p. 1



# OAR Box 

# 1313
Prepped by LaTeia Shed



### Document

Number: 

# 66 ) ll-B-4 0
Docket Number: 

# A-88-0 2

Printed 6/12/20089:03:30A M

Sheet 66 of 99P. 2 

# MRI ® MIDWES TRESEARC H INSTITUT E Suite . , * : -0 1 Harriso n Oak

s Boulev- n Gary
. NC
. 27 ? 1 

## A-88-0 2

Date : Ma

y 19 , 198 8 (Finalize dJun e 30 , 1988 ) Subject : Sit e Visit—Sac o Defens e Inc. , Saco , Main e

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 : Randy

Strai t
To : Andre w

Smit h ESD/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 evaluat e th e singl e packed-be d horizontal-flo w

scrubbe r use dt o contro l chromium emission s fro

m thre e hardchromiu

m platin g tanks . Th e scrubbe r system i s bein g considere da s a candidat e fo r emissio ntestin g t o determin e th e exten t t o whic h reconditionin g ca nimprov e scrubbe r performance . II . Plac e an

d Dat e
Sac o Defens e Inc . 29 1 Nort hStree t Saco , Main e 0407 2 Januar y 25 , 198 8 (207 ) 283-361 1
III . Attendee s
Sac o Defens e Inc . Rober t Daigle , Manager , Manufacturin g Service s Rober t Noonan , Senio r Environmenta l Enginee r Midwes t Researc hInstitut e Rand y Strai t

/P. 3

IV
. Discussio n Th e visi t began wit h a discussio n abou t EPA' s emissio n tes t progra m an d th e captur e an

d contro l equipmen t use d t o contro l chromiu memission s fro mth e hard chromiu

melectroplatin g tank s a t th e plant
. Th e discussio n wa s followe d b

ya tour o f th e plating shop an d a n evaluatio n o f th e captur e an

d contro l equipment

. A
. Genera l
Sac o Defens e Inc. , i s a larg e captiv e sho p tha t manufacture s militaryartillery

. Th e plan t operate s 1 8 har d chromiu

mplating tanks
. Tank s 2 2 through 2 4 ar e controlle d b ya singl e packed-be d horizontal-flo w scrubber ; Tank s 3 3 through 3 6 ar e controlle d b ya vertical-flo w packed-be d scrubber ; an

d Tank s 1 through 4 , Tank s 1 0 an d 11 , an

d Tank s 2 5 through 2 9 ar e controlle d b

ythre e separat e horizontal-flo w scrubbers
. Th e focu s o f th e visi t wa s th e singl e packed-be d horizontal-flo w scrubbe r use d t o contro l emission s fro mTank s 2 2 throug

h 24
. I t i s the onl yhorizontal-flo w packed-be d scrubber s a t the plant
. Detaile d informatio n o n Tank s 2 2 through 2 4 an d th e singl e packed-be d scrubbe r i s presente d below
. Genera l informatio n o n th e othe r fou r scrubber s use d a t th e plan t i s presente d i n Sectio n F o f thi s report
. B
. Proces s Informatio n Tank s 22 , 23 , an

d 2 4 ar e use d t o deposi t chromiu mo n th e insid e surfac e o f artiller ygu n barrels
. Base d o n operating parameter s suc h a s current , voltage , chromi c aci d concentration , an d plating time , th e plating tank s appea r t o b e typica l o f othe r hard chromiu mplatin g tank s i n th e electroplatin g industry

. Eac h tan k i s 2. 4 meter s (m ) (8. 0 fee t [ft] ) long , 0. 6 m(2. 0 ft ) wide , an d 1. 3 m(4. 2 ft ) dee p an d hold s abou t 1,70 0 liter s (45 0 gallons ) o f plating solution

. The plating solutio n contain s 24 7 gram s o f chromi c aci d pe r lite r (3 3 ounce s pe r gallon ) o f solution

