 

a ^ a 

3 

ro Crt 

. 

-j zr Vt C 

o ro 3 

< TJ ro 

-,•—•-. a. ro 0 crt 

ro 3 -a c Q.CO O T J r t -J T J O" 3 " r f -» «< -•• ro 0 0 trt r t -fi 3 crt 3 " pi pi 

ro rt —1 3 

-J> r f 

< 3 rf Crt 

ro ro 0 3 Pi n . pi r f -J 0 zr ro -j TJ ro Crt —1 0 . pi 3 ro aC r t C T J Pl -J - 3 —' 

trt 3 cr ro 

to ro rt 

pi -$ ro 

o. —. a. C-j. -J . 0 C 3 -tiT J w ro -. rt T J -J -

ro -•• pi 3 

0.1/1 -t pi 

rt -J 

O" O Crt -J-

pi -a - J 

crt ro TJ "< 

ro -j —• 

a. pi pi CJ-

rt ct »< 

0 ro ro 3 a . 0 . 0. ^— - s r f » .—>. pi 

ZT "£ CO 

ro rt* 3- 0 

3" -J- C 

-1 ro O rf 

ro 3- • 

< 0 

- J. O -•• 

Crt Crt Crt 

ro rf Q . 

rt 3 cO coiCl.-Ja—'-hcrtrtcr t 

-J (D -Ja 01 —"CQ (ON C -•• -!• -"• 

0rtN3Tiro0-'Tf300 0 a . ro ro 0 c » 0 3 p» ro 3 3 3 

ro-jo.o.-j i<a a to crt l/l Ul . -J . -la <-|- pi -HTCrt ' O 

tM03"rtO C O S 

rf O -$ O" 

3- o- ro PI 

0) rt < lrt 

Pl -J. fD 

- tt -J. trt o . 

C 3 -"• 3 ro o o —i (II Q . 3 3 3 " 

crt ro Crt O" Q- C fll £ Ol 3 

pi rt pi -!• ro -J«TJ TJTJ t/ipiTJcrtfOrt O 

-J3-33PI <ropiTJ-Hrt O.TJ (B 1 fli a 

ro PI Q-ua n*oro-»-s-»picrtr o 

rf -i. ro pi pi ro o-

ro rtSO-IOrtScrt—jpir f 3 in J O 03*-iarocrtro3 0 (t tii n a i ro i o rt m w a 

-jn ro a> 3 o 3 ro 3 rt coroo—'(trtgw , rtl\) 3 3* 

-••O'o -•• -•• • crt or o NrtrortOrf C OPir t rD -jpi.-j . 3-J-I-.0 3 3 

CLDOI3 3 roOCrtQ-rtO 

-so.ro ro 

ro o —. Crt O 3 o- 14 3 O rt" 0 pi O. fli —• 3 r f fB -J - OJ r t ZT 3 3 

ro oi ro rt 

O -h CL 

O TJ rt* pi 

crt -•• ro -n 3 

•m oitTf ro 3 w i rt 3-nrtro i i a 

t/» _i. c/i —) OTJ oororo 

s:rt3 3-roa.roo.o. —< 

rrtrtto-i. ro—JtiiorooiTJ-Ja 

-•• 3 ro --rtn rt-, 3 rt 

f) » rf fl TJ tl -"• O PI CD -!• Ol 

3"-$-J. —Jpirtrt<-$ Crtrt 3 

ro3c-$-jpiropi-ero-Ja7cr 

pi roo-pios—'rtfD 3P I 

-t»TJ ro 3 O. 7T«< -J. -J rt —i-O 

-t- —i o rorocrt«<ro PI 

ropi-ttrtrtcrt ro rt3 1 

03 3-0) -•• -J-3-pip i 

rtrtrtro-IP)3—i n ZS n 7C 3 

trt zr vt -. o 3- 3- -•• roro 

oroxj ro—'ffl rt3 C rt 

rt*a ro rt c o-j-o-or o 

3- ro —• -$ 3" 0) Q.T3 3 Pl Q- - i 

ro-jpif*)Pi3rooi-Ja—'rooc/i 

oi-jrortro -$ c —i —• o • 

O rttO 3 -S rtfli 3«< vt 

T3-Ja (t rtSiQ 3*3 rtr t 

Irt < o 

-J-rf 3 3 

Oi O 3" O 

-$ C rt) rt Q. 

