p.1 

OAR Box 1313 

Preppedby LaTeiaShed 

Document Number: 

12) l-B-5 

Docket Number: 

A-88-02 

Printed 6/12/2008 9:03:27AM Sheet 12 of 99 
P.2 

^ | W MIDWES MIDWEST RESEARCH W INSTITUTE 

X"-6> - "5

 4505 Creedmoor Road 

Raleigh, N.C. 27612 

Telephone (919) 781-5750 

FINA L psLE GOPY 

Date: April 15, 1985 

(Finalized: May 20, 1985) 

Subject: Site Visit—Carolina Plating-Roll Division 

Survey of Chromium Emission Sources—Chromium Plating 

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

MRI Project 7711-L 

From: Barb Duletsky 

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 

on the chromium plating operation at this plant and to determine the 

suitability of this plant for chromium emissions testing. 

II. Place and Date 

Carolina Plating 

4412 White Horse Road 

Greenville, South Carolina 29611 

(803) 269-7703 

March 7, 1985 

III. Attendees 

JAN I 8 1991 

Carolina Plating-Roll Division [ .!"|:'.4 A;"v I'-•"••" •"-' ;' j 

J. F. Tucker, Vice President 

Lew Walker, Jr., Vice President 

Midwest Research Institute (MRI) 

Barb Duletsky 

Charles Hester 

Principal Laboratories 425 Volker Boulevard. Kansas City, Missouri 64110 
P.3 

IV. Discussion 

We arrived at the plant at 10:45 a.m. The visit consisted of a 

discussion about chromium plating and a tour of the chromium plating and 

metal finishing operations. 

A. General 

The Carolina Plating Roll Division is a job shop specializing in 

precision finishing and refinishing of industrial rolls. Operations 

performed at this facility include hard chromium plating, sulfamate nickel 

plating, machining, grinding, and mirror finishing. The plant plates rolls 

that are used primarily in the paper manufacturing, roofing, laminating, 

and coating industries. There are only four other plants in the country 

that are capable of plating and finishing rolls with the same degree of 

accuracy that is attained by Carolina Plating. These companies are located 

in California, Connecticut, New Jersey, and Illinois. Although details of 

the finishing processes performed at this plant are atypical, the actual 

plating process is similar to that at most other hard chromium plating 

operations. 

The Carolina Plating facility was originally built in 1971. Much of 

the plating equipment was replaced in 1976 after a fire destroyed a portion 

of the plant. All of the existing air pollution control devices were 

installed at that time. Currently, there are 34 full-time employees, 9 of 

whom are responsible for the chromium plating process. The employees work 

1 shift per day, 5 days per week, although the chromium plating tanks 

usually operate 24 hours per day, 7 days per week. Annual chromic acid 

consumption at the plant is 20,000 to 25,000 pounds. 

B. Process 

There are seven chromium plating tanks at this facility, arranged as 

shown in Figure 1. Operating specifications for each tank are listed in 

Table 1. On the average, the tanks are charged 20 hours per day; 

approximately 4 hours per day are required for the change-over of rolls. 

Tank Nos. 1, 2, 3, and 7 are situated below floor level and are 

oriented with the longest dimension in the vertical direction to 

accommodate the plating of large rolls. Each tank is serviced by an 

electric hoist that lowers and raises the rolls into and out of the plating 

solution. In addition, each tank is equipped with a timer which allows 

plating operations to be completed during evenings or weekends when no 

personnel are available to turn off the electricity. Typical plating times 

range from 12 to 36 hours per roll. A typical roll measures 6 to 10 feet 

in length and 10 to 18 inches in diameter. After plating, the rolls are 

removed from the tanks and transferred to the polishing and grinding 

room. 

The other three tanks are oriented horizontally and are used to plate 

smaller rolls, aircraft engine pistons, and rotary pumps. Tank Nos. 4 
P.4 

SULFAMATE 

NICKEL PLATING, 

GRINDING, AND 

POLISHING AREA 

EMISSIONS DUCTED TO HEIL FUME 

SCRUBBER ON FLOOR ADJACENT TO TANK 

EMISSIONS DUCTED TO HEIL FUME SCRUBBER 

ON FLOOR ADJACENT TO TANK 

f*~CONTROLLED EMISSIONS DUCTED TO FAN ON ROOF 

/NAPCO V, 

OFFICES 

STORAGE AREA 

X 

OFFICES 

EMISSIONS DUCTED TO 

KCH FUME SCRUBBER ON ROOF 

Figure 1. Plan view of Carolina Plating facility. 
P.5 

Tank 

No. 