. Th e temperatur e o f th e plating solutio n i s maintaine d a t 60° C (140°F)
. Eac h tan

k i s equippe d wit h on e rectifie r wit h maximu mrating s o f 1 2 volt s an

d 3,00 0 amperes . Typically , 2 0 barrel s ar e plate d a t a time in each tan

k a t 2,00 0 ampere s fo r 3. 5 hours
. Each tan k i s operate d abou t 2 0 hour s pe r day , 5 day s pe r week , 5 0 week s pe r year . C
. Emissio n Contro l Figur e 1 i s a plan vie w o f the captur e an d contro l systemfo r Tank s 22 , 23 , an

d 24
. Al l thre e tank s ar e equippe d wit h push-pul l captur e systems
. Tank s 2 3 an d 2 4 wer e no t operating durin g the visit

. I

n addition , plan t personne l ha d turned of f the push-ai r sid e o f the captur e syste mo n Tan

k 2 2 becaus e th e pus h ai r forced chromi c aci d mis t int o th e roo mair

. Plan t personne l speculate d tha t th e push ai r wa s no t being draw n through the pul l sid e o f the hood eithe r becaus e o f interferenc e produce d b

yth e par t rack s in the tan k and/o r becaus e o f a potentia l defici t in makeu

p air

. Eve n wit h the ai r curtai n syste moffline , no visibl e emission s wer e observe d escaping the captur e syste mo n Tan

k 2 2 durin g th e visit

.

<£,

# T j

8 FT 1 

# J 8 T
8 F T 

# i T !
8 F T 

# l ! A TRN K 2 2 

# y

TAN K 2 3

TRN K 2 4

RINS E TRN K 

# T : •^ 1 

## DURL L SINGL E PRCKED-BE D SCRUBBE R STAC K

RECIRCULATIO N PIP E

DUC TDIMENSION S R T SEGMEN TR

—LENGT H ~ 8 FT
.

—DIAMETE R —2. 5 FT
.

LEGEND : RI R FLO U URL L

Fiyur e 1

. Pla n vie wo f captur e an d contro l syste m fo rhar d chromiu m platin g Tank s 22 , 23 , an d 2 4 a t Sac o Defense

.



### lm 

## E

## ROO F

DUC T FRO M PLR T IN G TANK S ~ 

# -

£

^ : ^ 

## DUAL

L SINGLE PACKED-BE D SCRUBBE R STAC K (DIflnETE R rv

2. 5 FT )

I B F T



### MEZZANIN E RECIRCULATIO N PIP E •SID E RAI L

2 8 F T LEGEND : R I R FLO U 

### <—URLL (VERTICAL )

M FLOO R
Figur e 2

. Sid e vie wo f singl e packed-be d scrubbe rfo rhar d chromiu m platin g

Tank s 22 , 23 , an d 2

4 a t Sac

o Defense

.

^ * • inP. 6

Chromi c aci demission s fro m th e plating tank s ar e vente dt o a singl e packed-be dhorizontal-flo w scrubber . Th e scrubbe r an dfa nar e locate do na mezzanin e ina room

nex t t o th e plating sho p(se e Figur e 2) . Th e scrubbe r exhaus t i s discharge dthroug ha stac k inth e roof . Th e scrubbe r wa s manufacture db y Dual l Industries , Inc. , (Duall ) an d installe di n1971 . Th e scrubbe r i s designe dfo r anairflo w rat e o f 34 0 cubi c meter s pe r minut e (12,00 0 cubi c fee t pe r minute ) an da pressur e dro po f 0. 5 kilopasca l (2. 0 inche s o f wate r column) . Th e packe dbe di s abou t 0. 3 m