ro crt 3- ro 

o ro - J 

pi crt O O- ro Crt OO rt 

c_i. rt rf ro pi 

C O 3 

trt O Cx. rt yc 

rt -h pi -•• 

ro rt O TJ 

Q. 3 pi 3 pi 

O -J 

-Ja Q. "tl I—* PI 

3 ro o *-* 3 

—< -j ji ro 

rt rt 

ZT rt -ti -i. ro 

-J. pi C 3 -5 

n >3 ro-JaroroT3croitrtOirt33-fitrt 

-aCOSrl-IM rt-ifli 3 3 

pi o-Jarorooropic/iTT^— • 

rf rf O. 3 O.TJ -s rt ro ro << 

- J. _i. ro ro n » roc/i-j. Q.*O T 

33—' 3" -$ 3 OifBr f 

co ro ro pi PI PI rf co oi i zr 

TJ —' 3 3 rt 3- —• 01 Ol rD 

rt fli —i ro io a. -J. oi oi o 3 -t> -Ja3fliOr o 3rt33n>-t> 3 3 Q. 3 r t a . rtc o Q.cQ r t ro Oi 

ro rt-$ 3- « roo-iT J . OT-roc->roo£-jrt 3 

O ro Q.O C 1 3* J. lfl It rt 

-h -j ro i n -i ro -i rt o.ro 

O—.Crt 3"-» 03*C 3 

-••ros- rf-jror>3 *o D*O I 

33ro0i3"O33--i. rtOl< 3 

Q-rt -«ro3rfOi03-3 O 

-J- ro -^ 3 ro rt ro 

< rt nnoicooi K zr 

-<•-•• 3- 3roor>3-r o 0 . 3 -S0iO.Q.-JaC-J.Cr t 

c ro oo o-ior o 

pi 3 -•• -ti -j 3 " 

_i -J. Q. o ro 

O 1 -J 3 r t 

7-r nt o 

3 -is : 

ro TJ crt 3 ro 

3 pi C pi - j 

O -J TJ rf ro 

-. Pl TJ ->• 

Pi 3 -1 O -J 

3 ro ro 3 ro O. r t lrt < c ro trt -j -J . 3 -j pi ro irt to 3 -Q ro r t • r f C O . o trt ro 

Vt -J . 

1 H3*rt 3 

ro 3- pi crt 

-h ro cx • zm 

—• ~i Ot 

ro ro cr -$ 

r» -it ro —. n 

r tO ID T-J-

-j 3 ro 

rt ro Crt *—• 

3-» ro co 

ro oo 0 0 

ro 

\ 

-rj 
P.4 

B. Annual Costs of Fume Suppressants 

1. Model tanks. Fume suppressant cost information was obtained for 

two different sizes of model tanks (42 square feet [ft ] of surface area 

and 72 ft of surface area) that are used to develop model plants. Makeup 

and maintenance addition costs of permanent and temporary fume suppressants for the 42-ft model tank are presented in Tables 4 and 5, respectively. Makeup and maintenance2addition costs of permanent and temporary 

fume suppressants for the 72-ft model tank are presented in Tables 6 and 

7, respectively. Maintenance addition cost estimates for the fume 

suppressants were based on a tank operating time of 1,600 hours per year 

(h/yr) for the 42-ft tank and 4,800 h/yr for the 72-ft tank. 

2. Model plants. The average makeup and maintenance addition costs 

of both the permanent and temporary fume suppressants for each tank size 

were used to compute the annual costs for the decorative chromium plating 

model plants. These annual costs are presented in Tables 8 and 9, 

respectively. 

