3/10/2004 1

Reduced Air Emissions for Hard Chrome Plating at the NADEP NAS

North Island, San Diego

Using an Alternative Emission Control Technology

Presented by: Terry HutchinsSales & Marketing Manager

Equipment DivisionPalm International, Incorporated

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4. TITLE AND SUBTITLE Reduced Air Emissions for Hard Chrome Plating at the NADEP NASNorth Island, San Diego Using an Alternative Emission Control Technology

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The NADEP’s Hard Chrome Plating Facility

The NADEP facility located on the NAS North Island, San Diego, CA currently has five (5) hard chrome plating tanks in operation. The facility typically plates 3-5 million amp-hours per year and is identified as a Small Hard Chromium Electroplating Facility by the San Diego Air Pollution Control District.

3/10/2004 3

The NADEP’s Cr+6 Permit Conditions“THE HEXAVALENT CHROMIMUM EMISSIONS SHALL NOT EXCEED 0.233 POUNDS IN EVERY CONSECUTIVE 12-MONTH PERIOD. THE HEXAVALENT CHROMIUM SHALL BE DETERMINED USING THE THREE MOST RECENT APPLICABLE SOURCE TESTS APPROVED BY THE DISTRICT* FOR THE ABOVE EQUIPMENT.”

* San Diego Air Pollution Control District

3/10/2004 4

The NADEP’s Current Air Pollution Control Device

The NADEP currently incorporates a 40,000 CFM Mesh Pad Mist Eliminator Exhaust System driven by a 100 HP motor as its add-on control device. The measured Cr+6 emissions at the stack is 0.0015 mg/amp hour. At this emission level, the NADEP could plate approximately 70 million amp hours annually and remain in compliance with their permit. The exhaust fan motor is operated 24 hours per day 7 days per week at an average cost of 10.7 cents per kilowatt hour.

3/10/2004 5

ENCAPSULATING TANK COVERSThis presentation addresses the implementation of encapsulating tank covers, hereafter referred to as the Chrome Plating Emission Elimination Device (EED), on the NADEP’s hard chrome plating process tanks, as an alternate control devise used to eliminate Cr+6 emissions to the outside environment, reduce operating costs, and provide enhanced operator safety and exposure in the chrome plating facility.

3/10/2004 6

EED DEFINITION

As a stand-alone, self-contained system requiring no exhaust fans, scrubbers or mesh pad mist eliminators, fume suppressants, or exhaust ducts and vents to the outside environment, the EED System has by definition, zero emissions to the outside environment.

3/10/2004 7

CONVENTIONAL EXHAUST SYSTEM

Conventional Exhaust System

Hepa-Filters

In-Line Mesh Pad Mist Eliminator

Chrome 1 Chrome 2 Chrome 3

Mesh Pad Mist Eliminator

Exhaust Fan

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SAME TANKS WITH EED SYSTEM

EED SystemsChrome 1 Chrome 2 Chrome 3 EED Adapter

Plate

EED Cover

Water Seal

3/10/2004 9

BUILDING AN EED SYSTEMThe EED system is comprised of the following components: • Chrome Plating Tank• Adapter Plate-Tank Lip Seal• EED Adapter Plate w/Water Seal• EED Membrane & Frame• EED Membrane Cover• EED Evacuation System

3/10/2004 10

BUILDING AN EED SYSTEM

Chromic Acid Plating SolutionOperating Temperature: 135-140°F

Two-Piece Membrane Frame: 1/2" PVC Material

Copper Anode Rods

Miscellaneous Penetrations :Heating, Cooling, Solution Reicrculation, etc.

