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EMISSION FACTOR DOCUMENTATION for AP-42 SECTION 12.20 Electroplating

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EMISSION FACTOR DOCUMENTATION for AP-42 SECTION 12.20 Electroplating Emission Factor Documentation for AP-42 Section 12.20 Electroplating Final Report For U. S. Environmental Protection Agency Office of Air Quality Planning and Standards Emission Factor and Inventory Group EPA Contract 68-D2-0159 Work Assignment No. III-01 MRI Project No. 4603-01 July 1996 Emission Factor Documentation for AP-42 Section 12.20 Electroplating Final Report For U. S. Environmental Protection Agency Office of Air Quality Planning and Standards Emission Factor and Inventory Group Research Triangle Park, NC 27711 Attn: Mr. Ron Myers (MD-14) EPA Contract 68-D2-0159 Work Assignment No. III-01 MRI Project No. 4603-01 July 1996 NOTICE The information in this document has been funded wholly or in part by the United States Environmental Protection Agency under Contract No. 68-D2-0159 to Midwest Research Institute. It has been reviewed by the Office of Air Quality Planning and Standards, U. S. Environmental Protection Agency, and has been approved for publication. Mention of trade names or commercial products does not constitute endorsement or recommendation for use. ii PREFACE This report was prepared by Midwest Research Institute (MRI) for the Office of Air Quality Planning and Standards (OAQPS), U. S. Environmental Protection Agency (EPA), under Contract No. 68-D2-0159, Work Assignment No. III-01. Mr. Ron Myers was the requester of the work. Approved for: MIDWEST RESEARCH INSTITUTE Roy Neulicht Program Manager Environmental Engineering Department Jeff Shular Director, Environmental Engineering Department July 1996 iii CONTENTS Page LIST OF FIGURES ........................................................... viii LIST OF TABLES ........................................................... ix 1. INTRODUCTION ......................................................... 1-1 2. INDUSTRY DESCRIPTION ................................................. 2-1 2.1 INDUSTRY CHARACTERIZATION ..................................... 2-1 2.2 PROCESS DESCRIPTION ............................................. 2-1 2.2.1 Chromium Electroplating ......................................... 2-2 2.2.2 Other Types of Electroplating ...................................... 2-10 3. GENERAL DATA REVIEW AND ANALYSIS PROCEDURES ..................... 3-1 3.1 LITERATURE SEARCH AND SCREENING ............................... 3-1 3.2 DATA QUALITY RATING SYSTEM ..................................... 3-1 3.3 EMISSION FACTOR QUALITY RATING SYSTEM ......................... 3-3 3.4 EMISSION TEST METHODS FOR CHROMIUM ELECTROPLATING AND CHROMIC ACID ANODIZING ......................................... 3-3 3.5 FACTORS AFFECTING CHROMIUM EMISSIONS FROM ELECTROPLATING AND ANODIZING ................................................... 3-5 3.6 EMISSION FACTOR UNITS FOR ELECTROPLATING AND CHROMIC ACID ANODIZING ........................................................ 3-8 3.6.1 Electroplating Emission Factor Units ................................ 3-8 3.6.2 Chromic Acid Anodizing Emission Factor Units ........................ 3-8 4. AP-42 SECTION DEVELOPMENT ........................................... 4-1 4.1 REVIEW OF SPECIFIC DATA SETS ..................................... 4-1 4.1.1 Reference 1 .................................................... 4-1 4.1.2 Reference 2 .................................................... 4-1 4.1.3 Reference 3 .................................................... 4-2 4.1.4 Reference 4 .................................................... 4-3 4.1.5 Reference 5 .................................................... 4-4 4.1.6 Reference 6 .................................................... 4-4 4.1.7 Reference 7 .................................................... 4-6 4.1.8 Reference 8 .................................................... 4-7 4.1.9 Reference 9 .................................................... 4-7 4.1.10 Reference 10 ................................................... 4-8 4.1.11 Reference 11 ................................................... 4-9 4.1.12 Reference 12 ................................................... 4-10 4.1.13 Reference 13 ................................................... 4-11 4.1.14 Reference 14 ................................................... 4-12 4.1.15 Reference 15 ................................................... 4-13 4.1.16 Reference 16 ................................................... 4-13 4.1.17 Reference 17 ................................................... 4-15 4.1.18 Reference 18 ................................................... 4-15 4.1.19 Reference 19 ................................................... 4-16 4.1.20 Reference 20 ................................................... 