CHROME
Chrome plating involves the electrolytic deposition of chromium onto metal components. Plating baths of hexavalent chromic acid are the most widely used in the industry. These baths produce very fine mists of chromic acid which must be controlled. Airborne emissions of hexavalent chrome are facing increasingly stringent pollution abatement requirements.
In almost all applications where high efficiency control of hexavalent chromium is required for regulatory compliance, Kimre’s B-GON® Mist Eliminator Systems featuring its composite mesh-pad designs have been used. EPA-sponsored test results have shown that Kimre systems exceed the most stringent requirement in the U.S. and around the world. Our designs achieve emissions below 0.002 mg/m3.
Our systems provide the lowest economic impact to the customer when compared to other competing technologies.
Composite mesh-pad technology has been determined to be the most effective control technique and represents the most reasonable approach to controlling emissions of chromic acid from all hard chrome plating operations.
Kimre designs typically incorporate several stages of our composite mesh-pads. Each stage provides progressively higher efficiency. The initial stages provide coarse separation and the bulk removal of the chromic acid mists. Our intermediate stage provides greater than 99% collection of all droplets down to 1 micron in size. This level of performance is required to meet the most stringent emission limits. However, the stage is also protected from fouling and maintenance due to the stage-wise separation of the droplets.
Our composite B-GON® mesh-pads are provided in removable cassettes which allow for ease of cleaning and maintenance, when necessary. This feature allows the B-GON Pads to be cleaned and re-used for many years, providing cost-effective solutions for your plating emission needs.
Let Kimre engineers review your process emission needs. We are happy to provide the best, most cost-effective designs of chrome scrubbers to meet your requirements.
Use Case History: Chrome Plating
Background
- Chrome Plating
- Significance: Chrome plating, commonly referred to as chromium electroplating, is a crucial technique in metal finishing for applying a thin layer of chromium onto substrates such as steel, aluminum, or plastic. This process enhances the substrate's mechanical properties, including hardness, corrosion resistance, and aesthetic quality. It is extensively utilized in automotive, aerospace, electronics, and industrial machinery applications.
Process Description:- Electroplating Technique: The chrome plating process involves immersing the substrate in an electrolytic bath containing chromic acid (H₂CrO₄) and sulfuric acid (H₂SO₄). An electric current is passed through the solution, facilitating the reduction of chromium ions to metallic chromium, which deposits onto the substrate. Key parameters include bath composition, temperature, pH, and current density, all of which are tightly controlled to ensure high-quality deposition.
- Bath Chemistry: The bath solution typically consists of chromic acid to provide chromium ions and sulfuric acid to stabilize the bath’s pH. The concentration of these chemicals, combined with the electroplating conditions, dictates the quality and characteristics of the deposited chromium layer.
Key Products- Chromium-Plated Components: The application of chromium plating results in components with superior hardness, wear resistance, and an enhanced surface finish. This includes decorative coatings for automotive trim, protective coatings for aerospace parts, and functional coatings for industrial tools and machinery.
Challenges
- Pollutants
- Hexavalent Chromium (Cr(VI)): The chromic acid plating process generates hexavalent chromium, a highly toxic and carcinogenic compound. Effective control measures are essential to manage Cr(VI) emissions and prevent environmental and health hazards.
- Chemical Waste: The plating operation produces significant quantities of chemical waste, including spent plating solutions and chromium-containing residues, which must be managed to mitigate environmental contamination.
- Process Water Contaminants: Wastewater from the plating process contains toxic chromium compounds and requires sophisticated treatment to meet environmental discharge standards.
- Regulatory Compliance
- Emissions Control: Compliance with environmental regulations necessitates the implementation of advanced technologies for capturing and neutralizing Cr(VI) emissions from plating operations.
- Waste and Water Management: Proper management of chemical waste and process water is required to adhere to regulations concerning waste treatment and water discharge, ensuring minimal environmental impact.
- Process Efficiency
- Optimization Needs: Process optimization involves improving bath chemistry, current distribution, and plating parameters to maximize coating quality and minimize waste. This includes fine-tuning operational variables to enhance efficiency and reduce costs.
- Waste Minimization: Strategies to reduce chemical waste and optimize resource utilization are crucial for operational cost management and environmental sustainability.
Solutions
- Emission Control Technologies
- Advanced Scrubbing Systems: Implement high-efficiency wet and dry scrubbing systems designed to capture and remove hexavalent chromium emissions and other pollutants from exhaust streams. These systems use various scrubbing solutions and techniques to achieve high removal efficiencies.
- Mist Eliminators: Employ mist eliminators to effectively capture and remove aerosolized chromium compounds and particulates from the exhaust, ensuring compliance with air quality standards and reducing atmospheric contamination.
- Chromium Control
- Chromium Recovery Systems: Integrate systems designed for the recovery and recycling of chromium from waste streams, thereby reducing the consumption of raw materials and minimizing waste. These systems can include chemical precipitation, ion exchange, and other recovery technologies.
- Advanced Filtration Systems: Implement state-of-the-art filtration systems such as membrane filtration and ion exchange to effectively remove chromium compounds and other contaminants from process water, ensuring compliance with discharge regulations.
- Process Optimization
- Plating Efficiency: Apply advanced process controls and optimization techniques to improve bath composition, current distribution, and plating conditions. This enhances coating uniformity and quality while reducing defects and waste.
- Energy Efficiency: Incorporate energy-efficient technologies and practices to reduce energy consumption and operational costs. This includes optimizing heat integration, employing energy recovery systems, and improving process management.
Benefits
- Compliance
- Regulatory Adherence: Ensures compliance with stringent environmental regulations, reducing legal and financial risks associated with hazardous emissions and waste management.
- Efficiency
- Process Improvement: Enhanced process efficiency results in cost savings, increased productivity, and optimized resource utilization, leading to superior coating quality and reduced operational costs.
- Protection
- Equipment Durability: Advanced emission control and waste management systems protect equipment from corrosive effects, extending operational lifespan and reducing maintenance requirements.
- Environmental Impact
- Sustainable Practices: Effective management of emissions, and waste minimizes the environmental footprint of chromic acid plating, supporting sustainability initiatives and improving overall environmental performance.
Implementation
- Recommended Products
- Wet Scrubbers: Advanced wet scrubbers with high-efficiency mist eliminator filters designed for the effective removal of hexavalent chromium and particulates from exhaust streams.
- High-Efficiency Filters: Specialized filtration systems to capture the finest contaminants and enhance air and water quality.
- Custom Solutions
- Tailored Systems: Develop and implement custom-engineered solutions to address specific emission profiles and operational requirements of chromic acid plating facilities.
- Seamless Integration: Ensure the integration of new technologies into existing systems with minimal disruption, enhancing overall process efficiency and regulatory compliance.
- Operational Continuity
- Efficiency Enhancement: Ensure that newly implemented systems and technologies contribute to improved process efficiency and regulatory compliance, minimizing disruptions to ongoing operations.