*1 

*2 

*3 

4 

5 

6 

*7 

TABLE 1. 

Capacity, 

gal 

1,000 

2,000 

3,000 

340 

1,000 

2,400 

2,400 

SPECIFICATIONS OF HARD CHROMIUM 

AT CAROLINA PLATING 

Voltage, 

V 

12 

12 

10 

12 

12 

12 

10 

Current, 

A 

7,000 

20,000 

30,000 

4,000 

5,000 

8,000 

15,000 

Method 

of 

cooling 

Air 

Water 

Water 

Air 

Air 

Air 

Water 

PLATING TANKS 

Constituents, 

oz/qal 

Cr03 H2S0* 

33 0.33 

33 0.33 

33 0.33 

— Proprietary** 

— Proprietary** 

33 0.33 

33 0.33 

Fn 

0 

0 

0 

— 

— 

0 

0 

•Emissions are exhausted to a common control device. 

••Plating solution is sold to Carolina Plating as a proprietary mixture 

that contains some fluoride. 

NOTE: All tanks have PVC liners that are replaced every 2 to 3 years. 

/. 
P.6 

and 5 contain a proprietary mixture of chromic acid and fluoride in 

solution. This type of plating solution is more efficient than 

conventional solutions in terms of how much electricity is required to 

deposit a specified amount of chromium. Although fluoride improves plating 

efficiency, there are drawbacks to using fluoride in some plating 

applications. Fluorides have a tendency to attack and etch steel surfaces 

that are not properly masked. The rolls plated at this facility would be 

ruined if they were etched in this way, so all exposed steel surfaces are 

carefully masked before the rolls are plated in these solutions. 

C. Emissions Control 

Of the electricity supplied to the plating tanks, only 11 to 

17 percent is used to deposit chromium on the rolls. The rest is used to 

generate hydrogen gas during the reduction of chromic acid. It is the 

hydrogen gas that entrains chromic acid particles and creates the visible 

yellow mist at the surface of chromium plating solutions. The amount of 

mist generated from a tank is largely dependent on the surface area plated 

and the amperage supplied to the tanks. [Mr. Tucker suggested that any 

regulation be based on these two parameters at maximum operating conditions 

of the tank.] 

All seven tanks are equipped with hoods on three sides for emissions 

capture. Visible chromic acid mist was observed to be drawn into the hoods 

on each tank that was operating during the visit. For the purpose of 

demonstration, the induction fan that draws mist from tank Nos. 1, 2, 3, 

and 7 was turned off for a short time. In less than 15 seconds, the yellow 

mist had risen from the floor (top of plating tanks) to our nostrils, 

causing a sharp, stinging sensation. After the fan was turned back on, the 

effects diminished. 

A plan view of the exhaust system for tank Nos. 1, 2, 3, and 7 is 

shown in Figure 2. As illustrated, each successive tank is ducted to a 

horizontal circular duct, which in-turn connects to a square duct (not 

shown) that rises vertically to the control device. There is a straight 

section of ductwork about 5-feet-long that has a 6-inch-diameter port in 

one side. This port is used occasionally for directing emissions from a 

portable plating tank through the main control device. A Duall model No. 

H-66 industrial fan draws emissions from the tanks through a fume 

scrubber. The ductwork between the scrubber and the fan is divided into 

two parallel sections due to physical constraints imposed by the structural 

design of the building. A centrifugal mist eliminator downstream of the 

induction fan removes any remaining chromic acid mist from the exhaust 

gases. 

The scrubber serving tank Nos. 1, 2, 3, and 7 is manufactured by 

Napco, model No. MA-101, and is located on a mezzanine structure in the 

plating area. It is a wet double packed-bed type scrubber with a rated 

control efficiency of 99 percent. Mr. Steve Grenier from Napco, Inc. 

oversaw the installation of this device and has mailed us some information 

about it. Tank Nos. 4 and 5 are equipped with Heil fume scrubbers. 

<r 
M«*p 

I'-i'- flXMCXr 

Figure 1. Plan view of exhaust system on Tank Nos. 1, 2, 3, and 7. 

