p. 1



# OAR Box 1313
Preppedby LaTeiaShed



### Document

Number: 

# 12 ) l-B- 5
Docket Number: 

# A-88-0 2

Printed 6/12/20089:03:27AM

Sheet 12 of 99P. 2

^ | W MIDWES TRESEARC H W MIDWES INSTITUT E X"-6 > - " 5 4 50 5 Creedmoo rRoad

Raleigh , N.C

. 2761 2 Telephon e (919 ) 781-575 0 

# FINA L 

# psL E GOP

Y

Date : Apri l 15 , 198 5

(Finalized : Ma y

20 , 1985 ) Subject : Sit e Visit—Carolin a Plating-Rol l Divisio n

Surve y o f Chromiu m

Emissio nSources—Chromiu m Platin g EP A Contrac t 68-02-3817 ; ESE D Projec t 85/0 2 MR I Projec t 7711- L From : Bar bDuletsk y To : A l 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 o nth e chromiu m

platin g operatio na t thi s plan t an d t o determin e th e suitabilit y

o f thi s plan t fo r chromiu m emission s testing . II . Plac e an d Dat e Carolin a Platin g 441 2 Whit e Hors e Roa d Greenville , Sout hCarolin a 2961 1 (803 ) 269-770 3 Marc h7 , 198 5
III . Attendee s 

## JA N I 8 199 1
Carolin a Plating-Rol l Divisio n[ .!"| : '.4 A;" v I'- •"••" •"- ' ; ' j J . F . Tucker , Vic e Presiden t Le w Walker , Jr. , Vic e Presiden t Midwes t Researc hInstitut e (MRI ) Bar bDuletsk y Charle s Heste r

Principa l Laboratorie s 42 5 Volke rBoulevard

. Kansa s City , Missour i 6411 0P. 3

IV . Discussio n W e arrive da t th e plan t a t 10:4 5 a.m . Th e visi t consiste do f a discussio nabou t chromiu m platin g an

da tou r o f th e chromium platin g an

d meta l finishin g operations . A . Genera l Th e Carolin a Platin g Rol l Divisio ni s a jo bsho pspecializin g i n precisio nfinishin g an drefinishin g o f industria l rolls . Operation s performe da t thi s facilit y includ e har dchromiu m plating , sulfamat e nicke l plating , machining , grinding , an dmirro r finishing . Th e plan t plate s roll s tha t ar e use dprimaril y i nth e pape r manufacturing , roofing , laminating , an dcoatin g industries . Ther e ar e onl y fou r othe r plant s i nth e countr y tha t ar e capabl e o f platin g an dfinishin g roll s wit hth e same degre e o f accurac y tha t i s attaine db

y Carolin a Plating . Thes e companie s ar e locate d i nCalifornia , Connecticut , Ne w Jersey , andIllinois . Althoug hdetail s o f th e finishin g processe s performe da t thi s plan t ar e atypical , th e actua l platin g proces s i s simila r t o tha t a t mos t othe r har dchromium platin g operations . Th e Carolin a Platin g facilit y wa s originall y

buil t i n1971 . Muc ho f th e platin g equipmen t wa s replace di n197 6 afte r a fir e destroye da portio n o f th e plant . Al l o f th e existin g ai r pollutio ncontro l device s wer e installe da t tha t time . Currently , ther e ar e 3 4 full-tim e employees , 9 o f whom ar e responsibl e fo r th e chromiu m platin g process . Th e employee s wor k 1 shif t pe r day , 5 day s pe r week , althoug hth e chromiu m platin g tank s usuall y operat e 2 4 hour s pe r day , 7 day s pe r week . Annua l chromi c aci d consumptio na t th e plan t i s 20,00 0 t o 25,00 0 pounds . B . Proces s Ther e ar e seve nchromiu m platin g tank s a t thi s facility , arrange da s show ni nFigur e 1 . Operatin g specification s fo r eac htan k ar e liste di n Tabl e 1 . Onth e average , th e tank s ar e charge d2 0 hour s pe r day ; approximatel y

