Pollution Prevention Technology Profile Trivalent Chromium Replacements For Hexavalent Chromium Plating November 18, 2003
Pollution Prevention Technology Profile Trivalent Chromium Replacements For Hexavalent Chromium Plating November 18, 2003
Pollution Prevention Technology Profile Trivalent Chromium Replacements For Hexavalent Chromium Plating November 18, 2003
Introduction
The purpose of this Technology Profile is to provide general information about trivalent chromium
plating as a replacement for hexavalent chromium plating. Trivalent chromium is also known as tri-
chrome, Cr+3, and chrome (III), whereas hexavalent chromium is also known as hex-chrome, Cr+6, and
chrome (VI). The Profile has the following sections:
It should be noted that this Technology Profile is not intended to be an “approval” of this technology.
The appropriateness of the use of trivalent chromium plating technologies should be determined on a
site-by-site basis. Potential users should contact officials in the state in which the facility is located to
determine the state-specific regulatory requirements that could apply. A listing of state contacts is
located at the end of this Profile.
The most common hexavalent chromium-bearing solutions include decorative and hard chromium,
aluminum conversion coating, bright dipping of copper and copper alloys, chromic acid anodizing, and
chromate conversion coatings on cadmium, zinc, silver and copper. This Technology Profile is for the
use of trivalent chromium processes as replacements for decorative and hard hexavalent chromium
processes.
Decorative Chromium
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Decorative chromium plating provides a durable coating with a pleasing appearance and is usually
deposited in a thickness range of 0.002 to 0.020 mils. It is most often applied over a bright nickel-
plated deposit, which is usually deposited on substrates such as steel, aluminum, plastic, copper alloys
and zinc die casting. Decorative chromium plating typically ranges from 0.005 mils to 0.01 mils in
thickness. Common items with decorative chrome include appliances, jewelry, plastic knobs, hardware,
hand tools, and automotive trim.
Hard Chromium
When chromium is applied for any other purpose, or when appearance is a lesser feature, the process is
commonly referred to as hard chromium plating, or functional chromium plating. Hard chromium plating
typically ranges from 0.1 to 10 mils thickness. Common applications of functional plating include:
hydraulic cylinders and rods, crankshafts, printing plates/rolls, pistons for internal combustion engines,
molds for plastic and fiberglass parts manufacture, and cutting tools. Functional chromium is commonly
specified for rebuilding worn parts such as rolls, molding dies, cylinder liners, and crankshafts.
Chromium plating provides excellent hardness (typically 700-1,000 Vickers), bright appearance with no
discoloration, and resistance to corrosive environments; it is easily applied and has a low cost.
However, hexavalent chromium plating suffers from low cathode efficiency, poor metal distribution, lack
of coverage around holes, and is very difficult to use in barrel plating. It is also a worker- and
environment-unfriendly process. Some of the most important parameters for evaluating the effectiveness
of chromium plating include: plating thickness, hardness, plating rate, and cathode efficiency.
In the traditional hexavalent chrome plating process, the process steps are generally:
The activation bath, if used, is a separate tank of chromic acid. The activation step is typically
(depending on the alloy) a reverse current etch to prepare the surface of the parts to accept the plating
by removing oxides from the surface of the material. Sometimes the activation step takes place in the
chromium bath itself.
The composition of the chromium bath is chromic acid (CrO 3) and sulfate (SO4), with ratios ranging
from 75:1 to 250:1 by weight. The bath is extremely acidic with a pH of 0. The bath may be co-
catalyzed with fluorides. In the chromic acid, the chromium is in the +6 oxidation state, which is
reduced to Cr+3, then to unstable Cr+2 and finally to Cr0. Some Cr+3 is necessary in the bath to act as a
reducing agent, however, concentrations of Cr+3 exceeding 2-3% of the chromic acid content can cause
problems. (Many specifications require that this concentration not exceed 1%). The presence of other
oxides of metals (e.g., iron, copper, nickel) combined with the Cr+3 hinders bath performance.