^ 
P.8 

Emissions from tank No. 6 are controlled by a positive-pressure KCH fume 

scrubber. 

The capital cost of the four scrubbers at this facility was $53,000 

in 1976. The control systems, including scrubbers, fans, hoods, and 

ductwork, cost $3,000 to 4,000 annually to maintain. Electricity to power 

the fans costs about $250/month. These costs are minimal compared to the 

costs of the entire plating system. Approximately 80 percent of the 

capital and maintenance costs and all of the electricity costs would be 

incurred if only the ventilation systems (and not the control devices) had 

been installed. No demisting agents are used in the plating tanks at this 

facility because of the precise plating specifications. Much of the work 

performed must be accurate to within a few mi month s of an inch, so the 

plating solution must remain free of chemicals or plastic balls that might 

interfere with an even finish. 

D. Existing Regulations 

Mr. Tucker provided some permit information on the Napco fume 

scrubber, which is included as Attachment A. The State emission 

limitations for stack discharge are <3 pounds/hour for total suspended 

particulate matter and <3 pounds/hour for chromic acid. Soon after the 

Napco scrubber was installed, the South Carolina Department of Health and 

Environmental Control (DHEC) performed a stack test on it to determine 

compliance. Mr. Claude Miller of DHEC, Greenville, South Carolina, is the 

person to contact for the results of this test. (Mr. Miller was contacted 

for this information, but he said the compliance test consisted only of 

visible emissions observations.] 

Mr. Tucker also provided the results of two tests for employee 

exposure to various air pollutants. These results are included as 

Attachment B. The 8-hour permissible exposure limit (time-weighted 

average) is 0.1 mg/m^ for chromic acid. According to the results, the 

employees tested at Carolina Plating were exposed to concentrations 

substantially below the permissible limit. 

E. Conclusions 

Carolina Plating is a medium-sized job shop involved in hard chromium 

plating. The tanks at this facility appear to have effective emission 

capture and control systems. The Napco scrubber controlling emissions from 

tank Nos. 1, 2, 3, and 7 at this plant is a good candidate for testing 

because: (a) operation of the plating tanks is a relatively steady-state 

process, (b) parameters such as surface area plated and amount of chromium 

deposited are easy to calculate, and (c) there is a test port already in 

place at the scrubber inlet. Emissions testing at the scrubber outlet is 

complicated by the fact that the ductwork between the scrubber and the fan 

is divided, although Mr. Grenier of Napco, Incorporated, said that it would 

be safe to assume that the flow is evenly divided between the two 

ducts. 

2 Attachments 

7-
" -— ' — PQ 

Attachment A ,k, , 

ATTACH ADDITIONAL SHEETS IF NEEDED TO PROVII&roB*^^ INFORMATION 

PROCESS PERMIT APPLICATION • 

Permit No. 

1 . Permit t o be issued to ; CAROLINA PLATING CO. - ROLL DIVISION 

2 . Mailing Address: PO BOX 1387 . GREENVILLE. S.C . 2960 2 

3 . Facilit y Locatiom ^1 2 WHITE HORSE ROAD County: GREENVILLE 

4. Person t o contact: LEWIS M. WALKER I I - Phone no: 269-770 3 

5. Permit required for : 

X Construction Operation of existing source 

v Alteration (construetibn begun on or before February111, 1971) 

O 6. Construction start date:JV^/ if-77 Completion date: f-t=T? / f 78 

• P 7. A. Major raw materials: yype: Quantity used: 

(lbs/hr) 

B. Product: HARD CHROMIUM PLATING Rate of production: VAg.rf-yo.l-g: 

8. Process Description: g.tecy72.o FLAr/*J<Q H-^b^d <Z.ttApMG- Q<u CoCrr^tZ 

SOi4.\=AC:€- p/ZaCxCx.C7~S I.D. no.(e.g. , Unit #4) 

9. Air Pollution Control Device Description: /U/tffco t^A-ldl /HE. -SCHeugggfe- U/i77V 

'DiifrU^ PP. GC &.kHAOS7~ BLQi^GlL I.D. no.(e.g. , Unit #4) uu i f /uo. I 

10. Stack Data: Height from ground (ft) 33 f Velocit y (ft/sec)_£[2L1 3 

Inside diameter (ft) 2,g 7 Temperature (F) 7*3* (/\-/^Qi€^fl~^ 

11. Emission Data: (pounds/hr) 

uncontrolled controlled uncontrolled controlled 

Particulate -• NOx /^/h 

Hydrocarbons (specify) CO /OA 

N A S02 /QA 

Other (specify) H2SQ4 A)A . 