4 hour s pe r da y

ar e require dfo r th e change-ove r o f rolls . Tank Nos . 1 , 2 , 3 , an d7 ar e situate dbelow floo r leve l an

dar e oriente dwit hth e longes t dimensio ni nth e vertica l directio nt o accommodat e th e platin g o f larg e rolls . Eac htank i s service db y a n electri c hois t tha t lower s an draise s th e roll s int o an dou t o f th e platin g solution . Inaddition , eac htank i s equippe dwit ha time r whic hallow s platin g operation s t o be complete ddurin g evening s o r weekend s whe nno personne l ar e availabl e t o tur nof f th e electricity . Typica l platin g time s rang e fro

m 1 2 t o 3 6 hour s pe r roll . A typica l rol l measure s 6 t o 1 0 fee t inlengt han

d1 0 t o 1 8 inche s i ndiameter . Afte r plating , th e roll s ar e remove dfro

m th e tank s an

dtransferre dt o th e polishin g an dgrindin g room . Th e othe r thre e tank s ar e oriente dhorizontall y andar e use dt o plat e smalle r rolls , aircraf t engin e pistons , an drotar y

pumps . Tan k Nos . 4P. 4

SULFAMAT E NICKE L PLATING , GRINDING , AN D POLISHIN GARE A EMISSION S DUCTE D T O HEI L FUM E SCRUBBE RO

N FLOORADJACEN T T O TAN K EMISSION S DUCTE D T O HEI L FUME SCRUBBE R O N FLOO RADJACEN T T O TAN K f*~ CONTROLLED EMISSION S DUCTE D T O FA N O N ROO F 

## /NAPC O V , OFFICE S

STORAG E ARE A 

# X OFFICE S

EMISSION S DUCTE D T O KC H FUME SCRUBBE RO

N ROO F

Figur e 1 . Pla nvie w

o f Carolin a Platin g facility .P. 5

Tan k 

### No
.

* 1

* 2

* 3 

### 4 5 6

* 7 TABL E 1
.

Capacity , ga l 1,00 0 2,00 0 3,00 0 

### 34 0 1,00 0 2,40 0 2,40 0 SPECIFICATION S O F HAR D CHROMIU M

A T CAROLIN

APLATIN G

Voltage , V 

### 1 2 1 2 1 0 1 2 1 2 1 2 1 0 Current ,

A 7,00 0 20,00 0 30,00 0 4,00 0 5,00 0 8,00 0 15,00 0 Metho d

o f coolin g 

### Air Wate r Wate r 

### Ai r Ai r Ai r Wate r PLATING TANK S

Constituents , oz/qa l Cr0 3 H2S0 *
3 3 0.3 3 3 3 0.3 3 3 3 0.3 3

—Proprietary* *

—Proprietary* * 3 3 0.3 3 3 3 0.3 3 

### F n



### 0 0 0

—

— 

### 0 0
•Emission s ar e exhauste dt o a commo ncontro l device . ••Platin g solutio ni s sol dt o Carolin a Platin g a s a proprietar y mixtur e tha t contain s som

e fluoride . NOTE : Al l tank s hav e PV C liner s tha t ar e replace dever y 2 t o 3 years .

/
.P. 6

an d5 contai na proprietar y mixtur e o f chromi c aci dan dfluorid e i n solution . Thi s typ e o f platin g solutio ni s mor e efficien t tha n conventiona l solution s i nterm s o f ho w muc helectricit y

i s require dt o deposi t a specifie damoun t o f chromium . Althoug hfluorid e improve s platin g efficiency , ther e ar e drawback s t o usin g fluorid e i nsome platin g applications . Fluoride s hav e a tendenc y t o attac k an

detc hstee l surface s tha t ar e no t properl y masked . Th e roll s plate da t thi s facilit y woul db e ruine di f the y

wer e etche di nthi s way , s o al l expose dstee l surface s ar e carefull y

maske dbefor e th e roll s ar e plate di nthes e solutions . C . Emission s Contro l O f th e electricit y

supplie dt o th e platin g tanks , onl y 1 1 t o 1 7 percen t i s use dt o deposi t chromiu m o nth e rolls . Th e res t i s use dt o generat e hydroge nga s durin g th e reductio no f chromi c acid . I t i s th e hydroge nga s tha t entrain s chromi c aci dparticle s an dcreate s th e visibl e yellow mis t a t th e surfac e o f chromiu m platin g solutions . Th e amoun t o f mis t generate dfrom