Chrome Plating Tank

EED Cover -10 to 12 Gauge T-316SS

EED Membrane MediaPore Size: 0.1 micronSized at 2 Square Foot/1000 Amps DC Current

EED Membrane Cover - 16-Gauge T-304SS

Water Seal TroughIntegral to Adapter Plate

EED Adapter Plate - FRPCoRezyn 8441Fire Retardant Vinlyester3/8" Thick, Nominal

EED Adapter Plate Seal3/16" Thick Neoprene Rubber

3/10/2004 11

BUILDING AN EED SYSTEM

3/10/2004 12

THEORY OF OPERATION

Chromic Acid Plating SolutionOperating Temperature: 135-140°F

Condensation Zone

Water Vapor Zone

Hydrogen & Oxygen Gases

EED Membrane Cover - T-304SSEED Membrane EED Cover - T-316 SS

Water Seal Trough

EED Adapter Plate - FRPEED Adapter Plate Seal

Chrome Plating Tank

Chrome Mist ZoneParticle Size 6-7

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THEORY OF OPERATIONEED Operation:

As chrome plating takes place, several things occur simultaneously beneath the EED cover. Water vapor is created due to the 135oF operating temperature of the hard chrome bath. Chrome mist is generated due to electrolysis. Additionally, hydrogen and oxygen gasses are created at the cathode and anode due to the inefficiency of the hard chrome plating bath. As the water vapor rises beneath the cover, a cloud forms blanketing the plating solution. Chrome mist that comes in contact with the cloud is “washed” by the water vapor, creating heavy chrome droplets that fall, by gravity, back into the plating tank. As the water vapor continues to rise, it comes in contact with the cover, condenses, forms water droplets, which in turn fall back into the water seal trough and plating tank. The hydrogen and oxygen gasses rise to the highest point beneath the cover where the patented membrane allows free passage of these gases into the atmosphere.

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THE EVACUATION SYSTEM

OutIn

EED MoistureSeparator

Evacuation Pipe

EED Inline Filter

EED RegenerativeBlower

EED Final HEPA Filter

Air Flow From Chrome Plate Tank

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THE EVACUATION PROCESSEvacuation System Operation:

On completion of the plating cycle, residual hydrogen and oxygen gasses and water vapor must be evacuated from the unit prior to opening the cover. Once the rectifier has been turned off, it takes approximately 3-5 minutes to complete this effort. The evacuation system consists of a regenerative blower, moisture separator, pre-filter and final HEPA filter. The operation is as follows: The blower is activated, the air flow passes through the moisture separator where residual moisture is collected, through the pre-filter, into the blower, and finally into the room atmosphere through a 0.3 micron HEPA filter.

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AIR QUALITY MONITORINGIndoor Air Quality - Monitoring Chromium+6

Emissions at Evacuation Filter

0.10

0.05

0.025

0.05

0.00030

0.02

0.04

0.06

0.08

0.1

Measu

red R

esult

sOSHA Li

mitCalO

SHA Limit

NIOSH Li

mitACGIH

Limit

Expo

sure

(mg/

m3 )

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PROPOSED NADEP EED SYSTEM, TANK NO. 1

NADEP Building 472Chrome Plating AreaEED System 1005

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PROPOSED NADEP EED SYSTEM, TANK NO. 1

EEDMCC

Air Flow

Solution Flow

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PROPOSED NADEP EED SYSTEMS

Palm

EE

D S

yste

m 1

005

Palm

EE

D S

yste

m 1

007

Palm

EE

D S

yste

m 1

006

NADEP Building 472Chrome Plating Area

Palm

EE

D S

yste

m 1

008

Palm

EE

D S

yste

m 1

009

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ADVANTAGES OF THE EED• Associated scrubber costs are eliminated.

• Potentially leaking ductwork eliminated.

• Heated make-up air requirements are eliminated.

• Fume suppressants are no longer needed.

• Energy requirements are reduced by 60-70%.

• Floor space requirements could be reduced.

• Long life estimated to be 15 years or longer.

SAVINGS

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COST

SAVINGS

EED Equipment Cost (including installation) 293,715$

Total System Cost -$ Total System Cost 293,715$

Electrical Cost 76,004$ Yearly Membrane Costs 1,250$ Fan Motor HP 100 Annual Liscense Fee -$

Amperes 127.37 Evac Filter Replacement 840$ kW 81.09 Evac System Power Costs 1,000$

kWHours 710,322 Yearly Maintenance 500$ Cost/kWH 0.107$

Make-up Air Cost (no heat) 22,801$ Fan Motor HP 30

Amperes 38.21 kW 24.33

kWHours 213,097 Cost/kWH 0.107$

Push Air Blower 38,002$ Fan Motor HP 50

Amperes 63.68 kW 40.54

kWHours 355,161 Cost/kWH 0.107$

Annual Source Test 10,000.00$ Annual Operating Cost 3,590$ Water Treatment Costs 2,500.00$ Annual Maintenance Cost 1,500.00$ First Year Equipment Cost 293,715$

