United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 85-CHM-11
December 1985
Air
Neshap Screening
Study
Chromium
Emission Test
Report
Carolina Plating
Company
Greenville,
South Carolina
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EMISSION TEST REPORT
CAROLINA PLATING COMPANY
GREENVILLE, SOUTH CAROLINA
ESED 85/02
EMB 85-CHM-11
by
Entropy Environmentalists/ Inc.
Post Office Box 12291
Research Triangle Park, North Carolina 27709
Contract No. 68-02-3852
Work Assignments No. 18, 21, and 23
PN: 3023
EPA Task Manager
Dan Bivins
U. S. ENVIRONMENTAL PROTECTION AGENCY
EMISSION MEASUREMENT BRANCH
EMISSION STANDARDS AND ENGINEERING DIVISION
RESEARCH TRIANGLE PARK, NORTH CAROLINA 27711
January 1986
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APPENDICES
CONTENTS
Figures
Tables v
1.0 INTRODUCTION 1-1
2.0 PROCESS OPERATION 2-1
2.1 Process Description 2-1
2.2 Air Pollution Control 2-4
2.3 Process Conditions During Testing 2-4
3.0 SUMMARY OF RESULTS 3-1
3.1 Particulate Matter, Hexavalent Chromium and Total Chromium 3-1
3.1.1 Scrubber Inlet 3-3
3.1.2 Scrubber Outlet 3-5
3.2 Summary of Emissions in Units of Process Rate and
Collection Efficiency 3-8
3.2.1 Emissions in Units of Process Rate 3-8
3.2.2 Control Equipment Collection Efficiency 3-10
3.3 Summary of Analytical Results for Hexavalent and
Total Chromiun 3-10
3.4 Summary of Results of the Mediun Volume Sampling Train 3-12
4.0 SAMPLING LOCATIONS AND TEST METHODS 4-1
4.1 Scrubber Inlet (Sampling Location A) 4-1
4.2 Scrubber Outlet (Sampling Location B) 4-5
4.3 Velocity and Gas Temperature 4-7
4.4 Molecular Weight 4-7
4.5 Particulate Matter 4-8
4.6 Hexavalent Chromiun Content 4-8
4.7 Total Chromiun Content 4-9
5.0 QUALITY ASSURANCE 5-1
TEST RESULTS AND EXAMPLE CALCULATIONS ' A-1
Particulate, Hexavalent Chromium and Total Chromium A-3
Example Particulate Test Calculations A-9
Total Chromiun Analysis Calculation A-21
Explanation of Total Chromium Analysis A-22
Calculation Table
FIELD AND ANALYTICAL DATA B-1
Particulate Matter B-3
Total Particulate Analysis B-19
Hexavalent Chromiun Analysis B-33
Total Chromium Analysis B-36
11
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CONTENTS (Continued)
SAMPLING AND ANALYTICAL PROCEDURES C-1
Determination of Total Particulate Emissions C-3
Determination of Hexavalent Chromiun Emissions C-8
Determination of Total Chromiun Content C-15
Determination of Particulate Emissions Using the
Mediun Sample Volune Screening Technique C-22
CALIBRATION AND QUALITY ASSURANCE DATA D-1
MRI PROCESS DATA E-1
Source Sampling Program - Process Data Sheets E-3
Source Sampling Program - Job Descriptions E-12
Ampere-Hour Calculations E-14
TEST PARTICIPANTS AND OBSERVERS F-1
ill
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FIGURES
Number . Page
2-1 Plan View of Carolina Plating Facility 2-2
2-2 Plan View of Exhaust System on Tank Nos. 1, 2, 3, and 7 2-5
4-1 Simplified Process Air Flow Diagram of Chrome Plating Tanks
and Emission Control Equipnent at Carolina Plating 4-2
4-2 Scrubber Inlet (Sampling Location A) 4-4
4-3 Scrubber Outlet (Sampling Location B) 4-6
IV
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TABLES
Number Page
2.1 Specifications of Hard Chrcmiun Plating Tanks at Carolina Plating 2-3
2.2 Total Current Supplied to Tanks During Source Test Runs 2-7
3.1 Testing Schedule for Carolina Plating 3-2
3.2 Summary of Flue Gas Conditions 3-4
3.3 Summary of Particulate, Hexavalent Chromiun, and Total
Chromium Emissions 3-6
3.4 Summary of Emission Rates in Units of Process Rate and
Efficiency 3-9
3.5 Summary of Analytical Results for Hexavalent and Total
Chrcmiun 3-11
3.6 Summary of Analytical Results for Hexavalent and Total Chromiun
Quality Assurance Samples 3-13
3.7 Summary of Flue Gas Conditions for Runs Conducted Using
"Medium Volume" Sampling Train 3-14
3.8 Summary of Particulate, Hexavalent Chromium, and Total
Chromium Emissions for Runs Conducted Using "Medium Volume"
Sampling Train 3-15
4.1 Sampling Plan for Carolina Plating 4-3
5.1 Audit Report Chromium Analysis 5-2
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1.0 INTRODUCTION
During the week of May 13-17, 1985, the Emission Measurement Branch of the
U. S. Environmental Protection Agency conducted an emission measurement program
at Carolina Plating Company's plating plant located in Greenville, South
Carolina. The purpose of this program was to provide data for a screening
study to determine the quantity and form of chromium emissions associated with
hard chromium plating.
Comprehensive testing was conducted on a series of chrcmiun plating tanks
all of whose emissions are controlled by a single packed-bed wet scrubber.
This fume scrubber controlling emissions from hard chrcmiun plating tanks
No. 1, 2, 3, and 7 at the plant was selected for source testing for the
following reasons:
Carolina Plating applies hard chromium plate to large industrial
rollers. Typically the rollers remain in the tanks for 12 to 36
hours, depending on the dimensions of the rollers and the
chromium plate thickness required. Although there is no
industry wide "typical" part that receives hard chrcmiun plate,
it is not unusual for job shops to plate industrial rollers.