(1. 0 ft ) indepth , 1. 6 m (5. 3 ft ) i nheight , an d1. 7 m (5. 5 ft ) inwidth . Th e desig nfac e velocit y o f th e airflo w

throug hth e packe dbedi s 12 5 meter s pe r minut e (m/min ) (41 0 fee t pe r minut e [ft/min]) . Th e packin g medi a use dinth e packe dbe dwa s manufacture db y Protak . Th e packin g medi a i s mad e o f polypropylen e an dconsist s o f thre e concentri c circle s tha t for m a sphere . Eac hspher e i s 6.3 5 centimeter s (2. 5 inches ) i ndiameter . Th e packin g medi a ha s a surfac e area-to-volum e rati o o f 12 8 squar e meter s pe r cubi c mete r (3 9 squar e fee t pe r cubi c foot ) an da voi dspac e o f 90. 6 percent . A chevron-blad e mis t eliminato r wit ha singl e se t o f overlapping typ e blade s i s installe ddownstrea m o f th e packe dbed . Th e mis t eliminatio nsectio ni s abou t 0.2 0 m (0.6 7 ft ) i ndepth , 1. 6 m (5. 3 ft ) in height , an

d1. 6 m (5. 3 ft ) inwidth . Th e desig nfac e velocit y o f th e airflo w throug hth e mis t eliminatio nsectio ni s 13 0 m/mi n(43 0 ft/min) . Th e scrubbe r i s equippe dwit hfou r spra y nozzle s locate da t th e inle t o f th e scrubbe r an dfou r spra y

nozzle s tha t ar e locate dove r th e to p o f th e packe dbed . Th e desig nwate r flo w rat e t o th e scrubbe r i s 13 2 liter s pe r minut e (3 5 gallon s pe r minute) . Th e scrubbe r wate r i s pumpe dthroug hth e spra y nozzles , draine dt o a rins e tank , an d recirculate dcontinuousl y t o th e scrubber . Th e chromi c aci dconcentratio n o f th e scrubbe r wate r i s abou t 1. 1 gram s pe r lite r (0.1 5 ounc e pe r gallon) . Al l fou r o f th e spra y nozzle s a t th e inle t ar e partiall y plugged , an dno wate r wa s bein g pumpe dt o th e spray nozzle s locate dove r th e packe d bed . I naddition , ther e i s buildu po f chromi c aci donth e packin g media , insid e walls , an

dmis t eliminatio nsectio no f th e scrubber . Th e fram e holding the packin g medi a i s warped . Thi s warpin g ha s allowe dth e packin g medi a t o settle , leavin g a nempt y spac e betwee nth e topo f th e scrubbe r an dth e packin g media . Consequently , a portio no f th e ai r stream wa s passin g over , rathe r tha nthrough , the packin g medi a i nth e packe dbed . Dual l ha s indicate dtha t warpin g o f th e fram e o f th e packe dbedi s no t unusua l fo r unit s tha t hav e bee noperate dfo r severa l years . Warping o f th e packed-be dfram e typicall y occur s whe nth e strand s o f polypropylen e tha t ti e the wall s o f th e packe dbedtogethe r brea k du e t o wear . Oual l ha s agree dt o inspec t th e scrubbe r an dperform

an y maintenanc e neede dt o ensur e tha t th e scrubbe r i s operatin g accordin g t o desig nspecification s befor e an

y testin g i s performed . [Note : A Dual l fiel drepresentativ e inspecte dth e scrubbe r onMarc h31 , 1988 . Result s o f th e inspectio nar e summarize di na tri prepor t date dMarc h31 , 198 8 (attached)] .



### ^TP. 7

D . Availabilit y

o f Tes t Location s Ther e appear s t o b e sufficien t lengt ho f straigh t ductwor k betwee n th e exhaus t plenu

m o ntank No . 2 2 an

dth e scrubbe r t o allo w fo r inle t testing . Th e ductwor k i s abou t 2. 4 m (8. 0 ft ) i nlengt han d0.7 6 m (2. 5 ft ) indiameter . Outle t testin g ca nb e performe dinth e stac k locate donth e roo f o f th e plant . However , a stac k extensio nma y nee dt o b e installed . E . Conclusion s Th e scrubbe r use dt o contro l emission s from Tank s 22 , 23 , an

