Size and Concentration Measurements of Particles Produced in Commercial Chromium Plating Processes

Abstract

Optical measurements of particle size and concentration were made at the chromium plating tank and exhaust system at a commercial hexavalent chromium plating facility. Particles were examined at three locations in the exhaust system: 1) directly at the hexavalent chromium plating bath surface, 2) at the exit of a cyclone separator located in the exhaust system approximately three to four meters downstream of the bath, and 3) in the exhaust stack, downstream of the induced draft fan and all abatement devices. Particle diameters at the bath surface ranged from 0.3 to 25 μm. Downstream of the cyclone exit and mesh pad filters, particle top sizes were approximately 5 and 0.7 mm, respectively. On a mass basis, the collection efficiency of all abatement devices was 99.997%. Assuming that droplets in the flow consist primarily of water and chromium, correcting the total particle mass flow against water content gives a chromium emission rate of 64,000 μg/hr, which compares favorably with a value of 77,000 μg/hr measured with EPA methods. This initial agreement, which should be validated through additional measurements over a broad range of flow conditions, raises the possibility of continuous monitoring for chromium metal emissions using particle size/mass as a surrogate.