CfcQ-3 ,060000*?/ 

."? 12. Normal Operation Schedule: hr/day JL.9 day/week "/ week/year XT-^~ 

Seasonal Variation: Jan.-Mar. 6 % Apr .-June *3 % July-Sept, a * Oct.-Dec, o % 

jP 13. How will waste material from process and control equipment be disposed of? E^(^l.U€tST' 

ooiu. Esfc s&rrzjetx- C.L><T~/AJ g<ssg-/a</<s*//g. TA-*J£. AK>O ^.^cL^if^^c. 

14. Include the following information-: 

" A. Plot plan (show distance to nearest residence, business, etc.) 

B. Flow diagram of process to be permitted (indicate and identify emission points) 

^ C , Supply all technical data available from vendor (make, model, design criteria) 

I certify that, to the best of my knowledge and belief that no undesirable levels 

will be created and no applicable standards or regulations will be contravened or 

violated. I understand that any statements and descriptions which are found to be 

incorrect may be the cause for immediate revocation of any permit pursuant to this 

application. 

LEWIS M. WALKER ^ . PRESIDENT 

Signature of responsible person or company offical and title 

Date 

White/Air Quality Central Office Yellow/DHEC District Office Pink/Applicant 7/77 

—»_ _ - m' i^^marmmmmmilwi^^ismstMaKm^MJ!Xf3BSlBSIsrlX3i 

......-.ve«. :*•..?;_ # 
P.10 

Carolina Plating Company 

CONDITIONS FOR PERMIT NUMBER: 1200-0092 

DATE OF ISSUE: October 15, 1984 

page 2 

II. SPECIAL CONDITIONS 

A. EMISSION LIMITATIONS 

Air pollutant emissions shall not exceed the following 

ID No. Pollutant Emission Limitation 

01 TSP Less than 3 lbs/hr . 

01 Chromic acid Less than 3 lbs/hr 

The above emission limitations are based on operation at rated capacity. 

Operation at other than rated capacity must meet the emission limits 

specified in the applicable regulations based on that operating rate. The 

TSP and SO~ limits for the plant may be set lower than the state emission 

limit:: shown above, if necessary to prevent a PSD increment or NAAQS 

violation. Such source specific emission limits can be only determined on 

a case-by-case basis. 

P. CONTINUOUS MONITORING REQUIREMENTS 

ID No. Pollutant 

N/A 

SOURCE TSST SCHEDULE 

ID Nc. Pollutant Frequency 

N/A 

ADDITIONAL CONDITIONS 

ID NO. 

N/A 

• ;o deviation from the plans and specifications submitted with your 

application or the conditions specified herein is permitted, unless 

authorized in writing by the Bureau of &ir Quality Control. The owner/ 

operator is responsible for satisfactory compliance with all Air Pollution 

Reaulations and Standards. 
P.11 

Attachment*B "*--• 

ngineen'ng 

^•STRIAL-HyGiFj-t-E ANAI7/S!S REPORT 

UALYSIS NO. 

411-80 (4-4) 

CHEMICAL AND ENVIRONMENTAL 

SERVICES UNIT , 

Carolina Plating Co., Inc. Greenville, S.C. 

E SENT BY 

H. Mclntire 

DATE RECEIVED 

3-14-80 

DA* * MFMTtB 

3-22-80 

ANALYST 

TSS; JAC <%{^ 

IAL ANALYZED 

PVC Filters; HA Filters 

SAMPLE 

NUMBER LOCATION TEST RESULTS TIME-WEICHTED 

AVERAGE 

HYGIENIC 

STANDARDS 

829E 

40JX 

845E 

830E 

Chrome Plate Area-Jerry Smith 

Ni Plate Area-Mike Andruski 

Chrome Plate Area-Jerry Smith 

Chrome Plate Area-Jerry" Smith 

Chromium VI 

Less than 

0.004 mg/nP 

Nickel 

0.01 mg/m? 

