P.1 

OAR Box 1500 

Prepped by Ollie Stewart 

Document Number: 

46) ll-C-72 

Docket Number: 

A-94-52 

Printed 8/5/2008 1:51:28 PM Sheet 46 of 343 
P.2 

A-94-52 August 26, 1997 

H-C-rjfc 

Aocj2(b;/ff^ 

UNITED STATES ENVIRONMENTAL PROTECTION AGENCY 

Office of Air Quality Planning and Standards 

Emission Standards Division 

Coatings and Consumer Products Group 

Research Triangle Park, NC 27711 

FACSIMILE COVER SHEET 

EPA 

Please Print in Black Ink Only 

TO 

Steve McNally 

OFFICE 

Composites Fabricators Association 

FROM 

Madeleine Strum 

TELEPHONE* 

703 610 0220 

FAX PHONE # 

703 619 9756 

TELEPHONE # 

919 541 2383 

SUBJECT Information you requested at the Aug 19, 1997 meeting with EPA 

COMMENTS 

Attached is the information you requested. Attachment 1 is contains the resin cost determination. 

Please note that since Ashland will not confirm the numbers (we did get them from Ashland, but 

they won't sign the contact report) we will need to go the the Chemical Marketing Reporter for 

cost information. Alternatively, if you have a better idea on how to determine resin costs, please 

provide this information (and documentation) to us. Attachments 2-4 are copies of the add-on 

control spreadsheets that were used to estimate costs for the 3 different control devices in the 

example on page 8 of the Aug 19, 1997 briefing package. The methodology is in part from the 

document published by EPA's Office of Research and Development on the Assessment of Styrene 

Emission Controls for 

FRP/C and Boat Building Industries (EPA-600/R-96-109) and from the Addendum (EPA-600/R-96-

136). 

5 ?as^ 
P.3 

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<y ft fiff JM* &*>**+ / 

Project File *. 

January 8,1997 

Page 7 .* 

t 

Current and Compliant Cost Calculations 

Resin Costs 

According to information obtained fiom Ashland Chemical Company, a general purpose 

polyester resin containing 40 percent styrene by weight costs $0.70 per pound. A premium 

polyester resin with a 40 percent styrene content costs $0.85 per pound. The styrene cost is 

$0.30 per pound and directly affects the cost of a particular resin.' Thus, the price of a particular 

resin is determined by the styrene content and the quality grade of tiie resin. Assuming the use of 

a general purpose resin, the cost of pure resin without styrene is 96.7 cents per pound and was 

calculated as follows: 

4fS0.70/lb of 40% stvrene resin - ($0.30/lb stvrene x 0.4 lbs stvrene/lb of 40% stvrene resin) 

0.6 lbs of resin/1.0 lb of 40% styrene resin 

The cost of general purpose resin with various styrene contents was calculated based on a styrene 

cost of 30 cents per pound and a resin cost of 96.7 cents per pound. For example, a 

35% styrene resin costs: (0.35 lbs x $0.30/lb) + (0.65 lbs x $0.967/lb) - $0.734/lb 

Current Resin Costs. The current resin cost for each individual facility is based on the 

current amount of resin used at the facility and the cunent styrene percentage ofthe resin. -

Example price calculation for current resin usage: Facility A uses 16.5 tons per year of a 45% 

styrene resin: 

((0.45 lbs x $0.30/lb) + (0.55 lbs x $0.967/lb)) x 16.5 tons/yr x 2,000 lbs/ton - $22,006/yr 

"Z~-
CP 

CATALYTIC OXIDIZER 

' * * 

2 

3 

4 

b 

B 

7 

U 

9 

10 

11 

12 

13 

14 

15 

16 

17 

18 

19 

20 

21 

22 

23 

24 

25 

26 

27 

28 

A 

PARAMETER 

Flowrate (cfm) 

Control device input mass (tons/year) 

Concentration (ppm) 

Facility operating schedule (hours/year) 

Catalytic oxidizer temperature (F) 

Fuel cost, ($/million BTU) 

Electricity cost, ($/kwhr) 

COST CALCULA TIONS 

Heat recovery (%) 

Electrical power (kW) 

Fuel usage (Btu/hr) 

Equipment cost (EC), (Vendor quotes, July 1995 dollars for HR = 95%) 

Equipment Cost (EC), (CE equip, cost index, July 1995 dollars) 

Total Direct Cost (T0C), ($) 

Total Capital Investment (TCI), ($) 

Direct operating costs, minus utilities ($/year) 

Thermal incinerators fuel cost ($/year) ' 

Electrical cost ($/year) 

Overhead, property tax, insurance, administration ($/year) 

Capital recovery cost ($/year) 

Total annualized cost ($/year) ' ^ 

Cost per unit pollutant removed ($/ton) 

B 

INPUT 

0 

100 

50 

6664 

625 

4.5 

0.06 

0 

43 

24,540,068 

349,154 

399,447 

713,377 

861,971 

27,003 

735,908 

17,338 

50,680 

125,581 

956,509 

10,069 

C 

CALC. 