a tank i s largel y

dependen t o nth e surfac e are a plate d an dth e amperag e supplie dt o th e tanks . [Mr . Tucke r suggeste dtha t an y regulatio nb e base do nthes e two parameter s a t maximu m operatin g condition s o f th e tank. ] Al l seve ntank s ar e equippe dwit hhood s o nthre e side s fo r emission s capture . Visibl e chromi c aci dmis t wa s observe dt o b e draw nint o th e hood s o neac htank tha t wa s operatin g durin g th e visit . Fo r th e purpos e o f demonstration , th e inductio nfa ntha t draw s mis t from tank Nos . 1 , 2 , 3 , an d7 wa s turne dof f fo r a shor t time . Inles s tha n1 5 seconds , th e yello w mis t hadrise nfro

m th e floo r (topo f platin g tanks ) t o ou r nostrils , causin g a sharp , stingin g sensation . Afte r th e fa nwa s turne dbac k on , th e effect s diminished . A pla nvie w

o f th e exhaus t system fo r tank Nos . 1 , 2 , 3 , an d7 i s show ni nFigur e 2 . A s illustrated , eac hsuccessiv e tank i s ducte dt o a horizonta l circula r duct , whic hin-tur nconnect s t o a squar e duc t (no t shown ) tha t rise s verticall y t o th e contro l device . Ther e i s a straigh t sectio no f ductwor k abou t 5-feet-lon g tha t ha s a 6-inch-diamete r por t i n on e side . Thi s por t i s use doccasionall y fo r directin g emission s fro m a portabl e platin g tan k throug hth e mai ncontro l device . A Dual l mode l No . H-6 6 industria l fa ndraw s emission s fro m th e tank s throug ha fume scrubber . Th e ductwor k betwee nth e scrubbe r an dth e fa ni s divide dint o tw o paralle l section s du e t o physica l constraint s impose db y th e structura l desig no f th e building . A centrifuga l mis t eliminato r downstream o f th e inductio nfa nremove s an y remainin g chromi c aci dmis t fro m th e exhaus t gases . Th e scrubbe r servin g tank Nos . 1 , 2 , 3 , an d7 i s manufacture db y Napco, mode l No . MA-101 , an di s locate do na mezzanin e structur e inth e platin g area . I t i s a we t doubl e packed-be dtyp e scrubbe r wit ha rate d contro l efficienc y

o f 9 9 percent . Mr . Stev e Grenie r fro m Napco , Inc . oversaw th e installatio no f thi s devic e an dha s maile du s som

e informatio n abou t it . Tan k Nos . 4 an d5 ar e equippe dwit hHei l fume scrubbers .



## < rM«* p

I'-i' - flXMCXr

Figur e 1 . Pla nvie w o f exhaus t syste m

o nTan k Nos . 1 , 2 , 3 , an d7 .

^P. 8

Emission s fro

m tank No . 6 ar e controlle db y a positive-pressur e KC H fume scrubber . Th e capita l cos t o f th e fou r scrubber s a t thi s facilit y wa s $53,00 0 i n1976 . Th e contro l systems , includin g scrubbers , fans , hoods , an d ductwork , cos t $3,00 0 t o 4,00 0 annuall y t o maintain . Electricit y t o powe r th e fan s cost s abou t $250/month . Thes e cost s ar e minima l compare dt o th e cost s o f th e entir e platin g system . Approximatel y 8 0 percen t o f th e capita l an

dmaintenanc e cost s an dal l o f th e electricit y cost s woul db e incurre di f onl y

th e ventilatio nsystems (an dno t th e contro l devices ) had bee ninstalled . N

o demistin g agent s ar e use dinth e platin g tank s a t thi s facilit y becaus e o f th e precis e platin g specifications . Muc ho f th e wor k performe dmus t b e accurat e t o withi na fe w mi month s o f a ninch , s o th e platin g solutio nmus t remai nfre e o f chemical s o r plasti c ball s tha t migh t interfer e wit haneve nfinish . D . Existin g Regulation s Mr . Tucke r provide dsome permi t informatio no nth e Napc o fum e scrubber , whic hi s include da s Attachmen t A . Th e Stat e emissio n limitation s fo r stac k discharg e ar e < 3 pounds/hou r fo r tota l suspende d particulat e matte r an d< 3 pounds/hou r fo r chromi c acid . Soo nafte r th e Napc o scrubbe r wa s installed , th e Sout hCarolin a Departmen t o f Healt han d Environmenta l Contro l (DHEC ) performe da stac k tes t o ni t t o determin e compliance . Mr . Claud e Mille r o f DHEC , Greenville , Sout hCarolina , i s th e perso nt o contac t fo r th e result s o f thi s test . (Mr . Mille r wa s contacte d fo r thi s information , bu t he sai dth e complianc e tes t consiste donl y o f visibl e emission s observations. ]
Mr . Tucke r als o provide dth e result s o f tw o test s fo r employe e exposur e t o variou s ai r pollutants . Thes e results ar e include da s Attachmen t B . Th e 8-hou r permissibl e exposur e limi t (time-weighte d average ) i s 0. 1 mg/m ^ fo r chromi c acid . Accordin g t o th e results , th e employee s teste da t Carolin a Platin g wer e expose dt o concentration s substantiall y