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In addition to bath composition, the other important parameters are temperature and current density.
Together, these affect brightness and coverage. Generally, bath temperatures for decorative coating
range from 95 to 115o F and 120 to 150o F for hard coating. Generally, the higher the current density is,
the higher the temperature requirement. Current density also affects cathode efficiency. Agitation of the
bath is required to equalize the bath temperature and promote uniform brightness on the part.
Preheating the parts to be plated by placing them in the solution without current applied, may be
necessary to obtain a uniform deposit.
The low cathode efficiency of the hexavalent chromium results in the major issue with chromium plating:
poor coverage in low current density areas, and excessive build-up in high current density areas (e.g.
part edges). The ability of a coating to cover the part uniformly is referred to as “throwing power.” In
many cases, the part is over-plated, and ground back to final dimensions. In other cases, auxiliary
anodes are used to provide more uniform coating of the part.
Regulatory Requirements
The principal ingredient in hexavalent chromium plating solutions is chromium trioxide (chromic acid).
Chromium trioxide contains approximately 52% hexavalent chromium. Baths typically contain 28-32
ounces of hexavalent chromium per gallon. The hexavalent oxidation state is the most toxic form of
chromium which has led to it being identified by the U.S. Environmental Protection Agency (EPA) as
one of 17 “high priority” toxic chemicals for voluntary reduction through the 33/50 Program.
Air
Hexavalent chromium is a known human carcinogen and is listed as a hazardous air pollutant (HAP).
Due to low cathode efficiency and high solution viscosity, hydrogen and oxygen bubbles are produced
during the plating process, forming a mist of water and entrained hexavalent chromium. This mist is
regulated under the Clean Air Act Amendments of 1990 and the Occupational Safety and Health Act of
1970.
On January 25, 1995, EPA published the Final Rule for its "National Emission Standards for Hard and
Decorative Chromium Electroplating and Chromium Anodizing Tanks" (40 CFR Parts 9 and 63). EPA
recently reduced the emission standards for chromium from 0.05 mg/m3 to 0.03 - 0.010 mg/m3,
depending on the process, size of tank, and mist elimination technologies used. If a facility is using a
trivalent chromium process for decorative plating, there is no emission standard; only recordkeeping and
reporting requirements apply.
The Occupational Safety and Health Administration (OSHA) is scheduled to propose a new rule on
hexavalent chromium compounds by October 10, 2004. The current permissible exposure limit, ceiling
concentration, is 100 ug/m3.
Water
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Chromium air emissions are frequently controlled by wet scrubbers. The discharge of these systems is
treated with other process wastewaters. Wastewater that contains hexavalent chromium is treated first
by acidification to 2.5 pH. This is followed by reduction of the hexavalent chromium to trivalent
chromium using sulfur dioxide or sodium bisulfite. Finally, the solution is neutralized to precipitate the
chromium as chromium hydroxide. Typical discharge concentrations for hexavalent and/or total
chromium in wastewater are 0.1 to 1.0 ppm.
The EPA regulates chromium as a “priority pollutant” under the Clean Water Act. Under the Safe
Drinking Water Act, a maximum contaminant level (MCL) is set for chromium at 0.1 parts per million
(or 0.05 milligram/liter). The MCL is the maximum permissible level of a contaminant in drinking water
from a public water system.
Waste
Under the Resource Conservation and Recovery Act (RCRA), chromium is a “hazardous constituent”
and is a hazardous waste by toxicity characteristic if the concentration exceeds 5 mg/L (D007). Spent
chromium plating baths are handled as hazardous waste. Precipitated chromium hydroxide sludges are
regulated as F006 hazardous waste. For each pound of chromium that is lost to the waste treatment
operations, 9.5 pounds of sludge (35% solids) are created.
In addition, lead anodes are typically used in hexavalent chromium plating. These anodes decompose
over time, forming lead chromates, which slough off the anodes and deposit in the tank as lead chromate
sludge that must be removed from the tank by filtering or pumping and disposed of as hazardous waste.