d2 4 i s a goo dcandidat e fo r emissio ntestin g fo r th e followin g reasons : (1 ) operatin g parameter s o f th e platin g tank s ar e withi nth e range s typica l o f har dchromium platin g tanks , (2 ) th e typ e andamoun t o f wor k plate dwil l generat e a nemission s loadin g suitabl e fo r testing , (3 ) th e scrubbe r desig ni s representativ e o f th e packed-be dhorizontal-flo w scrubbe r design s previousl y tested , (4 ) ther e appear s t o b e a suitabl e locatio nfo r testin g a t th e inle t o f th e scrubber , an d(5 ) th e scrubbe r i s a use duni t tha t ca nb e teste dt o determin e th e exten t t o whic hcleanin g ca nimprov e scrubbe r performance . Th e effectivenes s o f the captur e system s o nth e tank s andth e operatin g conditio no f th e scrubbe r wil l nee dfurthe r evaluatio nbefor e a fina l decisio nca nb e mad e o nwhethe r t o tes t th e scrubber . Plan t personne l hav e hire da nindustria l hygien e consultan t t o evaluat e th e effectivenes s o f th e captur e system s o nth e tank s andwil l reques t Dual l t o evaluat e th e operatin g conditio no f th e scrubber . Evaluation s o f th e captur e system s an

dscrubbe r ar e expecte dt o b e complete dwithi n2 months . Sac o Defens e Inc. , personne l wer e ver y cooperativ e durin g th e visi t an dar e willin g t o allo w EPA t o tes t th e scrubber . Plan t personne l indicate dtha t the y

woul dhav e th e ventilatio nsystem inspecte dan

d balance dt o ensur e tha t th e ventilatio nsystem complie s wit hindustria l ventilatio nguideline s fo r chromiu m platin g tank s prio r t o an y emissio n testing . I f selecte dfo r testing , plan t personne l als o hav e agree dt o hir e Dual l t o reconditio nth e scrubber . Th e plan t ha s offere dt o provid e a hois t fo r tes t cre w acces s t o th e scrubbe r inle t ductwor k durin g th e test . F . Additiona l Informatio n Th e manufacture r o f th e vertical-flo w packed-be dscrubbe r use dt o contro l emission s fro m Tank s 3 3 throug h3 6 i s unknown . Th e duc t lengt ha t the inle t o f the scrubbe r i s no t adequat e fo r conductin g inle t testing . Th e thre e horizontal-flo w scrubber s tha t ar e use dt o contro l emission s fro

m Tank s 1 throug h4 , Tank s 1 0 an d11 , an

dTank s 2 5 throug h2 9 ar e ol dunit s tha t wer e manufacture db y CRECO , Inc. , Owosso , Michigan . CREC O refer s t o thei r scrubber s a s "ai r washers. " A produc t informatio n brochur e fo r th e ai r washe r i s presente di nAttachmen t 2 o f thi s report . Eacho f th e ai r washer s a t the plan t contain s fou r filte r pad s tha t ar eP. 8

abou t 1 5 centimeter s ( 6 inches ) i ndepth . Eac hfilte r pa di s a polyvinyl chlorid e fram e tha t i s wrappe dwit hon e laye r o f wove nmes hmad e o f polypropylene . Th e filte r pad s inth e ai r washer s a t th e plan t wer e empty ; the y

wer e no t fille dwit hpackin g media . Wate r spra y system s ar e locate do nbot hside s o f th e firs t filte r pad . Chromi c aci dmis t i nth e ventilatio nai r i s wette db y th e spra y

system s an

dthe nimpinge s o nth e wove nmes ha s th e ventilatio nai r passe s throug hth e filte r pads . 2 Attachment s

/P. 9



# CRECO, Inc . GuAtom. Plastic QdtJucatvU 50 0 Smit h Avenu e - P.O
. Bo

x 47 3 - Phon

e 517-725-535 5 OWOSSO
. MICHIGA

N4886 7

Ite m# 1 Standar d P.V. C i s mos t commonl yuse d an d recommended
. However , othe r materia l raayb e substitute d fo r fabricatio n o f ou r Ai r Washer
. Ite m*> 2 Dimension s ca n be change d slightl yfo r specia l condition s o r circumstances