The advantages of performing a source test on a tank used for
plating rollers instead of other types of metal parts are:
a) the long plating time accommodates continuous testing, b) the
amount of chromium deposited during the test can be easily
determined, and c) the surface area plated can be easily
determined.
The plating tanks appear to be typical of other hard chromium
plating tanks in the electroplating industry, based on operating
parameters such as current, voltage, plating time, and chromic
acid concentration. The tanks are situated with the longest
dimension in the vertical direction, which is common for tanks
that are used to plate large industrial rollers. There are no
demisting agents used in the plating tanks. The use of
demisting agents is not common practice for hard chromium
platers.
1-1
-------
o The emissions capture system is highly efficient in directing
fumes from the plating tanks to the control device. The
vertical orientation of the tanks minimizes the exposed surface
area of plating solution from which fumes must be drawn. Each
of the four tanks is equipped with hoods on three sides through
which a common induction fan pulls a total of 20,000 standard
cubic feet per minute (scfm).
o The Napco wet packed-bed fume scrubber at this facility is
typical of control devices in use at other hard chromium plating
facilities. Most hard chromium plating facilities that control
chromic acid emissions use impingement-type mist eliminators or
packed-bed fume scrubbers. As a result, emission data obtained
from testing at the outlet of the scrubber at this facility
should be representative of emissions from control devices
typically applied at hard chromium plating facilities.
Particulate concentrations and mass emission rates were measured at
the scrubber inlet and outlet using U. S. Environmental Protection Agency
(EPA) Reference Method 5.* Total chromium concentrations and hexavalent
chromium concentrations were measured at the same locations by further
analysis of the Method 5 samples using the alternate sample preparation
and analytical procedures as described in Appendix C. Flue gas flow
rates, temperature, moisture content, and composition [oxygen (02), carbon
dioxide (CO-), and carbon monoxide (CO)] were measured in conjunction with
the particulate tests. In addition, "medium volume" (MV) particulate matter
sampling was conducted at the same locations using a thimble filter and an
experimental MV sampling train as described in Appendix C.
Ms. Barbara Duletsky [Midwest Research Institute (MR!)] monitored process
operation throughout the test period. Mr. Dan Bivins (EPA Task Manager) of the
Emission Measurement Branch (EMB) and Mr. Al Vervaert of the Industrial Studies
Branch (ISB) observed the test program. Mr. J. F. Tucker, Vice-President
served as the contact for Carolina Plating.
40 CFR 60, Appendix A, Reference Method 5, July 1, 1980.
1-2
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This report is organized into several sections addressing various aspects
of the testing program. Immediately following this introduction is the
"Process Operation" section which includes a description of the process and
control device tested. Following this is the "Summary of Results" section
which presents table summaries of the test data and discusses these results.
The next section, "Sampling Locations and Test Methods" describes and
illustrates the sampling locations for emissions testing and grab sampling and
then explains the sampling strategies used. The final section, "Quality
Assurance," notes the procedures used to ensure'the integrity of the sampling
program. The Appendices present the complete Test Results and Example
Calculations (Appendix A); Field and Analytical Data (Appendix B); Sampling and
Analytical Procedures (Appendix C); Calibration Data (Appendix D); MRI Process
Data (Appendix E); and Test Participants and Observers (Appendix F).
1-3
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2.0 PROCESS OPERATION
2.1 PROCESS DESCRIPTION
The Carolina Plating Roll Division 1s 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 1n the paper manufacturing, roofing,
laminating, and coating industries. Although some parts of the finishing
processes performed at this plant are unique, the actual plating process
1s similar to that at most other hard chromium plating operations.
There are seven hard chromium plating tanks at this facility,
arranged as shown in Figure 2-1. On the average, the tanks are charged
for a total of 20 hours per day. Approximately 4 hours per day are
required for the change-over of rolls. During a change-over, the roll
that has been plated is raised out of the plating tank, rinsed with water
from a hose, and transferred to the grinding area. Then, the roll to be
plated is cleaned with an abrasive cleanser and lowered into the plating
solution. Plating times range from 2 to 36 hours, depending on the
surface area of the roll and the plate thickness required. Usually, rolls
that require longer plating times are plated overnight, and rolls that
require shorter plating times are plated during the day when personnel are
available to perform the change-over.
Tank Nos. 1, 2, 3, and 7 were tested during this source test
program. The tanks are situated below floor level and are oriented with
the largest dimension in the vertical direction. This orientation is
typical of tanks used to plate industrial rolls throughout the
electroplating industry. 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 that automatically turns off
the electrodes at the end of the specified plating time.
The plating tanks are typical of other hard chromium plating tanks in
the electroplating industry, based on operating parameters such as
current, voltage, plating time, and chromic acid concentration. Table 2-1
lists maximum operating conditions for the four tanks. Although the
2-1
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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
CONTROLLED EMISSIONS DUCTED TO FAN ON ROOF
EMISSIONS DUCTED TO
KCH FUME SCRUBBER ON ROOF
Figure 2-1. Plan view of Carolina Plating facility.
2-2
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TABLE 2-1. SPECIFICATIONS OF HARD CHROMIUM PLATING TANKS AT CAROLINA PLATING
ro
CO
Tank
No.
1
2
3
7
Capacity,
£ (gal)
3,800 (1,000)
7,600 (2,000)
11,400 (3,000)
9,100 (2,400)
Surface
n* (ft?)
1.3 (14)
1.7 (18)
3.3 (36)
2.2 (24)
Voltage,
voltsa
12
12
10
10
Current.
amperes
7,000
20,000
30,000
15,000
Method
of
cooling
Water
Water
Water
Water
Constituents,
g/a (oz/gal)
Cr03
250 (33)
250 (33)
250 (33)
250 (33)
H2S04
2.5 (0.33)
2.5 (0.33)
2.5 (0.33)
2.5 (0.33)
aValues represent maximum operating values.
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composition of the plating solution remains constant, the operating
voltage and current vary with each roll that is plated.