Hexavalent chromium plating solutions are typically treated with barium compounds to control the
sulfate concentration by forming barium sulfate. This must also be disposed of as hazardous waste.
Right-to-Know Act
Under the Emergency Planning and Community Right-to-Know Act, Toxics Release Inventory (TRI)
program, all large quantity (10,000 pounds/year) users of chromium must submit data on chromium
releases and transfers.
Superfund
Under the Comprehensive Environmental Responsibility, Compensation and Liability Act (CERCLA,
better known as Superfund), chromium is a “hazardous substance.” Users are liable for damages
resulting from a release to the environment that occurs during past use or disposal practices. A
company remains liable for its waste forever, even if the release to the environment occurs off-site at
licensed disposal facility.
International
The European Union has adopted the End-of-Life Vehicle Directive in order to address the waste
associated with vehicles at the end of their useful lives. The Directive aims to ensure the reuse, recycling
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and recovery of end-of-life vehicles and their components. Hexavalent chromium is identified in the
Directive as one of the hazardous materials used in the manufacture of vehicles. As such, it is banned
from use in the manufacture of vehicles in the European Union nation states on July 1, 2003. This
Directive is creating additional incentives for U.S. manufacturers to seek out alternatives to hexavalent
chromium.
Due to increasing environmental and worker health concerns, some companies are seeking non-
chromium alternatives for hard and decorative chromium applications. While non-chromium alternatives
are not the focus of this Profile, limited information on some non-chromium alternatives is presented
here.
The following table offers a summary of some of the non-chromium replacements for hard and
decorative chromium baths. Many of the replacements are based on nickel which is also on EPA’s list
of 17 high priority chemicals for voluntary reduction through the 33/50 Program, along with chromium.
Due to its complex mix of properties, no single coating will replace hexavalent chromium in all
applications. Substitute coatings should be chosen based on the most important properties for each
application. Solution trade names and manufacturers are included so that additional information can be
obtained as needed. However, mention of any company, process, or product name should not be
considered an endorsement by NEWMOA, NEWMOA member states, or U.S. EPA.
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Table 1: Summary of Non-Chromium Substitutes for Hard and Decorative Chromium Baths
Possible Non-Chromium
Notes Vendor, Product
Replacement
Uses conventional plating equipment and operates similar to a
Nickel-tungsten-boron conventional nickel plating bath; may be more costly than hex AMPLATE
chrome
May provide higher plating rates and higher cathode current
Electroplated nickel
Nickel-tungsten-silicon-carbide efficiencies; may provide better throwing power and better wear Takada Inc.
resistance; may be more costly than hex chrome
Good corrosion resistance in strong acids, breaks down above
Tin-nickel
320C, less wear resistance than hex chrome
Shining Surface Systems, METTEX 6
Vendor claims twice the wear resistance and 2.6 times the
Nickel-iron-cobalt (http://www.surface-
corrosion resistance of hex chrome; same color can be obtained
systems.com/presentation_6.html),
Contains no chloride or strong chelators; can be used in rack and Enthone, Enloy Ni-150
Nickel-tungsten-cobalt barrel plating; good corrosion resistance except in marine http://www.afonline.com/articles/00sum03.h
environments; may tarnish; contains ammonia tml
Seaboard Metal Finishing, Seachrome
Plate on nickel; decorative only
Non-nickel electroplate
www.seaboardmetalfin.com
Plate on decorative nickel and nickel alloy; may be used in
Tin-cobalt Enthone, Achrolyte
racking; mildly alkaline
Great color, light blue cast; no ammonia; no fluorides; no
MacDermid, CROMVET
chlorides
Nano-crystalline deposit produces extreme hardness;
Integran Technologies, Inc.
Cobalt Phosphorous Plating current waveform modification (electrically mediated
http://www.integran.com/
deposition) used to produce nanocrystalline deposit.