The methodology used for the cost calculations is also shown in 

Tables 8 and 9. The annual cost was calculated by multiplying the number 

of tanks in each model plant by the average fume suppressant makeup and 

maintenance addition costs associated with that size tank. Maintenance 

addition cost for each model plant includes an operating time adjustment 

ratio. The operating time adjustment ratio corrects for the difference 

between the operating time of the model tanks upon which the cost data 

were originally based and the revised operating time for the model 

tanks. As shown in Table 8, the average permanent fume suppressant 

maintenance addition cost supplied by vendors for the 42-ft model tank is 

$970 based on a tank operating time of 1,600 h/yr. The revised 42-ft 

model tank in the small model plant operates 1,200 h/yr. Therefore, the 

operating time adjustment ratio is 1,200/1,600 or 0.75, and the annual 

maintenance addition cost is $730 (0.75 times $970). Similar calculations 

were performed for the medium and large model plants. The revised model 

tanks in the medium and large model plant operate 2,400 h/yr and 

3,600 h/yr, respectively. 

IV. Chromic Acid Anodizing 

A. Information Sources 

Cost data were obtained for two brands of permanent fume 

suppressants—Metex® Spray Stop R, manufactured by MacDermid, Inc., and 

Zero-MistTM, manufactured by 0MIm/Udylite. • While Metex Spray Stop R is 

used only as a supplement in decorative chromium plating tanks, it is used 

for both makeup and maintenance additions for chromic acid anodizing 

operations. The requests for cost information that was submitted to fume 

suppressant vendors listed specific brands for which information was 

desired. While both temporary-, and permanent-type fume suppressants were 

included in this list, the vendors supplied cost data for only the 

permanent type. However, temporary fume suppressants are used in chromic 

acid anodizing baths. For this analysis, the cost of this type fume 

• ^ 
P.5 

suppressant is assumed to be comparable to the cost of permanent fume 

suppressants based on the cost data provided for decorative chromium 

plating tanks (refer to Tables 8 and 9) . 

B. Annual Costs of Fume Suppressants 

1. Model tanks. Fume suppressant (jost information was obtained for 

two different sizes of model tanks (42 ft of surface area and 150 ft of 

surface area). Makeup and maintenance addition costs of the permanent 

fume suppressants are presented in Table 10. Maintenance addition cost 

estimates for the fume suppressants were based on a tank operating time of 

500 h/yr for the 42-ft model tank, and 5,760 h/yr for the 150-ft model 

tank. 

2. Model plants. The makeup and maintenance addition costs of the 

permanent fume suppressants for each tank size were used to compute the 

annual costs for the small and large chromic acid anodizing model 

plants. The small model plant consists ^f one 42-ft model tank, and the 

large model plant consists of two 150-ft model tanks. The average annual 

cost of permanent fume suppressants for each tank size and model plant are 

presented in Table 11. The methodology used to calculate the annual costs 

for anodizing operations is the same as that used for decorative chromium 

plating operations (Section III.B.2). 

* 
TABLE 1. LIST OF MANUFACTURERS WHO PROVIDED COST INFORMATION ON 

INDIVIDUAL FUME SUPPRESSANTS 

P.6 

Manufacturer/brands Type of fume suppressant 

MacDermid, Inc. 

Proquel Ba 

Metex® Spray Stop HE 

Metex® Spray Stop Rr 

OMI"/Udylite International Corp. 

Zero-MistTM 

Zero-MistTM HT 

Zero-MistTM HT-2 

Foam Lok® L 

Harshaw/Filtrol Partnership 

MSP-1 

MSP-2 

MSP-ST 

M&T Chemicals'* 

FumetrolTM 103 

FumetrolTM 104 

FumetrolTM 205 

FumetrolTM 208 

FumetrolTM 210 

Frederick Gumrn Chemical Company 

Clepoa 

b c Temporary/foam blanket 

Permanent/combination

 e 

Permanent/comb ination 

Permanent/wetting agent^ 

Permanent/foam blanket 

Permanent/comb i nat i on 

Temporary/foam blanket 

Permanent/comb i nat i on 

Permanent/combination 

Permanent/wetting agent 

Temporary/foam blanket 

Temporary/foam blanket 

Permanent/comb ination 

Permanent/comb ination 

Permanent/combination 

Permanent/foam blanket 

aCost data were not included in development of annual costs for fume 

.suppressants. 