2.2 AIR POLLUTION CONTROL
All four tanks are equipped with hoods on three sides to capture the
chromic acid mist generated during the plating process. A plan view of
the exhaust system is shown in Figure 2-2. Emissions that are captured by
the exhaust system are treated by a fume scrubber located on a mezzanine
adjacent to the plating area. The scrubber is a double packed-bed type
manufactured by Napco, Incorporated (Model No. MA-101). Each bed contains
30 cm (12-inches) of polypropylene packing. The beds are sprayed
continuously with water, which drains into a holding tank and is
recirculated through the scrubber. The holding tank is flushed and filled
with clean water about 3 times a day. The.spent liquid is either used as
make-up solution for the plating tanks or is treated on site in a
wastewater treatment system.
The scrubber also contains a mist elimination stage for the removal
of water droplets entrained in the exhaust gas stream. This stage
consists of a "Chevron-type" arrangement of baffles that changes the
direction of gas flow four times at 30°-angles. The entire scrubbing unit
has a design control efficiency of 96 to 99 percent for the removal of
chromic acid.
The exhaust fan, which is located immediately downstream of the
scrubber, is manufactured by Dual! Industries, Incorporated (Model
No. NH-66). The fan is rated at 9.4 cubic meters per second (m3/s)
(20,000 standard cubic feet per minute (scfml) for air at 21°C (70°F);
however, a gas flow of 4.7 m /s (10,000 scfm) was measured during the test
series. Exhaust gases exit through a short stack located on the roof.
2.3 PROCESS CONDITIONS DURING TESTING
Process operating parameters such as plating solution temperature,
operating voltage, and operating current were monitored and recorded
during each test run. Copies of the actual data sheets are presented in
Appendix E. Also recorded were descriptions (dimensions and surface area)
and plating requirements (current and plating time) of each individual job
or item being plated during each test run. This information was obtained
2-4
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ro
en
V-
Figure 2-2. Plan view of exhaust system on Tank Nos. 1, 2, 3, and 7
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from log sheets maintained by plant personnel and is also presented in
Appendix E. No operating parameters were monitored for the scrubber;
however, there were no indications of any malfunction in the system during
the testing period.
Test run Nos. 1 and 3 were performed without interruption. Test run
No. 2 was suspended at one point because the production rate in the tanks
was significantly lower than normal. Testing was resumed after 1 hour
when the production rate was increased.
The total current supplied to the tanks during each test run is
calculated in terms of ampere-hours and included in Appendix E. A summary
of the total current values is presented in Table 2-2.
2-6
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TABLE 2-2. TOTAL CURRENT SUPPLIED TO TANKS DURING
SOURCE TEST RUNS
Total current, ampere-hours
Test No. Inlet Outlet
1 41,300 42,200
2 50,300 45,900
3 72,400 70,600
2-7
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3.0 SUMMARY OF RESULTS
Particulate matter and experimental "median volutie" tests were conducted at
the inlet and the outlet of the packed-bed wet scrubber controlling chromiun
plating tanks No. 1, 2, 3, and?. Table 3.1 summarizes the testing schedule.
In brief, from the results of the Method 5 testing, the uncontrolled
emissions from the tanks averaged 0.22 pounds per hour of particulate matter,
0.025 pounds per hour of hexavalent chrcmiun, and 0.052 pounds per hour of
total chromium. The controlled emissions averaged 0.11 pounds per hour of
particulate matter, 0.001 pounds per hour of hexavalent chrcmiun, and 0.004
pounds per hour of total chrcmiun. The resulting collection efficiency of the
wet scrubber was 43.5% for particulate matter, 95.7% for hexavalent chrcmiun,
and 93.0% for total chromium. The "mediun volune" testing results are not
included in the summary of results since this is a screening technique. These
results are discussed separately in Section 3.4.
In the following sections, the results addressed above and additional
results are presented and discussed in detail according to the emission type
and sampling location. The computer printouts of the emission calculations are
can be found in Appendix A. The original field data sheets and the analytical
data are located in Appendix B.
3.1 PARTICULATE MATTER, HEXAVALENT CHROMIUM, AND TOTAL CHROMIUM
Particulate matter tests (EPA Method 5) along with the determination of the
associated flue gas flow rates were conducted at both the scrubber inlet and
outlet. The particulate matter samples were initally analyzed using
gravimetric techniques to determine the mass of particulate matter. Then the
3-1
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TABLE 3.1. TESTING SCHEDULE FOR CAROLINA PLATING
U)
I
to
Date
(1985)
5-14
5-15
5-16
Sample Type
Medium Volume
Particulate
Medium Volume
Particulate
Particulate
Medium Volume
Scrubber Inlet
Run
No.
DIF1
1-1
DIF2
1-2
1-3
Test Time
24 h clock
1230-2130
1235-1723
1915-0730
0901-1442
1525-2013
Scrubber Outlet
Run
No.
0-1
0-2
0-3
DIF3
Test Time
24 h clock
1230-1724
0838-1419
1517-
2015-0850
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samples were further analyzed for hexavalent and total chromiun. Complete
descriptions of each sampling location and the sampling and analytical
procedures are given in Chapter 4 (and Appendix C).
3.1.1 Scrubber Inlet
The scrubber inlet represents the uncontrolled emissions from plating tanks
No. 1, 2, 3, and?. The circular horizontal inlet duct was only traversed in
one direction during the particulate sampling. The single traverse was
utilized because of the difficulty in gaining access to the duct and because
the very fine acid mist particles present in the duct would be expected to
behave like a gas resulting in a uniform cross-sectional particle distri-
bution. Prior to the Method 5 testing at the scrubber inlet, a pitot traverse
was conducted along two axes. Since the pitot traverse showed flow rates only
slightly less (1%) than the Method 5 sampling, the Method 5 test data was used
in the calculations and is presented in the sunmary tables.
Flue Gas Conditions and Isokinetic Sampling Rate - A sunmary of the flue
gas conditions at the scrubber inlet and outlet is presented in Table 3.2. The
volumetric flow rates were fairly consistent and averaged 16,500 actual cubic
meters per hour (582,000 actual cubic feet per hour). The flow rate at the
inlet was approximately 13% lower than the outlet flow rate; this was likely
due to measurement error in the outlet flow rate measurements which were
conducted in nonparallel flow.