Electroless nickel
-nickel-tungsten Abrite, Millenium series, www.abrite.com
Electroless
In some applications and at certain thicknesses, trivalent chromium plating can replace hexavalent
chromium. This is especially true for decorative applications where the trivalent chromium finish can
closely resemble the hexavalent chromium finish. Generally, the trivalent chromium process is similar to
that for hexavalent chromium except for the bath and the anode composition and/or configuration used.
Trivalent chromium plating baths can be divided into the following three basic types:
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1. Single electrolyte bath (chloride- or sulfate-based) using graphite or composite anodes and additives
to prevent oxidation of trivalent chromium at the anodes.
2. Sulfate-based bath using shielded anodes (lead anodes surrounded by boxes filled with sulfuric acid)
which prevent the trivalent chromium from reaching the anodes, thus preventing their oxidation.
3. Sulfate-based using insoluble catalytic anode that maintains an electrode potential level that
preventions oxidation of the trivalent chromium.
Trivalent chromium baths overcome the shortcomings of hexavalent chromium in three general areas:
Generally, the trivalent chromium plating rate and hardness of the deposit is similar to hexavalent
chromium plating. Trivalent chromium baths also operate in the same temperature ranges as hexavalent
chromium baths. Generally, the range of plating thickness for trivalent chromium is 0.005 to 0.050 mils.
Trivalent chromium baths tend to be more sensitive to metallic impurities than hexavalent chromium
baths. Impurities can be removed by using ion exchange or precipitating agents followed by filtration.
When trivalent chromium plating was first introduced, decorative customers generally did not accept the
different color tones compared to hexavalent chromium. However, additives to the trivalent chromium
bath can often adjust the tone to customers’ decorative coating needs.
To more closely resemble the functionality of hard chromium plating, pulse current plating has been used
in a trivalent chromium solution. However, these thicker trivalent chromium finishes have not quite
matched the corrosion resistance of a functional hexavalent chromium finish.
While the use of a trivalent chromium process instead of a hexavalent chromium process is more
protective of human health and the environment in and of itself, the potential pollution resulting from the
trivalent chromium processes can be further reduced by using pollution prevention techniques. For
example, static rinse tanks can be used to capture the drag out for return to the plating tank for reuse in
the bath makeup water. In addition, the plating bath can be recycled and recovered for reuse using
porous pots, membrane electrolysis, or ion exchange.
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Concurrent Technologies Corporation (www.ctc.com) is currently testing functional trivalent chromium
coatings from a few vendors. The results of this work should be available in 2004; contact technical
manager Margo Neidbalson ([email protected]) for additional information.
Research is on-going in the area of charge modulated electrodeposition to enhance the plating of
trivalent chromium by eliminating the adverse effects of hydrogen in the bath. (See Faraday
Technologies in the Vendor section).
The trivalent chromium products share these benefits and challenges for potential users when compared
to hexavalent chromium plating.
Benefits
Air Emissions
The trivalent chromium processes have higher cathode efficiencies than hexavalent chromium plating
which results in less chromium mist emitted into the air. Therefore, air pollution treatment requirements
are significantly reduced. Because air treatment is typically by wet scrubbing, wastewater treatment
requirements are also significantly reduced.
In addition, with trivalent chromium the anodes do not decompose, eliminating the sludge associated
with hexavalent chromium anode decomposition. The trivalent chromium processes produce
approximately thirty times less sludge (by volume) than the use of hexavelant chromium baths which can
significantly reduce hazardous material handling and disposal costs. In addition, the chromium in the
wastes is not in the more hazardous hexavalent form.
Energy Use
The trivalent chromium processes require less current density, so less energy is used compared with the
hexavalent chromium processes.
Product Quality
The throwing power is better in the trivalent chromium processes. The trivalent chromium processes
can also withstand current interruption without sacrificing finish quality, whereas the hexavalent
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chromium processes cannot. Therefore, a trivalent process has the potential to lower touchup and
rework costs, and improve customer satisfaction.