Temporary fume suppressants are depleted from dragout and decomposition 

of the fume suppressant. 

cFoam blankets produce a layer of foam on the surface of the plating 

.solution to entrap chromic acid mist. 

Permanent fume suppressants are depleted mainly from dragout of the fume 

suppressant. 

Combination fume suppressants are a combination of wetting agents and 

-foam blankets. 

Cost data were not included in development of annual costs of fume 

suppressants for decorative plating operations but were used in 

development of fume suppressant annual costs for anodizing operations. 

•^Wetting agents reduce the amount of chromic acid mist by lowering the 

surface tension of the bath. 

<T 
TABLE 2. PARAMETERS FOR DECORATIVE CHROMIUM PLATING MODEL TANKS 

Model tank 

Model tank information 

Tank dimensions, ft 

Tank capacity, gal 

Operating voltage, volts 

Operating current, amperes 

2 

Current density, amp/ft 

Temperature, °F 

Chromic acid concentration, oz/gal 

Chromic acid: sulfuric acid ratio 

Plant operating time, hours/year 

Time electrodes are energized, % 

Tank operating time, hours/yeard 

42-ft2a 

12.0, 3.5, 6.0 

1,730 

6-7.5 

4,000 

72-360 

100-115 

35-40 

170:1 

2,000 

80 

1,600 

12.0, 

42-ft2b 

3.5, 6.0 

1,730 

6 

2,600 

124 

100-115 

40 

100:1 

2,000 

60 

1,200 

12.0, 

72-ft2a 

6.0, 9.0 

4,580 

16 

6,000 

72-360 

100-115 

35-40 

170:1 

6,000c 

80 

4,800 

12.0, 

72-ft2b 

6.0, 9.0 

4,580 

10 

6,800 

124 

100-115 

40 

100:1 

6,000 

60 

3,600 

aFume suppressant cost data obtained from manufacturers were based on the original model tank 

parameters. 

Adjusted model tank parameters. 

cThe original model plant operating time was actually 6,240 hours/year but for simplicity 

6,000 hours/year was the value submitted to vendors. 

To obtain the tank operating time multiply the plant operating time by the percent time electrodes are 

energized. 

CS 
TABLE 3. 

Model tank information 

PARAMETERS FOR CHROMIC ACID ANODIZING MODEL TANKS 

Model tank 

42-ft2a 42-ft2b 150-ft2a 150-ft2b 

Tank dimensions, ft 12.0, 3.5, 6.0 12.0, 3.5, 6.0 30.0, 5.0, 9.0 

Tank capacity, gal 1,730 1,730 

Operating voltage (step-wise), volts 40 20 or 40 

2 

Current density, amp/in. 1-5 1-5 

Temperature, °F 90-95 90-95 

Chromic acid concentration, oz/gal 10 10 

Plant operating time, hours/year 2,000 2,000 

Time electrodes areenergized, percent 25 70 

Tank operating time, hours/yearc 500 1,400 

aFume suppressant cost data obtained from manufacturers were based on the original model tank 

parameters. 

Adjusted model tank parameters. 

cTo obtain the tank operating time multiply the plant operating time by the percent time electrodes are 

energized. 

, 9.0 

9,540 

40 

1-5 

90-95 

10 

7,200 

80 

5,760 

30.0, 5. 