The flue gas temperature averaged 28°C (82°F), with a moisture content
of 1.5 percent. The oxygen, carbon dioxide, and carbon monoxide content was
that of air at 20.9, 0.0, and 0.0 percent, respectively. The volunetric flow
rate at standard conditions averaged 15,200 dry standard cubic meters per hour
3-3
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TABLE 3.2. SUMMARY OF FLUE GAS CONDITIONS
Run
No.
Date
(1985)
Test Time
24 h clock
Volumetric Flow Rate
Actuala
acmh
x 106
acfh
x 106
Standard6
dscmh
x 106
dscfh
x 106
Stack
Temperature
°C
°F
Moisture
%
°2
co2
CO
%
Isoklnetlc
%
Scrubber Inlet
1-1
1-2
1-3
5/15
5/16
5/16
1235-1723
0901-1442
1525-2013
Average
0.0171
0.0160
0.0163
0.0165
0.6029
0. 5645
0.5772
0.582
0.0158
0.0149
0.0151
0.0152
0. 5589
0.5264
0.5333
0.540
29
26
29
28
84
79
84
82
1.6
1.5
1.4
1.5
20.9
20.9
20.9
20.9
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
97.1
100.1
98.9
LJ
I
Scrubber Outlet
0-1
0-2
0-3
5/15
5/16
5/16
1230-1724
0838-1 4 1 9
1517-
Average
0.0190
0.0190
0.0186
0.0189
0.6723
0.6721
0.6565
0.667
0.0177
0.0178
0.0173
0.0176
0.6246
0.6278
0.6103
0.621
29
25
27
27
85
77
81
81
2.2
2.2
1.7
2.0
20.9
20.9
20.9
20.9
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
95.9
96.5
95.8
Volumetric flow rate In actual cubic meters per hour (acmh) and actual cubic feet per hour (acfh) at stack conditions.
Volumetric flow rate in dry standard cubic meters per hour (dscmh) and dry standard cubic feet per hour (dscfh).
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(540,000 dry standard cubic feet per hour). Standard conditions are 20°c
(68°F), 760 mm Hg (29.92 in. Hg), and dry. The isokinetic sampling rate was
within the allowable range for all three sample runs.
Particulate Emissions - The participate emissions from the plating tanks
(see Table 3.3) were variable. The particulate emissions for the inlet runs
averaged 6.37 milligrams per dry standard cubic meter (0.0028 grains per dry
standard cubic foot) and 0.097 kilograms per hour (0.22 pounds per hour).
Hexavalent Chromium Emissions - The hexavalent chromium emissions for each
test run (see Table 3.3) were consistent with the corresponding particulate
run. They averaged 119, 95, and 127 milligrams of hexavalent chromium per gram
of particulate emissions for runs 1-1, 1-2, and 1-3, respectively. The
hexavalent chromium emissions for the inlet tests averaged 0.736 milligrams per
dry standard cubic meter (0.00032 grains per dry standard cubic foot) and
0.0113 kilograms per hour (0.025 pounds per hour).
Total Chromium Emissions - The total chromivm emissions for each test run
(see Table 3.3) were consistent with the corresponding particulate run and
averaged 249, 207, and 260 milligrams of total chromium per gram of particulate
emissions for runs 1-1, 1-2, and 1-3 respectively. The total chromium
emissions for the inlet tests averaged 1.54 milligrams per dry standard cubic
meter (0.00067 grains per dry standard cubic foot) and 0.024 kilograms per hour
(0.052 pounds per hour).
3.1.2 Scrubber Outlet
The scrubber outlet represents the controlled emissions from plating tanks
No. 1, 2, 3, and 7. Some nonparallel (cyclonic or swirling) flow was present
in the scrubber outlet stack. To estimate the effect of these flow conditions
3-5
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TABLE 3.3. SUMM/R Y OF P/«TICULATE, HEXAVALENT OROMIUM, AND TOTAL CWOMIUM EMISSIONS
Run
No.
Date
(1985)
Particulate
Concentration
mg/dscm
gr/dscf
Mass Emissions
kg/h
Ib/h
Hexavalent Chromium
Concentration
mg/dscm
gr/dscf
Mass Emissions
kg/h
Ib/h
Total Chromium
Concentration
mg/dscm
gr/dscf
Mass Emissions
kg/h | Ib/h
Scrubber Inlet
1-1
1-2
1-3
5/15
5/16
5/16
Average
7.548
4.962
6.586
6.37
0.00330
0.00217
0.00288
0.00278
0.119
0.074
0.099
0.097
0.263
0.163
0.219
0.215
0.898
0.473
0.837
0.736
0.00039
0.00021
0.00037
0.00032
0.0142
0.0071
0.0126
0.0113
0.0313
0.0155
0.0279
0.0249
1.868
1.027
1.713
1.54
0.00082
0.00045
0.00075
0.00067
0.0296
0.0153
0.0259
0.024
0.0652
0.0338
0.0570
0.052
U)
en
Scrubber Outlet
0-1
0-2
0-3
5/15
5/16
5/16
Average
2.620
3.41 1
2.788
2.94
0.00114
0.00149
0.00122
0.00128
0.046
0.061
0.048
0.052
0.102
0.134
0.106
0.114
0.0262
0.0202
0.0301
0.0255
0.000011
0.000009
0.000013
0.000011
0.00046
0.00036
0.00052
0.00045
0.00102
0.00079
0.00115
0.00099
0.1231
0.0510
0.1120
0.095
0.000054
0.000022
0.000049
0.000042
0.00218
0.00091
0.00194
0.0017
0.00480
0.00200
0.00427
0.0037
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on the sampling data, the angle of misalignment was determined at each sampling
point during a preliminary pitot traverse. Application of these angles to the
pitot traverse data resulted in a flow rate about 10% lower than the measured
inlet values. Thus, the flow rate data for each Method 5 test was used in the
calculations and is presented in the summary tables.