Production Rate
Due to the improved throwing power, rack densities can often be increased significantly.
Lower Toxicity
The trivalent processes are inherently less toxic due to the oxidation state of the chromium. In addition,
the trivalent chemistries also require a lower concentration of chromium in the bath, generally, 2/3 to 1
ounce/gal (5-7.5 g/L) of trivalent chromium compared to 17-30 ounces/gal (130-225 g/L) for
hexavalent chromium. Therefore, the toxicity of the trivalent chromium plating solutions is much lower
than hexavalent chromium solutions.
Worker Exposure
The lower toxicity of trivalent chromium combined with the lower concentration of chromium in the bath
and the substantial reduction in hazardous waste sludge produced mean that less hazardous material has
to be handled. In addition, substantially less air emissions are generated from the trivalent chromium
process. Finally, trivalent chromium baths have a higher pH than hexavelant baths, reducing the
potential for adverse damage. Therefore, the use of trivalent chromium solutions provides less potential
for worker exposure.
Regulatory Compliance
It is becoming increasingly difficult to comply with air emissions and worker health requirements of
hexavalent chromium plating operations. Due to its lower toxicity, trivalent chromium is not regulated as
aggressively, and therefore, compliance costs such as monitoring and recordkeeping can be lower.
Challenges
Chromium
Trivalent chromium processes still contain chromium, and therefore, are still potentially hazardous and
could be subject to future increased regulation.
Cost
The actual cost of the trivalent and hexavalent chromium processes are dependant on many factors and
are difficult to compare in a general sense. In general, chemical costs for trivalent chromium plating are
more costly than hexavalent chromium plating. However, when increased production rates, and the
costs of hazardous waste sludge disposal, and compliance with the restrictions placed on the use of
hexavalent chromium by the EPA and OSHA are factored in, the use of trivalent chromium may be a
good option for some applications. In addition, as noted previously, in some instances product quality
can be improved, reducing rework costs.
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Technical Capabilities
The trivalent chromium process may require more careful control than the hexavalent chromium process.
As mentioned previously, trivalent chromium baths tend to be more sensitive to metallic impurities. In
addition, trivalent chromium plating may not be suitable to replace every hexavalent chromium plating
requirement. For example, barrel plating with trivalent chromium solutions is possible, but difficult.
Process conditions, part configuration and other variables must be controlled for successful barrel
plating.
Change
Hexavalent chromium plating has been an industry standard for many, many years. Customers have
been satisfied with its range of properties and cost and therefore demand it. Specifications often require
hexavalent chromium plating. Platers are used to running hexavalent chrome baths. Change can be
difficult for people to seek out and/or accept.
Foss Plating in Sante Fe Springs, California, is a small, family-run chrome plating shop that has been in
business more than 40 years. They converted a hexavalent chromium plating line to a fully automated
single chrome-cell (III) system in 1989. At that time, the cost of conversion was approximately
$30,000.
As a result of the conversion, Foss Plating realized a return on their investment within the first year of
operating the chrome (III) system. They saw an increase in productivity, greater system efficiency,
fewer rejects, and lower treatment costs. The better throwing power and covering power of chrome
(III) allowed them to increase the surface area on the racks by 70 percent. At the same time, they
experienced a more than 90 percent decrease in the number of rejected parts and eliminated almost all
need for color buffing. Foss also found that chrome (III) plated more efficiently from an energy
standpoint.
The two biggest disadvantages Foss Plating experienced with chrome (III) were discoloration from
impurities in the bath and the need to passify the non-plated areas of the parts.
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Contacts for More Information
Mention of any company, process, or product name should not be considered an endorsement by
NEWMOA, NEWMOA member states, or U.S. EPA.
Atotech (www.atotechusa.com)
produces TriChrome® Plus, a decorative trivalent chromium process. Atotech states that the bath has
a low chromium metal content, exceptional covering power and produces a micro-discontinuous
deposit. This process is most appropriate for rack plating needs.