20 

0, 9.0 

9,540 

or 40 

1-5 

90-95 

10 

6,000 

40 

2,400 

^ 
TABLE 4. PERMANENT FUME SUPPRESSANT MAKEUP AND MAINTENANCE COST DATA FOR THE 

42-ft DECORATIVE CHROMIUM PUTING MODEL TANK 

Manufacturer/ 

fume suppressant brand 

M&T 

Fumetrol'" 205b 

FumetrolTM 208c 

Fumetrol'" 210c 

MacDermid 

Metex® Spray Stop 

Udylite 

Zero-Mist'"b 

Zero-M1st'" HTD 

Zero-Mist'" HT-2b 

Harshaw/Filtrol 

MSP-STC 

MSP-1C 

MSP-2C 

AVERAGE 

Purchase cost, 

$/gal or $/lb 

32.78 

68.38 

59.12 

HFb 23.50 

25.00 

21.00 

22.00 

49.00 

53.50 

56.50 

Initial 

makeup, 

gal or lb 

5.00 

2.50 

2.50 

8.5 

5.10 

2.50 

6.80 

3.46 

3.46 

3.46 

Initial 

makeup 

cost, $ 

163.90 

170.95 

147.80 

199.75 

127.50 

52.20 

149.60 

169.54 

185.11 

195.49 

156.00 

Annual tank 

maintenance 

consumption, 

gal or lb 

58.00 

23.00 

23.00 

44.00 

24.00 

36.00 

24.00 

12.30 

12.30 

12.30 

Maintenance 

cost, $/yra 

1,901 

1,572 

1,360 

1,031 

600 

756 

528 

600 

660 

690 

970 

^Maintenance costs are based on a tank operating time of 1,600 hours per year. 

Cost data and solution makeup and maintenance additions are in pounds. 

cCost data and solution makeup and maintenance additions are in gallons. 

OO 

*A 

CO 
TABLE 5. TEMPORARY FUME SUPPRESSANT MAKEUP AND MAINTENANCE COST DATA FOR THE 

42-ft DECORATIVE CHROMIUM PLATING MODEL TANK 

Manufacturer/ 

fume suppressant brand 

M&T 

FumetrolTM 103 

FumetrolTM 104 

Udylite 

Foam-Lok® L 

AVERAGE 

Purchase cost, 

$/gal 

19.31 

22.31 

13.00 

Initial 

makeup, 

gal 

0.63 

0.42 

1.70 

Initial 

makeup 

cost, $ 

12.17 

9.37 

22.10 

15.00 

Annual tank 

maintenance 

consumption, 

gal 

70.00 

70.00 

30.00 

Maintenance 

cost, $/yra 

1,351 

1,560 

390 

1,100 

-^Maintenance costs are based on a tank operating time of 1,600 hours per year. 

^ ^ a XI 

o 
TABLE 6. 

Manufacturer/ 

fume suppressant brand 

M&T 

FumetrolTM 205b 

FumetrolTM 208c 

FumetrolTM 210c 

MacDermid 

PERMANENT FUME SU PPRESSANT MAKEUF 

72-ft DECORATIVE CHROMIUM 

Purchase cost, 

$/gal or $/lb 

32.78 

68.38 

59.12 

Initial 

makeup, 

gal or lb 

14.00 

6.90 

6.90 

> AND MAINTENAJ 

PLATING MODEL 

Initial 

makeup 

cost, $ 

458.92 

471.82 

407.93 

<CE COST DATA FOR 

TANK 

Tank 

maintenance 

consumption, 

gal or lb 

157.00 

62.00 

62.00 

FHE 

Maintenance 

cost, $/yrd 

5,146 

4,239 

3,665 

Metex® Spray Stop HF[ 

Udylite 

23.50 22.90 538.15 238.00 

Zero-Mist'"b 

Zero-MistTM HTb 

Zero-MistTM HT-2b 

Harshaw/Filtrol 

MSP-STC 

MSP-1C 

MSP-2C 

25.00 

21.00 

22.00 

49.00 

53.50 

56.50 

13.50 

6.80 

18.00 

9.16 

9.16 

9.16 

337.50 

142.80 

396.00 

448.84 

490.06 

517.54 

90.00 

108.00 

60.00 

97.60 

97.60 

97.60 

5,593 

2,250 

2,268 

1,320 

4,780 

5,220 

5,510 

AVERAGE 420.00 4,000 

^Maintenance costs are based on a tank operating time of 4,800 hours per year. 