below th e permissibl e limit . E . Conclusion s Carolin a Platin g i s a medium-size djo bshopinvolve dinhar dchromiu m plating . Th e tank s a t thi s facilit y appea r t o hav e effectiv e emissio n captur e an

dcontro l systems . Th e Napc o scrubbe r controllin g emission s fro m tank Nos . 1 , 2 , 3 , an d7 a t thi s plan t i s a goo dcandidat e fo r testin g because : (a ) operatio no f th e platin g tank s i s a relativel y steady-stat e process , (b ) parameter s suc ha s surfac e are a plate dan damoun t o f chromiu

m deposite dar e eas y

t o calculate , an

d(c ) ther e i s a tes t por t alread y in plac e a t th e scrubbe r inlet . Emission s testin g a t th e scrubbe r outle t i s complicate db

y th e fac t tha t th e ductwor k betwee nth e scrubbe r an dth e fa n i s divided , althoughMr . Grenie r o f Napco , Incorporated , sai dtha t i t woul d b e saf e t o assume tha t th e flow i s evenl y

divide dbetwee nth e tw o ducts . 2 Attachment s


# 7-" - —' —P Q

Attachmen tA , k , , ATTAC H ADDITIONA L SHEET S I F NEEDE D T O PROVII&roB*^ ^ INFORMATIO N PROCES S PERMIT APPLICATIO N • Permi tNo . 1 . Permi tt o b e issue d to ; CAROLINA PLATIN G CO . - ROL L DIVISIO N 2 . Mailin g Address : P O BO X 1387 . GREENVILLE . S.C . 2960 2 3 . Facilit y Locatio m ^1 2 WHITE HORS E ROA D County : GREENVILL E 4 . Perso n t o contact : LEWI S M . WALKE RI I - Phon e no : 269-770 3 5 . Permi trequire d for : XConstructio nOperatio no f existin g sourc e v Alteratio n(construetibnbegu no n o r befor e February 1 11 , 1971 ) O 6 . Constructio nstar t date:JV^ / if-7 7 Completio ndate : f-t=T ? / f 78
• P 7 . A . Majo r ra w materials : yype : Quantit y used : (lbs/hr ) B . Product : HAR

D CHROMIU

M PLATIN G Rat e o f production : VAg.rf-yo.l-g : 8 . Proces s 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. , Uni t#4 ) 9 . Ai rPollutio n Contro l Devic e Description : /U/tffc o t^A-ldl /HE . -SCHeugggfe - U/i77 V 'DiifrU^ PP. GC

&.kHAOS7~ BLQi^GlL I.D . no.(e.g. , Uni t#4 ) uu i f /uo . I 10 . Stac k Data : Heigh tfro m groun d (ft ) 33 f Velocit y (ft/sec)_£[2L 1 3 Insid e diamete r(ft ) 2,g 7 Temperatur e (F ) 7*3 * (/\-/^Qi€^fl~^ 11 . Emissio n Data : (pounds/hr ) uncontrolle dcontrolle duncontrolle dcontrolle d Particulat e -• NO x/^/h Hydrocarbon s (specify ) C O /OA N A S0 2 /QA Othe r (specify ) H2SQ 4 A)A . CfcQ- 3 ,060000*? / ."? 12 . Norma l Operatio nSchedule : hr/da y JL.9 day/wee k "/

week/yea r XT-^~ Seasona l Variation : Jan.-Mar . 6 % Ap r .-Jun e * 3 % July-Sept , a * Oct.-Dec , o % j P 13 . How

wil l wast e materia l fro m proces s and contro l equipmen t b e dispose dof ? E^(^l.U€tST' 

