Integrated Electrolytic Chrome Stripping/Recycling Technology without Hexavalent Chromium Formation

This Phase II SBIR addresses the need to eliminate the environmental and safety hazard associated with hexavalent chromium generated during conventional electrolytic chrome stripping. An integrated electrolytic FARADAYIC(R) Chrome Stripping/Recycling process will enable direct recovery of the stripped chromium metal from the electrolyte, return the electrolyte to the stripping process, and be a drop-in replacement for the current stripping process. Phase I demonstrated removal of chrome from high strength steel substrates using a weak acid electrolyte while eliminating hexavalent chromium, without adversely affecting the substrate surface. The process was scaled to 4x6 panels and the stripping rate was 1-2 mil/hr. A preliminary economic analysis showed that the process has the potential to meet DOD and OEM safety and economic requirements. There is a substantial reduction in energy use and up to an 88% savings in energy cost, which may be able to further be reduced. In Phase II we will optimize the FARADAYIC Stripping/Recycling technology, design and build a pilot-scale facility to strip larger parts, perform compatibility testing for functional performance metrics, demonstrate replating after stripping, develop the FARADAYIC Recycling unit technology to recover the chrome and enable a zero-discharge process, and further develop the economic analysis and transition plan.