Cost data and solution makeup and maintenance additions are in pounds. 

cCost data and solution makeup and maintenance additions are in gallons. 

^ 
TABLE 7. TEMPORARY FUME SUPPRESSANT MAKEUP AND MAINTENANCE COST DATA FOR THE 

72-ft DECORATIVE CHROMIUM PLATING MODEL TANK 

Manufacturer/ 

fume suppressant brand 

M&T 

FumetrolTM 103 

FumetrolTM 104 

Udylite 

Foam-Lok® L 

AVERAGE 

Purchase cost, 

$/gal 

19.31 

22.31 

13.00 

, 

Initial 

makeup, 

gal 

1.69 

1.15 

4.00 

Initial 

makeup 

cost, $ 

32.63 

25.66 

52.00 

37.00 

Tank 

maintenance 

consumption, 

gal 

189.00 

189.00 

90.00 

Maintenance 

cost, $/yra 

3,649 

4,216 

1,170 

3,012 

Maintenance costs are based on a tank operating time of 4,800 hours per year. 

TJ 

ro 
12 

TABLE 8. AVERAGE ANNUAL COST OF PERMANENT FUME SUPPRESSANTS 

FOR DECORATIVE CHROMIUM PLATING MODEL PLANTS 

P.13 

Component- Cost data 

72 

420 

4,000 

A. Model tank dataa 

2 

1. Surface area of model tank, ft 42 

2. Average makeup cost of fume 156 

suppressant, $ 

3. Average maintenance cost of fume 970 

suppressant, $/yr 

4. Operating time basis, h/yr 

B. Model plant datac 

1. No. of model tanks 

2 

2. Surface area of model tanks, ft 

3. Operating hours, h/yr 

4. Makeup cost of fume suppressant, $ 

(A2xBl) 

5. Maintenance cost of fume suppressant, $/yrd e 

(A3xBl)(B3/A4) 

6. Annual cost of fume suppressant, $/yr 890 

(B4+B5) 

aFume suppressant cost basis (original model tank parameters). 

Operating time of tanks = (operating time of plant, h/yr) multiplied by 

(percent time electrodes energized). 

^Based on revised model plant parameters. 

Cost data were rounded to the nearest $10. 

Maintenance cost is adjusted by applying a ratio that corrects for the 

difference between the operating time of the model tanks upon which the 

cost data are based and the revised operating time of the model tanks. 

1,600 

Small 

1 

42 

1,200 

160 

Medium 

2 

42 

2,400 

310 

4,800 

Larqe 

5 

72 

3,600 

2,100 

730 2,910 15,000 

3,220 17,100 

/ ^ 
P.14 

13 

TABLE 9. AVERAGE ANNUAL COST OF TEMPORARY FUME SUPPRESSANTS 

FOR DECORATIVE CHROMIUM PLATING MODEL PLANTS 

Component Cost data 

A. Model tank dataa 

1. Surface area of model tank, ft 42 72 

2. Average makeup cost of fume 15 37 

suppressant, $ 

3. Average maintenance cost of fume 1,100 3,012 

suppressant, $/yr 

4. Operating time basis, h/yr 

B. Model plant datac 

1. No. of model tanks 

2 

2. Surface area of model tanks, ft 

3. Operating hours, h/yr 

4. Makeup cost of fume suppressant, $ 

(A2xBl) 

5. Maintenance cost of fume suppres- 830 3,300 11,300 

sant, $/yrd e 

(A3xBl)(B3/A4) 

6. Annual cost of fume suppressant, $/yr 850 3,330 11,490 

(B4+B5) 

aFume suppressant cost basis (original model tank parameters). 

Operating time of tanks = (operating time of plant, h/yr) multiplied by 

(percent time electrodes energized). 

^Based on revised model plant parameters. 

Cost data were rounded to the nearest $10. 