### ooiu. Esf

cs&rrzjetx-

C.L><T~/AJ



### g<ssg-/a</<s*//g

. TA-*J£. AK>O 

### ^.^cL^if^^c. 14 . Includ e the followin g information- : " A . Plo t pla n(sho w distanc e t o neares t residence , business , etc. ) B . Flow

diagram

o f proces s t o b e permitte d(indicat e an d identif y

emissio npoints ) ^ C , Suppl y

al l technica l dat a availabl e fro m vendo r (make , model , desig ncriteria ) I certif y

that , t o the bes t o f m y knowledg e and belie f tha t n o undesirabl e level s wil l b e create dand n o applicabl e standard s o r regulation s wil l b e contravene do r violated . I understan dtha t any statement s and description s whic har e foundt o b e incorrec t ma y

b e th e caus e fo r immediat e revocatio no f an y permi t pursuan t t o thi s application . LEWI S M . WALKE R^ . PRESIDEN T Signatur e o f responsibl e perso no r compan y offica l an

d titl e

Dat e

White/Ai r Qualit y

Centra l Offic e Yellow/DHE C Distric t Offic e Pink/Applican t 7/7 7

—»_

_- m'i^^marmmmmmilwi^^ismstMaKm^MJ!Xf3BSlBSIsrlX3i ......-.v e « . :*•..?;_ #P.1 0



### Carolin a Plating Compan y CONDITION S FO

R PERMI T NUMBER : 1200-009 2 DAT E O F ISSUE : Octobe r 15 , 198 4

pag e 2

II
. SPECIA

L CONDITION S A
. EMISSIO

NLIMITATION S Ai r pollutan t emission s shal l no t excee d the following I D No
. Pollutan t Emissio n Limitatio n 0 1 TS P Les s than 3 lbs/hr . 0 1 Chromi c aci d Les s than 3 lbs/hr

The abov e emissio n limitation s ar e base d o n operatio n a t rated capacity
. Operatio n a t othe r than rate d capacit ymus t mee t th e emissio n limit s specifie d i

n the applicabl e regulation s base d o n tha t operating rate
. The TS P an d SO ~ limit s for th e plan t ma yb e se t lowe r than the stat e emissio n limit: : show

n above , i f necessaryt o preven t a PS D incremen t o r NAAQ S violation
. Suc h sourc e specifi c emissio n limit s can be onl ydetermine d o n a case-by-cas e basis
. P
. CONTINUOU S MONITORIN G REQUIREMENT S I D No
. Pollutan t N/ A

SOURC E TSS T SCHEDUL E I D Nc
. Pollutan t Frequenc y N/ A

ADDITIONAL CONDITION S I D NO
. N/ A

• ; o deviatio n fro

mthe plan s an

d specification s submitte d wit h your applicatio n o r the condition s specifie d herei n i s permitted , unles s authorize d in writing b ythe Burea u o f &i r Qualit yControl
. Th e owner / operato r i s responsibl e fo r satisfactorycomplianc e wit h al l Ai r Pollutio n Reaulation s an

d Standards
.P.1 1

Attachment* B "*--

• ngineen'n g ^•STRIAL-HyGiFj-t- E ANAI7/S! S REPOR T UALYSI S NO

. 411-8 0 (4-4 ) CHEMICA L AN D ENVIRONMENTA L SERVICE S UNI T, Carolina Plating Co. , Inc . Greenville , S.C . E SEN T B

Y H

. Mclntir e DAT E RECEIVE D 3-14-8 0 DA* * MFMTt B

3-22-8 0 ANALYS T TSS ; JA C <%{^ IA L ANALYZE D PV C Filters ; H

A Filter s SAMPL E NUMBE R LOCATIO N TES T RESULT S TIME-WEICHTE D AVERAG E HYGIENI C STANDARD S 829 E

40J X

845 E

830 E Chrom

e Plat e Area-Jerr

y Smit h

N i Plat e Area-Mik e Andrusk i

Chrom e Plat e Area-Jerry Smit h

Chrom e Plat e Area-Jerry " Smit h Chromiu m V I Les s than 0.00 4 mg/n P Nicke l 0.0 1 mg/m ?