Flue Gas Conditions and Isokinetic Sampling Rate - A sunmary of flue gas
conditions at the scrubber outlet is presented in Table 3.2. The volunetric
flow rates for the three outlet runs were very consistent. The outlet
volunetric flow rate averaged 18,900 actual cubic meters per hour (667,000
actual cubic feet per hour) with a flue gas temperature of 27 °C (81°F) and
a moisture content of 2.0 percent. The oxygen, carbon dioxide, and carbon
monoxide concentrations were that of ambient air at 20.9, 0.0, and 0.0 percent,
respectively. The volunetric flow rate at standard conditions averaged 17,600
dry standard cubic meters per hour (621,000 dry standard cubic feet per hour).
Standard conditions are 20°C (68°F), 760 mm Hg (29.92 in. Hg), and dry.
These flow rate measurements are likely to be biased high due to the
nonparallel flow conditions.
The isokinetic sampling rates were well within the allowable range for all
runs.
Particulate Emissions - The particulate emissions from the control equip-
ment to the atmosphere were variable (see Table 3.3) with all runs being within
approximately 20% of the averages. Over all three runs, the particulate emissions
averaged 2.94 milligrams per dry standard cubic meter (0.00128 grains per dry
standard cubic foot) and 0.052 kilograms per hour (0.114 pounds per hour).
Hexavalent Chromium Emissions - The hexavalent chromium emissions for each
test run were fairly consistent with their corresponding particulate run and
averaged 10.0, 5.9, and 10.8 milligrams of hexavalent chrcmiun per gram of
3-7
-------
particulate emissions for runs 0-1, 0-2, and 0-3, respectively. The hexavalent
chromiun emissions averaged 0.0255 milligrams per dry standard cubic meter
(0.000011 grains per dry standard cubic feet) and 0.00045 kilograms per hour
(0.00099 pounds per hour) .
Total Chromium Emissions - The total chromium emissions were variable (see
Table 3.3) when compared to the corresponding particulate runs and averaged 47,
15, and 40 milligrams of total chromiun per gram of particulate for runs 0-1,
0-2, and 0-3 respectively.. The total chromiun emissions averaged 0.095
milligrams per dry standard cubic meter (0.000042 grains per dry standard cubic
foot) and 0.0017 kilograms per hour (0.0037 pounds per hour).
3.2 EMISSIONS IN UNITS OF PROCESS RATE AND CONTROL EQUIPMENT COLLECTION
EFFICIENCY
The emission rates in units of process rate are given in terms of grams of
emissions per hour per square foot of tank surface area, and in units of milli-
grams of emissions per amperage input to the plating operation. To determine
the collection efficiency of the scrubber, the milligrams per hour per square
foot (uncontrolled emissions and controlled emissions) were used for the
calculations.
3.2.1 Emissions in Units of Process Rate
Two process parameters were used to determine the emissions in terms of
units of the process rate as shown in Table 3.4. The first was milligrams of
emissions per amperage input into the plating operation. The second was grams
of emissions per hour per square foot of tank surface area. The surface area
of the tank was 92 ft2 for all tests.
3-8
-------
TABLE 3.4. SUMMARY OF EMISSION RATES IN UNITS OF PROCESS RATE AND EFFICIENCY
Run
Nos.
1-1
0-1
1-2
0-2
1-3
0-3
Process Rate
amps/hr
41,300
42, 300
50, 300
45,900
72, 400
70, 600
Average
Uncontrolled Emissions
particul ate
mg/amp
2.88
1.47
1.37
1.91
9/hr
ft2*
1.29
0.80
1.08
1.06
hex av a lent
chromium
mg/amp
0.345
0.141
0.174
0.22
q/hr
ft2*
0.154
0.077
0.137
0.12
total
chromium
mg/amp
0.717
0.304
0.358
0.46
g/hr
ft2*
0.322
0.166
0.282
0.26
Controlled Emissions
particul ate
mg/amp
1.09
1.33
__
0.68
1.03
g/hr
ft2*
0.50
_
0.66
__
0.52
0.56
hex av a lent
chromium
mg/amp
0.011
0.008
0.007
0.009
q/hr
ft2*
0.005
0.004
0.006
0.005
total
chromium
mg/amp
0.052
0.020
.__
0.027
0.033
g/hr
ft2*
0.024
0.010
.
0.021
0.018
Collection Efficiency**
particul ate
%
61.2
17.5
51.9
43.5
hex av a lent
chromium
%
96.8
94.8
95.6
95.7
total
chromium
%
92.5
94.0
92.6
93.0
U)
I
(O
'Emission rate In units of grams per hour per square foot of tank surface (g/hr/ft ) using tank surface of 92 ft .
**Collection efficiency of control equipment is based on the uncontrolled and controlled emission rate In units of emissions per hour
if.
per ft of tank surface.
-------
3.2.2 Control Equipment Collection Efficiency
The collection efficiency of the packed-bed scrubber (see Table 3.4)
averaged 43.5 percent by weight for particulate matter, 95.7 percent by weight
for hexavalent chromium, and 93.0 percent by weight for total chromiun.
The much greater collection efficiency for hexavalent chromium emissions as
compared to particulate emissions is probably a result of one or a combination
of two things: (1) the solubility of hexavalent chromiun in water, and/or (2)
the measured hexavalent chromiun results at the outlet (which were extremely
low) could be biased low.
3.3 SUMMARY OF ANALYTICAL RESULTS FOR HEXAVALENT AND TOTAL CHROMIUM
The sunmary of analytical results for the hexavalent chromiun and total
chromiun analyses of samples collected is presented in Table 3.5. The
analytical data sheets are contained in Appendix B. The results shown in Table
3.5 for hexavalent and total chromiun are the results obtained by the EPA
tentative method for "Determination of Hexavalent Chromiun Emissions from
Stationary Sources" and the "EPA Protocol for Emissions Sampling for both
Hexavalent and Total Chromiun" (see Appendix C). When, for total chromiun
analysis, the table indicates that the sample "residue" was analyzed, then the
values presented for total chromiun content are the a sun of (1 ) the hexavalent
chromiun in the sample filtrate from the extraction of the sample and (2) the
chromiun in the residue from the extraction as measured by Neutron Activation
Analysis. When the table indicates that the "total" sample was analyzed, then
the values presented for total chromiun content are from the direct analysis
for total chromiun by Neutron Activation Analysis. A table showing the total
chromiun calculations for each sample can be found at the end of Appendix A of
this report.