First Year Operating Cost 1,000$

Annual Operating Cost 150,808$ Total First Year Cost 294,715$

Annual Estimated Operating Cost Annual Estimated Operating Cost

ESTIMATED EED COST & PAYBACK ANALYSIS

FIVE-TANK SYSTEM

Tank Size - Length: 101" x Width: 34" NADEP - SAN DIEGO, CA

Conventional Chrome Plating Tank Chrome Plating Tank w/EED System

3/10/2004 22

COST

SAVINGS

First Year Equipment Cost -$ First Year Operating Cost 150,808$

Exhaust System Investment -$

Total First Year Cost 150,808$ EED System Investment 293,715$

Equipment Savings (293,715)$

One-year Operating Cost Savings 150,808$ Total Savings One Year (142,907)$

First Year Savings (142,907)$ Second Year Savings 147,218$ Pay Back - Months 23.74

Total Installation Cost -$ Total 1st Year Cost 294,715$

10-Year Operating Cost (per above) 1,508,080$ 10-Year Operating Cost (per above) 32,310$

Total Ten Year Cost 1,508,080$ Total Ten Year Cost 327,025$

1,181,055$ Projected Ten Year Savings

10 Year Estimated Cost 10 Year Estimated Cost

EED Payback Analysis

3/10/2004 23

ADVANTAGES OF THE EED• Reduced danger of hydrogen explosion; rectifiers are off during start-up – preventing arcing. • The patented design allows hydrogen to freely leave the EED. In the unlikely event of an explosion, the EED shields the operator from any splashing solution.• Potential hood or duct fires eliminated. • Noise from fan and pump motors is eliminated. • The potential for worker exposure is minimized when the EED is installed because no Cr+6 molecules are emitted to the atmosphere while plating is taking place.

SAFETY

3/10/2004 24

AIR QUALITY MONITORINGIndoor Air Quality - Monitoring Chromium+6 Emissions

0

0.02

0.04

0.06

0.08

0.1

0.12

1 2 3 4

Sample ID (Sample Time: Approximately 300 Minutes)

Expo

sure

Res

ults

(mg/

m3 )

Actual Results

OSHA Limit

ACGIH Limit

3/10/2004 25

ADVANTAGES OF THE EEDENVIRONMENTAL

• Air: The need for exhaust hoods, ductwork and fume scrubbers/fans is eliminated.

Air: With a properly installed and operated EED system, emissions are eliminated.

• Air: Because no exhaust stacks are required, chrome fumes cannot escape into the atmosphere as they could if the scrubber system fails. The EED is environmentally friendly.

• Water: Effluent control for treating scrubber solutions is no longer required.

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ADVANTAGES OF THE EEDREGULATIONS

• Since there are no exhaust stacks with the EED, no exhaust operational reports are required. Stack source testing is eliminated resulting in savings of $10,000 annually, as required by local regulatory authorities.

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ADVANTAGES OF THE EEDPRODUCTION

• Because the EED includes a cover that must be opened, operators become more aware of their work habits. Production throughput will actually improve due this renewed attention to procedures.

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CONCLUSIONSThe EED System, when operated properly, is a proven The EED System, when operated properly, is a proven alternative control device that will meet or exceed all alternative control device that will meet or exceed all requirements of the Chrome Plating NESHAP while requirements of the Chrome Plating NESHAP while eliminating the need for conventional ventilation systems and eliminating the need for conventional ventilation systems and fume suppressants. Due to the simple design and operation of fume suppressants. Due to the simple design and operation of the EED, significant savings are achievable using this the EED, significant savings are achievable using this technology when compared to conventional exhaust systems.technology when compared to conventional exhaust systems.In the particular case of the NADEP, as shown above, tenIn the particular case of the NADEP, as shown above, ten--year year savings are estimated to be greater than $1.18 Million with an savings are estimated to be greater than $1.18 Million with an investment payback of approximately 24 months. investment payback of approximately 24 months.