Chromium VI' 

Less than 

0.018 mg/m5 

Chromium VI" 

Less than 

0.019 mg/m5 

K 0.003 mg/m3 

0.0075 rag/m^ 

Chromic Acid 

(as CR VI) 

0.05 mg/m* 

Nickel/Metal & 

Insoluble Crapds 

(as Ni) 

1 mg/m5 

Chromic Acid * 

a Cr VI 

0.3 mg/nr 

Nickel, Metal & 

insoluble Cmpds.

 4 

(as Ni)3 

3 mg/m-3 

NALYTICAL METHODS 

Colorimetry 

Atomic Absorption 

SPECIAL NOTES 

•Excursion Yalue 

EF1NITION OF TERMS 

Time-Weighted Average (TWA) - The employee's exposure averaged over 8 hours per day or 40 hours per week using this 

equation: 

TWA equivalent = ( cl ) Cl ) + ( c2 ) ( T2 ) + ... (C n ) ( Tn ) ; where C = concentration measured. 

8~hrs """

 = dura-iot-i in hours, of 

exposure at concentration C. 

The TWA evaluations of this report are based on the exposure time given on the corresponding "Industrial Hygiene 

Survey Data Sheet." 

• Ceiling limit (designated by a "C " in front of the Hygienic Standard) - This is a maximum allowable concentration 

which should never be exceeded. 

Excursion limit - This limit defines the maximum concentration of contaminant to which on employee con be exposed 

for a short period of time. 

Hygienic standard is the applicable allowable level in air, such as the TL V or PEL (permissible exposure limit). 

-15449 REV . 6-79 PHiNTtc"iN U.S.A. TRAVELERS INSURANCE COMf-'ANIES 

HARTFORD,CONNECTICU T 

/D 
P.12 

S. C. DEPARTMENT OF LABOR 

DIVISION OF OSH CONSULTATION 

CONSULTATIVE INSPECTION FINDINGS 

.N8R. 008 OC. NBR. 008 

ivity Date: September 11, 1982 

FY 83 Page _2 _ of _3_ 

Description of Alleged Violation and Recommendation for Correction Abatement 

Date 

In addition to the noted violations, the following information is provided 

concerning the occupational health courtesy Inspection of August 11 and 12, and 

September 9, 1982: 

This courtesy inspection included the monitoring of employee exposures to 

possible air contaminants and noise levels. 

Air sampling was conducted on August 12 and September 9 to determine employee 

exposures to chromic acid in the large and the small plating rooms, to nickel 

in the nickel plating room, to sodium hydroxide 1n the large plating room, and 

to nuisance dust (aluminum oxide) in the grit blasting area. Laboratory 

analyses indicated the following time weighted average (T.W.A.) exposures: 

EMPLOYEE 

Dean Shealey 

Tony Brown 

Leigh Veino 

Steve Riddle 

John Chandler 

Jerry Smith 

Area Sample 

AREA 

Large Plating 

Large Plating 

Small Plating 

Small Plating 

Nickel Plating 

Grit Blasting 

Large Plating 

MATERIAL 

Room Chromic Acid 

Room Chromic Ad d 

Room Chromic Acid 

Room Chromic Acid 

Room Nickel 

Nuisance Dust 

Room Sodium Hydroxide 

T.W.A. 

EXPOSURE 

.00008 Mg/M3 

.002 Mg/M3 

.00002 Mg/M3 

.00004 Mg/M3 

Nothing detected 

.8 Mg/M3 

.2 Mg/M3 

The 8 hour T.W.A. permissible exposure limits for these materials, 

as listed in Table Z-l, Z-2, and Z-3 of section 1910.1000, are: 

MATERIAL 

Chromic Acid 

Nickel 

Sodium Hydroxide 

Nuisance Dust 

PERMISSIBLE EXPOSURE LIMIT 

.1 Mg/M3 

1 Mg/M3 

2 Mg/M3 

15 Mg/M3 

The sampling results indicate that exposures to these materials are well 

below the permissible exposure limits. 