Chromiu m VI ' Les s than 0.01 8 mg/m 5 Chromiu m VI " Les s than 0.01 9 mg/m 5 

### K

0.00 3 mg/m 3

0.007 5 rag/m^ Chromi c Aci d

(a s CRVI ) 0.0 5 mg/m * Nickel/Meta l & Insolubl e Crapd

s (as Ni ) 1 mg/m 5 Chromi c Aci d * a C r V I 0. 3 mg/nr Nickel , Meta l & insolubl e Cmpds . 4 (a s Ni) 3 3 mg/m- 3

NALYTICA

L METHOD S Colorimetr

y Atomi c Absorption SPECIA L NOTE S
•ExcursionYalu e

EF1NITIO N O F TERM S Time-Weighte d Averag e (TWA ) - Th e employee' s exposur e average d ove r 8 hour s pe r da y o r 4 0 hour s pe r wee k usin g thi s equation : TW A equivalen t = ( c l ) Cl ) + ( c 2 ) ( T 2 ) + .. . (C n ) ( T n ) ; wher e C = concentratio n measured
. 8~hr s "" " = du

ra -i ot -i i n hours , o f exposur e a t concentratio n C
. Th e TW A evaluation s o f thi s repor t ar e base d o n th e exposur e tim e give n o n th e correspondin g "Industria l Hygien e Surve y Dat a Sheet. "

•Ceilin g limi t (designate d by a "C " i n fron t o f th e Hygieni c Standard ) - Thi s i s a maximu m allowabl e concentratio n whic h shoul d neve r b e exceeded
. Excursio n limi t - Thi s limi t define s th e maximu m concentratio n o f contaminan t t o whic h o n employe e co n b e expose d fo r a shor t perio d o f time
. Hygieni c standar d i s th e applicabl e allowabl e leve l i n air , suc h a s th e TL V o r PE L (permissibl e exposur e limit)
.

-1544 9 REV
. 6-7 9 PHiNTtc"i N U.S.A
. TRAVELER S INSURANC E COMf-'ANIE S HARTFORD,CONNECTICU T /DP.1 2

S . C . DEPARTMEN T O F LABO R DIVISIO N O F OS H CONSULTATIO N CONSULTATIV E INSPECTION FINDING S

.N8R . 00 8 OC . NBR . 00 8 ivit y Date : Septembe r 11 , 198 2 FY8 3 Pag e _2

_ o f _3

_

Descriptio no f Allege dViolatio nan dRecommendatio nfor Correctio n Abatemen t Dat e I nadditio nt o th e note dviolations , th e followin g informatio ni s provide d concernin g th e occupationa l healt hcourtes y Inspectio no f Augus t 1 1 an d12 , an

d Septembe r 9 , 1982 : Thi s courtes y

inspectio ninclude dth e monitorin g o f employe e exposure s t o possibl e ai r contaminant s an dnois e levels . Ai r samplin g wa s conducte do nAugust 1 2 andSeptembe r 9 t o determin e employe e exposure s t o chromi c aci di nth e larg e an

dth e smal l platin g rooms , t o nicke l i nth e nicke l platin g room , t o sodiu m hydroxid e 1nth e larg e platin g room , an d t o nuisanc e dus t (aluminu m oxide ) i nth e gri t blastin g area . Laborator y analyse s indicate dth e followin g time weighte daverag e (T.W.A. ) exposures :

EMPLOYE E Dea nSheale y Tony Brow n LeighVein o Stev e Riddl e Joh nChandle r Jerr y Smit h Are a Sampl e ARE A

Larg e Platin g Larg e Platin g Smal l Platin g Smal l Platin g Nicke l Platin g Gri t Blastin g Larg e Platin g MATERIA L

Roo m Chromi c Aci d Room Chromi c Ad d Roo m Chromi c Aci d Room Chromi c Aci d Roo m Nicke l Nuisanc e Dus t Roo m Sodiu

m Hydroxid e T.W.A .