. I t i s advisabl e t o mentio n the proble m involve d fo r solution s an d th e temperatur e involve d s o w e maymak e recommendation s accordingly

. Ite m# 3 FP R Washer s contai n multipl e washin g filte r packs
. 2 stag e washin g wit h extracto r filte r pack s fo r standard , an d 3 stag e washing wit h 2 extracto r filte r pack s fo r hard t o was h fumes
. Ite m# 4 Efficienc yexpecte d t o b e up t o 907
. o f al l wate r solubl e contaminates

. Ite m# 5 Onl y1-1/4 " t o 1-1/2 " o f stati c pressur e los s t o b e expected
. Ite m# 6 .Roun

d o r rectangula r inlet s an d outlet s ar e optional

.

• yP.1 0



### Attachmen t

2



# fr* Y

/"0AU&

,3"*>//»£•- 

# _y^3L ^ *Or£A/ 

### PO*. ratios* M43M


# I i-Z

C**t MAX SOO 

### /ooo ZOOO 3oao 4000 H /'7~ /'//" 

# zr 3'Z" 

### 3'cr I l'3" 

## rr W Z'/O 3'Z" 5000\ -4'0" | 3'8" <Yocoo I 4'3'\ y/r 7000 

### eooo 4'6T 4'/l" e 

### xxx>\ sr /oooo /zooo /4COO /6COO 

### /eooo zoooo ZZOOO Z40OO z&ooo 

### zaooo 30000 3SOOO 40OOO 4SOOO 50 OQ O Str S'9" 

# w £>'8~ TZ" 7'C" T9" 

## ev a'<r 

## sv 9'CT 9'S" /Ot' 

### /oa' /&4" d'Z" 4'7" 

### <r/o~

### szSS' C'O" 

## 6T b'/O" 

## rr IT TS"\ 8'Q~ a'<t~ S'6* 9'4" /OCT //'J" /2'Ct" A 

### a- / / " / £ " /9" 

# 1 Z2r 

## 1 zsr l zar j SO" 3Z" 24' 3&" 40' 4Z' 44' 47" SO" SZ' SS" S7" AO" 6Z" 6S m 70- 7Z' 7Z" t 8" //' / * * /9" ZZ' 

### zs m 

### zer 30" 

### *r 34" 

### fr" 40" 4Z' 44' 4T 

### ser SZ" SS" S7' 6Q" <UL" *S" 70" 7S m 84 AHA/ HPM 4 mY, 7 

### a 

## /o wr 

### /so /so /so zoo Z5Q 

## /z 1 z&s /4 300 

## /s /& /& /9 20 

## zz Z3 Z4 

## zc Z7 33S 37S 400 440 5ZS 6/0 700 740 

### tzs 675 Zt 9SS 

## so 3/ 3Z 36, 40 44 48 97Q /O/O 

### //oo /zso /400 /soo /<i50 

# CREC O FP R AI R WASHE R

P V C FABRICATIO N
Washer s ar e shippe d read yt o install , bu t d o no t includ e Fan , Pump , Recirculatio n Tank o r Piping

. Th e Washe r i s equippe d wit h a stee l bas e fo r a read ymean s o f securin g th e collecto r t o it s supportin g medi a insid e o r outsid e o f plant
. Th e Washe r i s a self-drainin g unit

. I n mos t location s i t i s mos t economica l t o recirculat e th e wate r fo r unit s using mor e tha n te n (10 ) gallon s pe r minute

. I f a recirculatio n tan k an d pum p ar e used , w e recommend th e tan

k b e locate d i n a heate d buildin g fo r eas e o f addin g a neutralize r a s wel l a s t o guar d agains t freezing

. Th e to p o f thi s tan

k mus t b e a t leas t 12 " belo w th e bas e o f th e washe r t o insur e prope r drainage

.

C£jer/r/£/? /ouecA/AS&e cr+i N

L \ 0/At£A/S/OAtS

aeo£M A/O. A / OAr£

M/A* 

# rss. <?