A noise survey was conducted on September 9 to determine employee exposures 

to noise at the grit blasting machine and the polishing machine. _ 

A Type II, General Radio sound level meter was used to measure noise levels and 

zr. verify dosimeter readings. Actual employee noise exposures were monitored 

using General Radio audio dosimeters, model #1954-9710, set on an operating 

range of 80-130 dBa. The dosimeters indicated the following noise exposures: 

// 
P.13 

Rl® A-88-02 

MIDWEST RESEARCH INSTITUTE 

*X - £>-L| 4505 Creedmoor Road 

Raleigh, N.C. 27612 

Telephone (919) 781-5750 

FILE COPY 

Date: March 29, 1985 FINAL 

(Finalized April 19, 1985) 

Subj'ect: Site Visit—T&S Brass and Bronze Works 

Survey of Chromium Emission Sources—Chromium Plating 

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

MRI Project 7711-L 

From: Barb Dule tsky £*#> 

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 

on the chromium plating operation at the subject plant and to determine the 

suitability of the plant for-chromium emissions testing. 

II. Place and Date _ . :-s 

r^Z~"Z"7""". • • • 

T&S Brass and Bronze Works i'^\ Z:.,--•••*-• 

Route 4 \\ -

!. 

Old Buncombe Road \\- 7 IAU \ 81991 ''

 j 

Travelers Rest, S.C. 29690 ilZ.M ^ 

(803) 834-4102 i L ~ -•••••••; 

March 7, 1985 > ^p& ^.£zZ~7*:.' ' 

III. Attendees 

T&S Brass and Bronze Works 

Jim Anderson, Vice President of Manufacturing 

Dick Goughnouer, Manufacturing Manager 

Cliff Theisen, Vice President 

Midwest Research Institute (MRI) 

Barb Duletsky 

Charles Hester 

IV. Discussion 

We arrived at the plant at 2:20 p.m. and were escorted to a 

conference room. After discussing the purpose of our visit with the three 

attendees from T&S Brass and Bronze Works (T&S), we were provided with 

general information about the chromium plating operation at the plant. 

/ • 

Principal Laboratories 425 Volker Boulevard, Kansas City, Missouri 64110 
P.M 

Following the discussion, Mr. Goughnouer showed us the chromium plating• 

operation and the associated control device. 

A. General 

T&S is a large faucet manufacturer, competing with companies such as 

American Standard, Kohler, and Crane. T&S has operated the plant in 

Travelers Rest for 7 years, having moved from a previous location in New 

York. 

B. Process 

The decorative plating line consists of a series of dip tanks 

containing nickel plating solution, chromium plating solution, and various 

cleaning and rinsing solutions. The line is serviced by an automatic hoist 

that transfers the racks of faucet parts to each tank in sequence. It 

takes 45 minutes for each rack of parts to complete the plating cycle. The 

plating sequence is staggered so that a rack comes off the line every 5 or 

6 minutes. 

There is one chromium plating tank on the line. The tank measures 

8 feet (ft) in length, 3% ft in width, 5 ft in depth, and holds 

1,000 gallons of plating solution. The solution is composed of a 

proprietary mixture called Chromatex, manufactured by McDermitt. The 

mixture contains a high ratio of chromic acid to sulfuric acid (higher than 

the conventional 100:1 ratio) and a small amount of fluoride. The exact 

proportion of constituents is considered by McDermitt to be a trade 

secret. T&S uses an average of 250 pounds of Chromatex each month. 

Typically, parts remain in the chromium plating tank for 1% minutes, 

receiving a plate thickness of 2 to 2% mil. The temperature of the 

solution is regulated by a steam heating system and is normally maintained 

at 110° to 112°F. The electrodes in the tank are energized by a single 

transformer/rectifier set. Although the voltage and current settings are 

highly variable, the average operating values are 5 volts (V) and 2,400 to 

2,500 amperes (A). During the visit the tank was operating at 3V and 

1,300A. The current required in the tank depends on the total surface area 

of parts to be plated. There is a chart in the plating area that indicates 

the best electrical settings for racks of parts of various shapes. 

C. Control 

T&S uses a demisting agent in the chromium plating solution called 

Fumetrol 205T, which is supplied by M&T Chemicals. The agent creates a 

layer of foam on the surface of the solution to inhibit the release of 

hydrogen gas bubbles. 

The chromium plating tank has two side-draft hoods along the 8-foot 

length of the tank. An induced draft fan draws emissions from the tank 

through a circular duct to a fume scrubber mounted on the roof. The 

scrubber is manufactured by Duall, Model No. 101-F, and has a design gas 

flow rate of 8,000 standard cubic feet per minute (scfm). The flow rate of 
P.15 

the scrubbing liquid through the system is 24 gallons per minute (gpm). 