Maintenance cost is adjusted by applying a ratio that corrects for the 

difference between the operating time of the model tanks upon which the 

cost data are based and the revised operating time of the model tanks. 

1,600 

Small 

1 

42 

1,200 

20 

Medium 

2 

42 

2,400 

30 

4,800 

Larqe 

5 

72 

3,600 

190 

/-3 
P.15 

14 

TABLE 10. PERMANENT FUME SUPPRESSANT MAKEUP AND MAINTENANCE COST 

DATA FOR THE CHROMIC ACID ANODIZING MODEL TANKS 

Model tank 

Model tank information 42-ft2 150-ft2 

1. MacDermid-Metex Spray Stop R 

a. Purchase cost, $/lb 

b. Initial makeup, lb 

c. Makeup cost, $ 

d. Maintenance consumption, lb/yr 

e. Maintenance cost, $/yr 

2. OMI/Udylite-Zero-Mist 

a. Purchase cost, $/lb 

b. Initial makeup, lb 

c. Makeup cost, $ 

d. Maintenance consumption, lb/yr 

e. Maintenance cost, $/yr 

23 

2.6 

59.80 

15 

345 

25 

5.5 

137.50 

24 

600 

23 

14.6 

335.80 

219 

5,037 

25 

32 

800 

96 

2,400 

/f 
15 

TABLE 11. AVERAGE ANNUAL COST OF PERMANENT FUME SUPPRESSANTS FOR 

CHROMIC ACID ANODIZING MODEL PLANTS 

P.16 

Component Cost data 

Model tank dataa 

2 

1. Surface area of model tanks, ft 

2. Average makeup cost of fume 

suppressant, $ 

3. Average maintenance cost of fume 

suppressant, $/yr 

4. Operating time basis, h/yr 

Model plant datac 

1. No. of model tanks 

2 

2. Surface area of model tanks, ft 

3. Operating hours, h/yrb 

4. Makeup cost of fume suppressant, $ 

(A2xBl) 

5. Maintenance cost of fume suppressant, $/yrd e 

(A3xBl)(B3/A4) 

6. Annual cost of fume suppressant, $/yrc 

(B4+B5) 

42 

99 

473 

500 

1 

42 

,400 

100 

150 

568 

3,718 

5,760 

2 

150 

2,400 

1,140 

1,320 

1,420 

3,100 

4,200 

aFume suppressant cost basis (original model tank parameters). 

Operating time of tanks = (operating time of plant, h/yr) multiplied by 

(percent time electrodes energized). 

^Based on revised model plant parameters. 

Cost data were rounded to the nearest $10. 

Maintenance cost is adjusted by applying a ratio that corrects for the 

difference between the operating time of the model tanks upon which the 

cost data are based and the revised operating time of the model tanks. 

/ ^ 
P.17 

16 

V. References 

1. Cost Enclosure for Fume Suppressant Vendors: MacDermid, Inc. 

Prepared for U. S. Environmental Protection Agency, Research Triangle 

Park, North Carolina. February 20, 1987. p. 2-3. 

2. Cost Enclosure for Fume Suppressant Vendors: OMI/Udylite 

International Corporation. Prepared for U. S. Environmental 

Protection Agency, Research Triangle Park, North Carolina. 

February 26, 1987. p. 2-3. 

3. Cost Enclosure for Fume Suppressant Vendors: Harshaw/Filtrol 

Partnership. Prepared for U. S. Environmental Protection Agency, 

Research Triangle Park, North Carolina. January 20, 1987. p. 2-3. 

4. Cost Enclosure for Fume Suppressant Vendors: M&T Chemicals. Prepared 

for U. S. Environmental Protection Agency, Research Triangle Park, 

North Carolina. January 20, 1987. p. 2-3. 

5. Cost Enclosure for Fume Suppressant Vendors: Frederick Gumm Chemical 

Company, Inc. Prepared for U. S. Environmental Protection Agency, 

Research Triangle Park, North Carolina. February 9, 1987. p. 2-3. 

6. Reference 1, p. 6. 

7. Reference 2, p. 6. 

/h