37,061 

100.000 

50 

35 

72 

15,766,202 

297,158 

339,961 

620,580 

747,046 

27,003 

472,797 

28,896 

46,083 

108,837 

683,616 

7,196 

D 

50 

101 

12,005,974 

428,300 

489,992 

854,629 

1,036,906 

27,003 

360,035 

40,454 

57,678 

151,067 

636.237 

E 

70 

152 

6,992,336 

483,623 

553,285 

953,365 

1,159,186 

27,003 

209,686 

60,682 

62,569 

168,882 

528,821 

F 

95 

159 

725,289 

755.916 

755,916 

1,269.469 

1,550,670 

27,003 

21,750 

63.571 

78,228 

225,917 

416,469 

6,697 5,567 4,384 

1 / 

I: 

Page 1 

I 
THERMAL OXIDIZER 

2 

3 

4 

b 

6 

7 

8 

y 

10 

i i 

12 

13 

14 

15 

16 

17 

IB 

19 

20 

21 

22 

23 

24 

25 

26 

27 

28 

A 

PARAMETER 

Flowrate (cfm) 

Control device input mass (tons/year) 

Concentration (ppm) 

Facility operating schedule (hours/year) 

Thermal oxidizer temperature (F) 

Fuel cost, ($/million BTU) 

Electricity cost, ($/kwhr) 

COST CALCULATIONS 

Heat recovery (%) 

Electrical power (kW) 

Fuel usage (Btu/hr) 

Equipment cost (EC), (OAQPS Manual, 1988 dollars) 

Equipment Cost (EC), (CE equip, cost index, July 1995 dollars) 

Total Direct Cost (TDC), ($) 

Total Capital Investment (TCI), ($) 

\ 

Direct operating costs, minus utilities ($/year) 

Thermal incinerators fuel cost ($/year) 

Electrical cost ($/year) 

Overhead, property tax, insurance, administration ($/year) 

Capital recovery cost ($/year) 

Total annualized cost ($/year) 

Cost per unit pollutant removed ($/ton) 

B 

INPUT 

0 

100 

50 

6664 

1450 

4.5 

0.06 

" 

0 

29 

61,669,791 

122,621 

140,321 

309,141 

361,340 

27,003 

1,849,354 

11,558 

30,655 

52,644 

1,971,213 

20,114 

C 

CALC. 

37,061 

100 

50 

35 

58 

39,900,522 

204,608 

234,143 

455,503 

542,604 

27,003 

1,196,537 

23,117 

37,906 

79.052 

1,363,614 

13,914 

D 

50 

87 

30,570,835 

237,149 

271,380 

513.593 

614.547 

27,003 

916,758 

34,675 

40,783 

89,533 

1,108,753 

11.314 

E 

70 

137 

18,131,253 

296,118 

338,861 

618.864 

744,921 

27,003 

543,720 

54,903 

45,998 

108,527 

780,151 

7,961 

F 

95 

152 

2,581,775 

649,196 

742,906 

1,249,173 

1,525,534 

27,003 

77,422 

60,895 

77,223 

222,255 

464,797 

4.743 

Page 1 

M 
P.6 

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H 

ROTARY CONCENTRATOR 

* ) • 

4^&&hn.4m+4' 

Cost spreadsheet for the rotary concentrator 

PARAMETER 

Flowrate (cfm) 

Control device input mass (tons/year) 

Concentration (ppm) 

Facility operating schedule (hours/year) 

Thermal oxidizer temperature (R 

Fuel cost, ($/million BTU) 

Electricity cost, ($/kwhr) 

COST CALCULA TIONS 

Heat recovery (%) 

Electrical power (kW) 

Fuei usage (Btu/hr) 

Equipment cost (EC), (Durr budgetary costs, 3/15/96) 

Equipment Cost (EC), (CE equip, cost index, July 1995 dollars) 

Total Direct Cost (TDC), ($) 

Total Capital Investment (TCI), ($) 

Direct operating costs, minus utilities ($/year) 

Thermal incinerators fuel cost ($/year) 

Electrical cost ($/year) 

Overhead, property tax, insurance, administration ($/year) 

Capital recovery cost ($/year) 

Styrene recovery cost ($/year) 

Total annualized cost ($/year) 

Cost per unit pollutant removed ($/ton) 

INPUT 

0 

100 

50 

6664 

1450 

4.5 

0.06 

60 

29 

1,733,622 

422,750 

421,765 

748,193 

905,090 

40,458 

51,988 

16,746 

60,478 

131,863 

0 

301,533 

3,174 

CALC. 

37,061 

100 

50 

. 

Page 1 

Z