The treated emissions are exhausted through the fan and a 3-foot high stack 

before exiting to the atmosphere. A diagram of the control system, which 

also treats emissions from a small nickel strip tank, is presented 1n 

Figure 1. A description of the fume scrubber has been supplied by Duall 

Industries, Inc. and is included as Attachment A. 

The fume scrubber was installed when the plant was built in 1978. 

The reason for installing the system was to reduce chromium air emissions 

to a level that would comply with State and local standards. The company 

also installed an extensive wastewater treatment system to treat the 

various types of metal finishing wastes generated at the site. Currently, 

the plant treats the 24 gpm flow of scrubbing water used in the Duall 

scrubbber with the other wastewater from the chromium plating process. 

D. Conclusions 

T&S is a captive plater performing decorative chromium plating of 

nickel-plated brass faucet parts. Emissions from the chromium plating tank 

are controlled by a demisting agent, side draft hoods, and a fume scrubber. 

There were no visible emissions from the scrubber stack the day of the 

visit. Inlet and outlet testing of the scrubber is feasible, however, 

ports would need to be installed. Plant personnel are not opposed to a 

test being performed at this site. Test data from this plant could be used 

to determine both the emissions from an automated decorative chromium 

plating tank controlled by a demisting agent and the performance of a fume 

scrubber in controlling those emissions. 
P.16 

8,000 

scfm 

DUALL 

# 101-F 

SCRUBBER 

y y^y 

DIRECTION 

OF RACKS 

Figure 1. Emissions control system on chromium plating tank. 

* 
P.17 

Attachment A 

r 

T>uaxCC INDUSTRIES 

PVC Constructed, 100% Corrosion Free 

FUME SCRUBBERS 

FW-300 Vertical Pack with Blower 

5 00 TO 12,000 C.f.M. .. plus multiple installations 

This packed tower type scrubber is not only a space saver, 

it's also a true economy model. It incorporates a built-in 

rugged fan with convenient exterior, belt driven, TEFCBB 

motor. During installation, the horizontal air discharge can 

be swivelled 360° before sealing into permanent position. 

Efficiency is equal to the F-101 and the PT-500. Compact-

ness and versatility make it an unusually popular model. 

This FW-300 saves three ways ... in initial cost, installation, 

and in space. Also available with double pack. 

F-101 Horizontal Single Filter Pack 

5 00 TO OVER 60,000 C.F.M. . . plus multiple installations 

Being our most popular scrubber design, this compact 100% 

corrosion resistant P.V.C. unit has proven its efficiency in 

46 states. The Duall F-101 incorporates high efficiency, low 

maintenance filter media and the open orifice type spray 

nozzles, forthe assurance of a thoroughly saturated collection 

chamber. Our mist eliminator outlet section gives four air 

direction changes to properly remove the entrained moisture. 

Where a horizontal installation is preferred, the F-101 should 

be your choice. 

F-101-D Horizontal Double Filter Pack 

5 00 TO OVER 60,000 C.F.M. . . plus multiple installations 

An extra heavy duty scrubber for real "tuffies'7 It incorpo-

rates two filter packs with two sets of sprays for more thorough 

scrubbing . . . plus an effective mist eliminator at the air out-

let. Serious concentrations of rough fumes, such as nitric, 

hydrofluoric, and hydrochloric acid are double scrubbed 

through six stages for maximum efficiency. For such problems in your plant, use this high efficiency fume scrubber, at only a small increase in price. 

PT-500 Vertical Pack 

5 00 TO OVER 30,000 C.F.M. . .plus multiple installations 

The upright PT-500 is the space saver. This scrubber is a 

vertical packed tower type designed to fit into restricted 

spaces where floor space is at a premium. Its efficiency is 

equal to the F-101, and also 100% corrosion-free. Air flow is up through a thoroughly water saturated bed of filter media. 

The mist eliminator pack near the top outlet assures properly 

dried air. If space is your problem, take a good look at the 

PT-500. Also available with double pack. 

T>ua£C 

s. 

INDUSTRIES, INC. 

700 S. McMillan Street, Owosso, Michigan 48867, Ph. (517) 725-8184