EXPOSUR E .0000 8 Mg/M 3 .00 2 Mg/M 3 .0000 2 Mg/M 3 .0000 4 Mg/M 3 Nothin g detecte d

. 8 Mg/M 3

. 2 Mg/M 3 Th e 8 hou r T.W.A . permissibl e exposur e limit s fo r thes e materials , a s listedi

nTabl e Z-l , Z-2 , an dZ- 3 o f sectio n1910.1000 , are : MATERIA L Chromi c Aci d Nicke l Sodiu m Hydroxid e Nuisanc e Dus t PERMISSIBL E EXPOSUR E LIMI T

. 1 Mg/M 3 1 Mg/M 3 2 Mg/M 3 1 5 Mg/M 3 The samplin g result s indicat e tha t exposure s t o thes e material s ar e wel l below the permissibl e exposur e limits . A nois e surve y

wa s conducte do nSeptembe r 9 t o determin e employe e exposure s to nois e a

t th e gri t blastin g machin e an dth e polishin g machine . _ A Typ e II , Genera l Radi o soun dleve l mete r wa s use dt o measur e nois e level s an d zr. verif y

dosimete r readings . Actua l employe e nois e exposure s wer e monitore d using Genera l Radi o audi o dosimeters , mode l #1954-9710 , se t o na noperatin g rang e o f 80-13 0 dBa . Th e dosimeter s indicate dth e followin g nois e exposures : / /P.1 3 

# Rl® A-88-0 2 MIDWES TRESEARC H INSTITUT E

* X - £>-L | 4505 Creedmoo rRoad

Raleigh , N.C

. 2761 2 Telephon e (919 ) 781-575 0 

# FIL E COP Y

Date : Marc

h 29 , 198 5 

# FINA L (Finalize dApri l 19 , 1985 ) Subj'ect : Sit e Visit—T& S Bras s an dBronz e Work s Surve y o f Chromiu

m Emissio nSources—Chromiu m Platin g EPA Contrac t 68-02-3817 ; ESE DProjec t 85/0 2 MR I Projec t 7711- L From : Bar bDul e 

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£*# > 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 o nthe chromiu

m platin g operatio na t th e subjec t plan t an dt o determin e th e suitabilit y

o f th e plan t for-chromiu m emission s testing . II . Plac e an

dDat e _. : 

### - s r^Z~"Z"7""" . • • • 

### T& S Bras s an

dBronz e Work s i'^ \ Z:.,--•••*- • Rout e 4 \\ - ! 

### . Ol dBuncomb e Road\\- 7 IA U\ 8199 1 ' ' j 

### Traveler s Rest , S.C . 2969 0 i l

### Z. M ^ (803 ) 834-410 2 i L ~ -••••••• ; Marc h7 , 198 5 > ^p& ^.£zZ~7*:. ' ' III . Attendee s T& S Bras s andBronz e Work s Ji m Anderson , Vic e Presiden t o f Manufacturin g Dic kGoughnouer , Manufacturin g Manage r Clif f Theisen , Vic e Presiden t Midwes t Researc hInstitut e (MRI ) Bar bDuletsk y Charle s Heste r IV . Discussio n We arrive da t th e plan t a t 2:2 0 p.m . an dwer e escorte dt o a conferenc e room . Afte r discussin g th e purpos e o f ou r visi t wit hth e thre e attendee s fro

m T& S Bras s an

dBronz e Work s (T&S) , we wer e provide dwit h genera l informatio nabou t th e chromiu m platin g operatio na t th e plant .

/ • Principa l Laboratorie s 425 Volke rBoulevard , Kansa s City , Missour i 6411 0P. M

Followin g th e discussion , Mr . Goughnoue r showe du s th e chromiu m plating • operatio nan

dth e associate dcontro l device . A . Genera l
T& S i s a larg e fauce t manufacturer , competin g wit hcompanie s suc ha s America nStandard , Kohler , an dCrane . T& S ha s operate dth e plan t i n Traveler s Res t fo r 7 years , havin g move dfro m a previou s locatio ni nNew York . B . Proces s Th e decorativ e platin g lin e consist s o f a serie s o f di ptank s containin g nicke l platin g solution , chromiu m platin g solution , an dvariou s cleanin g an

drinsin g solutions . Th e lin e i s service db y anautomati c hois t tha t transfer s th e rack s o f fauce t part s t o eac htan k i nsequence . I t take s 4 5 minute s fo r eac hrac k o f part s t o complet e th e platin g cycle . Th e platin g sequenc e i s staggere ds o tha t a rac k come s of f th e lin e ever y 5 o r 6 minutes . Ther e i s on e chromiu m platin g tank o nth e line . Th e tan k measure s 8 fee t (ft ) i nlength , 3 % f t i nwidth , 5 f t i ndepth , an dhold s 1,00 0 gallon s o f platin g solution . Th e solutio ni s compose do f a proprietar y