4-17 4.1.21 Reference 21 ................................................... 4-18 iv TABLE OF CONTENTS (continued) Page 4.1.22 Reference 22 ................................................... 4-19 4.1.23 Reference 23 ................................................... 4-19 4.1.24 Reference 24 ................................................... 4-19 4.1.25 Reference 25 ................................................... 4-20 4.1.26 Reference 26 ................................................... 4-20 4.1.27 Reference 27 ................................................... 4-21 4.1.28 Reference 28 ................................................... 4-21 4.1.29 Reference 29 ................................................... 4-21 4.1.30 Reference 30 ................................................... 4-22 4.1.31 Reference 31 ................................................... 4-22 4.1.32 Reference 33 ................................................... 4-23 4.1.33 Reference 58 ................................................... 4-23 4.1.34 Reference 59 ................................................... 4-24 4.1.35 Reference 62 ................................................... 4-24 4.1.36 Reference 63 ................................................... 4-25 4.1.37 Reference 66 ................................................... 4-25 4.1.38 Reference 67 ................................................... 4-25 4.1.39 Reference 71 ................................................... 4-26 4.1.40 Reference 74 ................................................... 4-27 4.1.41 Reference 75 ................................................... 4-27 4.1.42 Reference 77 ................................................... 4-27 4.1.43 Reference 78 ................................................... 4-28 4.1.44 Reference 81 ................................................... 4-28 4.1.45 Reference 83 ................................................... 4-29 4.1.46 Reference 84 ................................................... 4-29 4.1.47 Reference 85 ................................................... 4-29 4.1.48 Reference 86 ................................................... 4-30 4.1.49 Reference 88 ................................................... 4-30 4.1.50 Reference 89 ................................................... 4-31 4.1.51 Reference 90 ................................................... 4-31 4.1.52 Reference 93 ................................................... 4-31 4.1.53 Reference 94 ................................................... 4-32 4.1.54 Reference 95 ................................................... 4-32 4.1.55 Reference 98 ................................................... 4-33 4.2 DEVELOPMENT OF CANDIDATE EMISSION FACTORS ................... 4-34 4.2.1 General Procedures .............................................. 4-34 4.2.2 Hard Chromium Electroplating ..................................... 4-35 4.2.3 Decorative Chromium Electroplating ................................. 4-36 4.2.4 Chromic Acid Anodizing .......................................... 4-37 4.2.5 Total PM Emissions From Chromium Electroplating and Chromic Acid Anodizing ................................................. 4-38 4.2.6 Electroplating of Other (Nonchromium) Metals ......................... 4-39 4.2.7 Statistical Analysis of Emission Factor Data ........................... 4-39 v TABLE OF CONTENTS (continued) Page 4.3 ESTIMATES OF EMISSIONS FROM OTHER TYPES OF ELECTROPLATING ... 4-39 4.3.1 Uncontrolled Emissions From Nonchromium Electroplating ................ 4-39 4.3.2 Controlled Emissions From Nonchromium Electroplating ................. 4-40 4.3.3 Emissions From Air Sparging and Electroless Plating .................... 4-41 4.3.4 Example Calculations ............................................ 4-42 5. PROPOSED AP-42 SECTION 12.20 .......................................... 5-1 vi LIST OF FIGURES Figure Page 2-1 Flow diagram for a typical hard chromium plating process .................. 2-13 2-2 Flow diagram for decorative chromium plating on a metal substrate ........... 2-14 2-3 Flow diagram for a typical chromic acid anodizing process ................. 2-15 vii LIST OF TABLES Table Page 4-1. REFERENCES NOT USED FOR EMISSION FACTOR DEVELOPMENT ...... 4-44 4-2. SUMMARY OF PARAMETERS AND RESULTS OF EMISSION TESTS FOR REFERENCE 1 .................................................... 4-46 4-3. SUMMARY OF PARAMETERS AND RESULTS OF EMISSION TESTS FOR REFERENCE 2 .................................................... 4-47 4-4. SUMMARY OF PARAMETERS AND RESULTS OF EMISSION TESTS FOR REFERENCE 3 .................................................... 4-48 4-5. SUMMARY OF PARAMETERS AND RESULTS OF EMISSION TESTS FOR REFERENCE 4 .................................................... 4-49 4-6. SUMMARY OF PARAMETERS AND RESULTS OF EMISSION TESTS FOR REFERENCE
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