3-10
-------
TABLE 3.5. SUMM/R Y OF ANALYTICAL RESULTS F(R HEXAVALENT AND TOTAL CWOMIUM
Run
No.
Sampl e
Type
Sample
No.
Analyzed
Amount of
Sample
mg or ml
Hex av a lent Chromium
Results
mg
Concentration
mg/g
Amount of
Samp 1 e
Anal yzed
Total Chromium
Results
mg
Concentration
mg/g
Sample
Prep
Method9
Scrubber Inlet
1-1
1-1
1-2
1-3
1-3
DIF1
DIF2
Partlculate Front Half
Implnger Contents
Partlculate Front Half
Particulate Front Half
Implnger Contents
Thimble Filter
Thimble Fl Iter
C-227
C-233
C-228
C-229
C-234
C-237
C-221
60.5
Total
38.6
51.3
Total
100.0
147.3
7.200
0.007
3.680
6.520
0.0004
23.099
29.099
119
negl Iglble
95.3
127
negl iglble
231
198
Residue
Total
Residue
Residue
Total
Residue
Residue
14.977
0.011
7.993
13.345
0.002
31.883
43.209
247.6
negl Iglble
207.1
260.1
negl Iglble
318.8
293.3
1
2
1
1
2
1
1
Scrubber Outlet
0-1
0-1
0-2
0-3
0-3
DIF3
Partlculate Front Half
Impinger Contents
Partlculate Front Half
Particulate Front Half
Impinger Contents
Thimble Fi Iter
C-224
C-231
C-225
C-226
C-232
C-222
15.5
Total
20.4
16.1
Total
55.2
0.155
0.0008
0.121
0.174
O.0005
6.499
10.0
negl Iglble
5.93
10.8
negl igible
118
Residue
Total
Residue
Residue
Total
Residue
0.728
0.002
0.305
0.647
0.001
10.090
47.0
negl Igib le
15.0
40.2
negl igible
182.8
1
2
1
1
2
1
Blank Samples
Fi Iter & Acetone Blank
Th imble Bl ank
C-230
C-223
<0.0005
0.001
Residue
Residue
no value
no value
Sample preparation methods are as follows:
1 = For the Msthod 5 and thimble filters: Hexavalent chromium was extracted from the filter, acetone rinse, (and water rinse for Method 5 filters)
and the filtrate from this process was analyzed for Cr . The residue from the extraction was analyzed for total chromium. Total chromium
results reported (mg) are the sum of both measurements (blank corrected).
2 = For Impinger contents: The liquid samples were concentrated; one measured aliquot was taken for hexavalent chromium analysis and one measured
aliquot taken for total chromium analysis. Chromium concentrations are expressed as mg Cr per g of partlculate matter catch.
-------
For this testing program, there is some sample analysis variability due to
the small amount of hexavalent chromium present. However, the average values
for the runs are believed to be fairly accurate.
Quality assurance audit samples were analyzed for both the hexavalent and
total chromium methods. As shown in Table 3.6 no bias was present and the
results are considered acceptable.
3.4 SUMMARY OF RESULTS FOR THE MEDIUM VOLUME SAMPLING TRAIN
EPA employed the use of the "medium volume" sampling train during the test
program. This technique is a screening method and was used prior to testing to
obtain an estimate of uncontrolled emissions. The data collected is not
intended for the purposes of source evaluation or emissions estimates. The
method was additionally evaluated to determine its ability to collect samples
over a wide variation in stack velocities and to collect samples over an
extended period of time. Tables 3.7 and 3.8 present the data obtained. This
data cannot be compared to the emission data from the Method 5 testing since
was collected at different times and under different process operating
conditions.
3-12
-------
TABLE 3.6. SUMMWY OF ANALYTICAL RESULTS FCR HEXAVALENT AND TOTAL CWOMIUM QUALITY ASSIRANCE SAMPLES
Run
No.
Samp 1 e
Type
Sample
No.
True
Value
Hexavalent Chromium
Results
y g/ml
%
Oev.
Total Chromium
Results
yg
%
Dev.
Quality Assurance Samples
~
Qual Ity Assurance
Qual Ity Assurance
Qual Ity Assurance
C-76
C-239
C-240
150 yg/ml Cr*6
10 yg Cr
450 yg Cr
149
-
-0.7
___
10.88
412.5
.. _
+8.8
-8.3
-------
TABLE 3.7. SUMMARY OF FLUE GAS CONDITIONS FOR RUNS
CONDUCTED USING "MEDIUM VOLUME" SAMPLING TRAIN
Run
No.
Date
(1985)
Test Time
24 h clock
Volumetric Flow Rate
Actual3
acmh
x 106
acth
x 106
Standard0
dscmh
x 106
dsc fh
x 106
Stack
Temperature
°C
°F
Moisture
%
Scrubber Inlet
DIF1
DIF2
5/14
5/15,
5/16
1230-1440,
1535-2130
1915-0730
Average
0.0163
0.0167
0.0165
0.5762
0.5904
0.583
0.0149
0.0155
0.0152
0.5269
0.5482
0.538
33
28
31
92
82
87
1.5
1.6
1.6
Scrubber Outlet
DIF3
5/16,
5/17
2015-0850
0.0184
0.650
0.0171
0.604
27
81
1.7
aVolumetric flow rate in actual cubic meters per hour (acmh) and actual feet per hour
(acfh) at stack conditions.
"Volumetric flow rate in dry standard cubic meters per hour (dscmh) and dry standard
cubic feet per hour (dscfh).