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Typically hexavalent chromium plating is performed using cathodic DC current. In this case, the
waveform is modified to include cathodic DC current, anodic DC current and relaxation, or zero
current, phases. The modulation of these current phases, including frequency and peak amperages,
allow:
• improvements in mass transfer of chromium ions to the part surface, improving plating rate; and,
• reduction in hydrogen evolution at the surface, reducing hydrogen embrittlement and improving
deposit characteristics such as corrosion resistance, adhesion, lower porosity, deposit stress.
In Connecticut: In Maine:
Kim Trella Peter Cooke
Department of Environmental Protection Department of Environmental Protection
79 Elm Street 17 State House Station
Hartford, CT 06106 Augusta, ME 04333
(860) 424-3242 (207) 287-6188
In Massachusetts: In Massachusetts:
John Raschko Linda Benevides, STEP Program
Office of Technical Assistance Executive Office of Environmental Affairs
251 Causeway Street, Suite 900 251 Causeway Street
Boston, MA 02114 Boston, MA 02108
(617) 292-1093 (617) 626-1197
In Vermont: At NEWMOA:
Greg Lutchko Jennifer Griffith
Department of Environmental Conservation NEWMOA
103 South Main Street 129 Portland Street, 6th Floor
Waterbury, VT 05671 Boston, MA 02114
(802) 241-3627 (617) 367-8558, ext. 303
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References
Chessin, Hyman et al., “Chromium Plating” in Metals Handbook – Volume 5, Metal Park, OH:
American Society for Metals.
Concurrent Technologies Corporation, “Information Source for Cadmium and Chromium Plating
Alternatives,” http://www.cdcralternatives.ctc.com/
EPA, “Final Report: A Cost-Competitive Functional Trivalent Chromium Plating Process To Replace
Hexavalent Chromium Plating”
http://cfpub.epa.gov/ncer_abstracts/index.cfm/fuseaction/display.abstractDetail/abstract/1363/report/F
EPA, “National Emission Standards for Hard and Decorative Chromium Electroplating and Chromium
Anodizing Tanks,” 40 CFR Parts 9 and 63), http://www.epa.gov/ttnatw01/chrome/chromepg.html
Graves, Beverly, “Alternatives to Hexavalent Chromium and Chromium Plating,” Winter 2000:
Automotive Finishing Online, http://www.afonline.com/articles/00win02.html
Northeast Waste Management Officials’ Association, “Pollution Prevention for the Metal Finishing
Industry: A Manual for Technical Assistance Providers,” February 1997,
http://www.wmrc.uiuc.edu/manuals/finishing/toc1.htm
Occupational Safety and Health Administration, “OSHA Plans Proposed Rule on Hexavalent
Chromium Compounds,” 12/4/02,
http://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=NEWS_RELEASES&p_id=984
2 http://www.osha.gov/pls/oshaweb.
Toxics Use Reduction Institute, “Chemical Factsheet: Hexavalent Chromium and Compounds,” 2000.
Wynn, Paul and Craig Bishop, “Replacing Hexavalent Chromium,” February 2001: PF Online,
http://www.pfonline.com/articles/020102.html
Zaki, Nabil, “Chromium Plating,” 2003 Products Finishing Directory and Technology Guide, December
2002, and PF Online, 2000 Products Finishing Directory,
http://www.pfonline.com/articles/pfd0016.html
The Northeast Waste Management Officials’ Association (NEWMOA) is a nonprofit, nonpartisan interstates
organization that addresses regional waste and pollution prevention issues. The membership is composed of state
environmental agency directors of the hazardous waste, solid waste, waste site cleanup, pollution prevention and
underground storage tank programs in Connecticut, Maine, Massachusetts, New Hampshire, New Jersey, New York,
Rhode Island, and Vermont. NEWMOA provides a forum for increased communication and cooperation among the
member states, a vehicle for the development of unified position on various issues and programs, and a source for
research and training.
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