mixtur e calle dChromatex , manufacture db y McDermitt . Th e mixtur e contain s a highrati o o f chromi c aci dt o sulfuri c aci d(highe r tha n th e conventiona l 100: 1 ratio ) an da smal l amoun t o f fluoride . Th e exac t proportio no f constituent s i s considere db y McDermit t t o b e a trad e secret . T& S use s a naverag e o f 25 0 pound s o f Chromate xeac hmonth . Typically , part s remai ni nth e chromiu m platin g tank fo r 1 % minutes , receivin g a plat e thicknes s o f 2 t o 2 % mil . Th e temperatur e o f th e solutio ni s regulate db y a stea m heatin g syste

m an di s normall y

maintaine d a t 110 ° t o 112°F . Th e electrode s i nth e tank ar e energize db y a singl e transformer/rectifie r set . Althoug hth e voltag e an dcurren t setting s ar e highl y variable , th e averag e operatin g value s ar e 5 volt s (V ) an d2,40 0 t o 2,50 0 ampere s (A) . Durin g th e visi t th e tank wa s operatin g a t 3 V an d 1,300A . Th e curren t require di nth e tank depend s o nth e tota l surfac e are a o f part s t o b e plated . Ther e i s a char t i nth e platin g are a tha t indicate s th e bes t electrica l setting s fo r rack s o f part s o f variou s shapes . C . Contro l T& S use s a demistin g agen t i nth e chromiu m platin g solutio ncalle d Fumetro l 205T , whic hi s supplie db y M& T Chemicals . Th e agen t create s a laye r o f foa

m o nth e surfac e o f th e solutio nt o inhibi t th e releas e o f hydroge nga s bubbles . Th e chromiu

m platin g tank ha s tw o side-draf t hood s alon g th e 8-foo t lengt ho f th e tank . A ninduce ddraf t fandraw s emission s fro m th e tan

k throug ha circula r duc t t o a fume scrubbe r mounte do nth e roof . Th e scrubbe r i s manufacture db y Duall , Mode l No . 101-F , an dha s a desig nga s flow rat e o f 8,00 0 standar dcubi c fee t pe r minut e (scfm) . Th e flo w rat e o fP.1 5

th e scrubbin g liqui dthroug hth e system i s 2 4 gallon s pe r minut e (gpm) . Th e treate demission s ar e exhauste dthroug hth e fa nan da 3-foo t hig hstac k befor e exitin g t o th e atmosphere . A diagram

o f th e contro l system , whic h als o treat s emission s fro m a smal l nicke l stri ptank , i s presente d1 n Figur e 1 . A

descriptio no f th e fume scrubbe r ha s bee nsupplie db y Dual l Industries , Inc . an

di s include da s Attachmen t A . Th e fume scrubbe r wa s installe dwhe nth e plan t wa s buil t i n1978 . Th e reaso nfo r installin g th e system wa s t o reduc e chromiu m ai r emission s t o a leve l tha t woul dcompl y wit hStat e an

dloca l standards . Th e company als o installe da nextensiv e wastewate r treatmen t syste m t o trea t th e variou s type s o f meta l finishin g waste s generate da t th e site . Currently , th e plan t treat s th e 2 4 gp m flow o f scrubbin g wate r use di nth e Dual l scrubbber wit hth e othe r wastewate r fro m th e chromiu

m platin g process . D . Conclusion s T& S i s a captiv e plate r performin g decorativ e chromiu m platin g o f nickel-plate dbras s fauce t parts . Emission s fro m th e chromiu

m platin g tank ar e controlle db

y a demistin g agent , sid e draf t hoods , an da fume scrubber . Ther e wer e no visibl e emission s fro m th e scrubbe r stac k th e da y o f th e visit . Inle t an

doutle t testin g o f th e scrubbe r i s feasible , however , port s woul dnee dt o b e installed . Plan t personne l ar e no t oppose dt o a tes t bein g performe da t thi s site . Tes t dat a fro m thi s plan t coul db e use d t o determin e bot hth e emission s fro m a nautomate ddecorativ e chromiu m platin g tank controlle db y a demistin g agen t an dth e performanc e o f a fume scrubbe r incontrollin g thos e emissions .P.1 6

8,00 0 scf m DUAL L

# 101- F SCRUBBE R



### y y^y

DIRECTIO N O F RACK S

Figur e 1 . Emission s contro l system o nchromiu

m platin g tank .

*P.1 7 Attachmen t A

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