-------
TABLE 3.8. SUMM/RY OF P/RTICULATE, HEXAVALENT CWOMIUM, AND TOTAL CffiOMIUM EMISSIONS
FCR RUNS CONDUCTED USING "MEDIUM VOLUME" SAMPLING TRAIN
Run
No.
Date
(1985)
Particul ate
Concentration
mg/dscm
gr/dscf
Mass Emissions
kg/h | Ib/h
Hexavalent Chromium
Concentration
mg/dscm
gr/dscf
Mass Emissions
kg/h
Ib/h
Total Chromium
Concentration
mg/dscm
gr/dscf
Mass Emissions
kg/h
Ib/h
Scrubber Inlet
DIF1
DIF2
5/14
5/15-5/16
Average
3.633
2.806
3.22
0.00159
0.00123
0.00141
0.054
0.044
0.049
0.119
0.096
0.108
0.839
0.554
0.696
0.000367
0.000242
0.00030
0.0125
0.0086
0.011
0.0276
0.0190
0.023
1.158
0.823
0.99
0.00051
0.00036
0.00044
0.0173
0.0128
0.015
0.0381
0.0282
0.033
Scrubber Outlet
DIF3
5/16-5/17
0.310
0.00014
0.005
0.012
0.036
0.000016
0.00062
0.0014
0.057
0.00002
0.001
0.002
-------
4.0 SAMPLING LOCATIONS AND TEST METHODS
This section describes the sampling locations and test methods used to
characterize emissions from hard chromium plating tanks No. 1, 2, 3, and 7 at
Carolina Plating Company in Greenville, South Carolina. Two sampling locations
were used in the emission testing program. At each sampling location (one at
the scrubber inlet and one at the scrubber outlet), emissions testing was
conducted for particulate matter, total chromiun content, and hexavalent
chromium content. Particulate and chromiun sampling was also conducted at both
sampling locations using the "medium volune" train under development by John
Brown (EMB). The relative positions and the type of testing conducted at each
location are shown in the simplified process flow diagram (see Figure 4-1 ) and
accompanying Table 4.1. The subsections which follow further describe each
sampling location and applicable test methods.
4.1 SCRUBBER INLET (SAMPLING LOCATION A)
Particulate matter, hexavalent chromiun, and total chromium were measured
at the inlet to the packed-bed scrubber controlling emissions from chromium
plating tanks No. 1, 2, 3, and 7 as shown in Figure 4-2. One sampling port was
installed on the side of the horizontal circular duct (36 inches in diameter).
This port was located 20 inches (0.55 duct diameters) upstream of a bend in the
duct to the scrubber and 37 inches (1.03 duct diameters) downstream from another
bend. Because of the close proximity of potential flow disturbances, this
location did not meet EPA Method 1 sampling requirements; however, there was no
other location available for inlet testing. For the particulate testing, a
4-1
-------
NEED TO
:I CONSTRUCT
B -i ' TEMPORARY
STACK
DIVIDED
DUCTWORK
ROOF
//////s
MEZZANINE
FLOOR
Figure 4-1. Simplified Process Air Flow Diagram of Chrome Plating
Tanks and Emission Control Equipment at Carolina Plating.
4-2
-------
TABLE 4.1. SAMPLING PLAN FOR CAROLINA PLATING
Sample Type
Sampling
Locations
Number
of Sanples
Methods
Particul ate matter
Hexavalent chromium
Total chromium
A, B
A, 3
A, B
3 (MS)
2 (MV at A)
1 (MV at B)
3 (MS)
2 (MV at A)
1 (MV at B)
3 (M5)
2 (MV at A)
1 (MV at B
EPA Method 5 or MV Train
EPA 5 or MV Train using
Tentative EPA Method
for Hexavalent Chromium
EPA 5 or MV Train using
EPA Protocol for Total
Chromium
4-3
-------
M5 TRAVERSE POINTS
2 AXES
12 POINTS/AXIS
EACH SAMPLED 2X
24 TOTAL POINTS
36" DIA.
VELOCITY TRAVERSE POINTS
2 AXES
12 PCiNT3/AXi3
24 TOTAL POINTS
SECTION L-L
FROM CHROMIUM
PLATING TANKS
JM(
TO SCRUBBER
4-20"-H
T
36"
37"-
TOP VIEW
t
FROM CHROMIUM
PLATING TANKS
O A
TO
SCRUBBER
SIDE VIEW
FIGURE 4-2. SCRUBBER INLET (SAMPLING LOCATION A)
4-4
-------
single traverse was chosen. This was because of the difficulty in gaining
access to the duct and because the very fine acid mist particles in the duct
would be expected to have the characteristics of a gas and thus, the
cross-sectional distribution of the particles in the duct should be uniform.
To check the cross-sectional flow distribution at this location, a pitot
traverse was conducted along two axes through the single port. The axis
perpendicular to the sampling axis was traversed by inserting the pitot tube
through the available port at a predetermined angle for a predetermined
distance, both of which were calculated geometrically.
For the Method 5 testing, (used for particulate matter, hexavalent
chromium, and total chromium determinations), 24 points were sampled, 12 going
into the port and 12 coming out of the port. Each of the 24 points was sampled
for 12 minutes for a total of 288 minutes of sampling per run. Each of the
three runs were conducted to coincide with the sampling at the scrubber outlet
location.
"Medium volume" (MV) sampling, was also conducted at the scrubber inlet.
The two runs were 485 and 735 minutes in duration and were each conducted at a
single sampling point. To avoid interference between the two trains, the MV
sampling was performed so as not to coincide with the Method 5 sampling.
4.2 SCRUBBER OUTLET (SAMPLING LOCATION B)
Particulate matter, hexavalent chromium, and total chromium were measured
at the scrubber outlet as shown in Figure 4-3. Four sampling ports were
installed 90° apart on the 22 3/16" diameter stack extension; however, only
the NW and NE ports were used in this testing program. The ports were located
about 24 inches (1.08 duct diameters) upstream from the stack exit and 64
inches (2.88 duct diameters) downstream from the mist eliminator.
4-5
-------
TRAVERSE POINTS
2 AXES
12 POINTS/AXIS
24 TOTAL POINTS
64"
- 22.25"-
NE "2
O
NV al
O
t
FROM SCRUBBER
24'
48'
22.25" DIA
NE "2
NV "1
SECTION T-T
- MIST
ELIMINATOR
ELEVATION VIEW
FIGURE 4-3. SCRUBBER OUTLET (SAMPLING LOCATION B)
4-6
-------
For the EPA Method 5 sampling (used for particulate matter, hexavalent
chromium, and total chromium determinations), a total of 24 points, as per
Method 1, were sampled. Each point was sampled for 12 minutes for a total
sampling time of 288 minutes. Because of the potential for cyclonic flow
conditions (which are fairly common at scrubber outlet sampling locations), a
preliminary traverse was conducted to determine the misalignment angles for
each of the sampling points. The angles measured indicated that cyclonic flow
was present; however, since the emissions were fumes and would be expected to
behave like a gas, testing in the normal manner was considered to be less
biased.
One sampling run was conducted at the outlet location using the MV sampling
train. This run was 735 minutes in duration and was conducted at a single
sampling point. As was done at the inlet location, the MV sampling was
performed so as not to coincide with the Method 5 sampling.
4.3 VELOCITY AND GAS TEMPERATURE
A type S pitot tube and an inclined draft gauge manometer were used to
measure the gas velocity pressure (Ap). Velocity pressures were measured at
each sampling point across the duct to determine an average value according to
the procedures outlined in Method 2 of the Federal Register.* The temperature
at each sampling point was measured using a calibrated Palmer bimetallic coil
thermometer.
4.4 MOLECULAR WEIGHT
Flue gas composition was determined utilizing procedures described in
Method 3 of the Federal Register.* A bag sample was collected during each
particulate test run. The bag contents were analyzed using an Orsat Gas
Analyzer.
4-7
-------
4.5 PARTICULATE MATTER
Method 5, as described in the Federal Register,* was used to measure
particulate grain loading at locations A and B. All tests were conducted
isokinetically by traversing the cross-sectional area of the stack and
regulating the sample flow rate relative to the flue gas flow rate as measured
by the pitot tube attached to the sample probe. A sampling train consisting of
a heated, glass-lined probe, a heated 79 mm (3 inch) diameter glass fiber
filter (Reeve Angel), and a series of Greenburg-Smith impingers was employed
for each test. An acetone rinse and a water rinse of the nozzle, probe, and
filter holder portions of the sample train were made at the end of each test.
The acetone rinse and the particulate caught on the filter media were dried at
room temperature, the water rinse was taken to dryness in an oven; all three
were then desiccated to a constant weight, and weighed on an analytical
balance. Total filterable particulate matter was determined by adding these
three values.
The "medium volune" (MV) sampling train was also used to measure
particulate matter at locations A and B. MV sampling was conducted at a single
sampling point. See Appendix C for detailed Method 5 and MV sampling
procedures.
4.6 HEXAVALENT CHROMIUM CONTENT
Hexavalent chromiun content was determined utilizing procedures described
in the tentative EPA Method "Determination of Hexavalent Chromiun Emissions
from Stationary Sources" (see Appendix C). The Method 5 filter catch collected
and weighed for each Method 5 run was taken and analyzed for hexavalent
chromiun content using this method. It was also used to determine the
hexavalent chromiun content of the MV sampling train filter catch and the
impinger contents.
* 40 CFR 60, Appendix A, Reference Methods 2, 3, and 5, July 1, 1980.
4-8
-------
.4.7 TOTAL CHROMIUM CONTENT
Total chrcmiuti content was determined using procedures described in the
" EMB Prototcol for Sample Preparation and Emission Calculation of Field Samples
for Total Chromium" in combination with Neutron Activation Analysis (NAA) (see
Appendix C). Samples collected during Method 5 runs and first submitted for
analysis for hexavalent chromiun were then analyzed for total chromivm using
this method. The total chromiun content of the MV sampling train filter catch
and the impinger contents were also determined using these procedures.
4-9
-------
5.0 QUALITY ASSURANCE
Because the end product of testing is to produce representative emission
results/ quality assurance is one of the main facets of stack sampling.
Quality assurance guidelines provide the detailed procedures and actions
necessary for defining and producing acceptable data. One such document used
in this test program to ensure the collection of acceptable data and to provide
a definition of unacceptable data was the EPA Quality Assurance Handbook
Volume III, EPA-600/4-77-027.
Relative to this test program, EMB used the following steps to ensure that
the testing and analytical procedures produce quality data.
o Calibration of field sampling equipment (Appendix E).
o Checks of train configuration and on calculations.
o Use of designated analytical equipment and sampling reagents.
In addition, the analytical balance used for filter weighing by Entropy was
audited with Class "S" weights.
Audit solutions prepared by the EPA were used to check the analytical
procedures of the laboratories conducting the hexavalent and total chromium
analyses. Table 5.1 presents the results of these analytical audits. The
audit tests show that the analytical techniques were good.
The sampling equipment, reagents, and analytical procedures for this test
series were in compliance with all necessary guidelines set forth for accurate
test results as described in Volume III of the Quality Assurance Handbook.
5-1
-------
TABLE 5.1. AUDIT REPORT CHROMIUM ANALYSIS
Plant:
Task No.:
Date samples received:
Sample analyzed by: (2.7"L - Off
Reviewed by:
Date analyzed: &/I4--
G?roK"5g- Date of review:
Sample
Number
C-7C,
£-23?
C-24^>
ug/ml
Cr+b or Cr
/ro^Uofo^
/(7/^ of Or
3-50 M$ of Cr
Source of
Sample
&A]>
6?Ab
a/4i>
Audit
Value
/ W MJ l*£
(0.88 ^3
3-1Z.Z M$
Relative
Error, %
-0.1 %
+ 0.8%
- 8-3&
5-2
------- |