1

MEMORANDUM 

DATE: March 24, 2011

SUBJECT: Revised Regulatory Alternative Impacts for ExxonMobil Group I Polymers and 

Resins Facilities

FROM: Bradley Nelson, EC/R Incorporated

Lesley Stobert, EC/R Incorporated

TO: Nick Parsons, EPA/OAQPS/SPPD/RCG 

Paula Hirtz, EPA/OAQPS/SPPD/RCG

The purpose of this memorandum is to present revised estimated impacts of regulatory 

alternatives identified to reduce hazardous air pollutant (HAP) emissions from two source 

categories that are subject to the Group I Polymers and Resins National Emission Standards for 

HAP (NESHAP) – 40 CFR 63, subpart U. These source categories are Butyl Rubber Production 

and Ethylene Propylene Rubber Production. The revisions are a result of comments received 

from ExxonMobil, which has facilities in both of these source categories, on the proposed 

changes to the NESHAP after the Risk and Technology Review (RTR) evaluation under section 

112(d)(2), 112(d)(6) and 112(f)(3) of the Clean Air Act (CAA). Section 1 provides background

information, followed by an identification of the regulatory alternatives in Section 2. Section 3 

summarizes the estimated costs and HAP emission reductions of the alternatives, and Section 4 

summarizes the secondary impacts.

1.0 BACKGROUND

EPA published a proposed rule and supplemental notice of proposed rulemaking in the 

Federal Register On October 21, 2010 (75 FR 65068) that took into consideration the residual 

risk and technology review analyses for several NESHAP, including five of the nine source 

categories regulated by the Group 1 Polymers and Resins NESHAP – Butyl Rubber Production, 

Epichlorohydrin Production, Ethylene Propylene Rubber Production, Neoprene Production, and 

Nitrile Butadiene Rubber Production. Sources of HAP emissions from these processes include 

raw material storage vessels, front-end process vents, back-end process operations, wastewater 

operations, and equipment leaks. The process “front-end” includes pre-polymerization, reaction, 

stripping, and material recovery operations; and the process “back-end” includes all operations 

after stripping (predominately drying and finishing). The emission sources regulated by the 

NESHAP for these source categories are storage tanks, front-end process vents, equipment leaks, 

and wastewater operations. 

For the proposed rule, regulatory alternatives were evaluated for the process “front-end” 

for Butyl Rubber Production, Halobutyl Rubber Production, and Ethylene Propylene Rubber 

Production to reduce hydrochloric acide (HCl) emissions. Two “front-end” process regulatory 

alternatives were identified. The first alternative was to establish an emissions limit based on the 
2

current level of HCl emissions. This option did not require the installation of any additional 

controls, only that HCl emissions be maintained at the current level. The second alternative was 

to require a 99 percent reduction of the HCl created from the combustion of chlorinated organic 

compounds. In each case, the HCl is generated by the combustion of chlorinated organic 

compounds in a flare. Since it is not technically feasible to install an add-on device to reduce 

these HCl emissions following the flare, the impacts were based on the replacement of the flares 

currently in use with incinerators followed by scrubbers that would achieve 99 percent reduction 

of the HCl emissions.

Regulatory alternatives were also identified for the process “back-end” for: Butyl Rubber 

Production, Epichlorohydrin Production, Halobutyl Rubber Production, Neoprene Production, 

and Nitrile Butadiene Rubber Production. Two alternatives were considered for each source 

category/subcategory. The alternative was to establish an emission limit based on the current 

HAP emissions levels considering existing levels of HAP stripping and recovery plus any 

existing controls. This option did not require the installation of any additional controls, only that 

emissions be maintained at the current level. The second regulatory alternative identified was to 

reduce the organic HAP emissions by requiring a 98 percent reduction in organic HAP 

emissions.

Information about emission points and emissions were provided by the industry in 

response to a questionnaire distributed by the EPA using their authority under section 114 of the 

CAA. These data were used to evaluate the impacts of the proposed regulatory alternatives. 

During the proposal comment period, ExxonMobil, which owns the only facility in the 

Butyl Rubber subcategory (located in Baytown, Texas) and the only facility in the Halobutyl 

Rubber subcategory (located in Baton Rouge, Louisiana), stated that both of these facilities now 

produce halobutyl rubber as the primary product, and the technical differences that distinguished 

the subcategories no longer exist. As a result of this comment, EPA is eliminating the 

subcategories in the Butyl Rubber source category (Butyl Rubber and Halobutyl Rubber). To 

address the two facilities together in one revised Butyl Rubber source category, we have reevaluated the emissions reductions, costs, and other impacts of controls for both the back-end 

operations and the front-end process vents for these two facilities. For the butyl rubber processes

at these two facilities, as well as the ethylene propylene rubber processes at its Baton Rouge 

facility, ExxonMobil also submitted information regarding the types of control equipment that 

would be feasible for use at these facilities and data on design flow rates, more information about 

HCl and HAP emissions, and control equipment costs. Considering these data, EPA has reevaluated the regulatory alternatives for the revised Butyl Rubber source category and the 

Ethylene Propylene Rubber source category and revised the estimated costs and HAP emission 

reductions associated with the alternatives for these source categories.

2.0 REGULATORY ALTERNATIVES

Considering the information provided by ExxonMobil after the proposal, we have reevaluated the proposed regulatory options. For the process “front-end” for the revised Butyl 

Rubber Production source category and the Ethylene Propylene Rubber Production source 

category, we again evaluated the first alternative to establish an emissions limit based on the 
3

current level of HCl emissions to reduce hydrochloric acid (HCl) emissions and the second 

alternative to require a 99 percent reduction of the HCl created from the combustion of 

chlorinated organic compounds. For the process “back-end” for the revised Butyl Rubber 

Production source category, we again evaluated the first alternative to establish an emission limit 

based on the current HAP emissions levels considering existing levels of HAP stripping and 

recovery plus any existing controls and the second alternative to require a 98 percent reduction in 

organic HAP emissions.

3.0 RELEVANT EMISSION POINTS AND BASELINE EMISSIONS

After the proposal was published, ExxonMobil provided additional information for the 

emission points for their Baytown and Baton Rouge facilities. The sections below summarize 

the new information and compare it to the emission point information used for the proposed rule.

3.1 Front-End Emissions

ExxonMobil had two facilities that reported emissions of HCl from the flaring of 

chlorinated organic compounds present in front-end process vent emissions, one producing butyl 

rubber (Baytown, TX facility) and one producing butyl rubber and ethylene propylene rubber

(Baton Rouge, LA facility). In the proposal, HCl control impacts were estimated using the 

emissions and flow rates obtained from the section 114 letter. After the proposal was published,

ExxonMobil clarified which front-end process vent HCl emissions streams were generated at the 

flare. ExxonMobil also provided information on the design flow rate that would be required for 

the emissions control systems to control streams from the butyl rubber processes at the Baytown 

facility and the design flow rate for a shared control device to control both the butyl rubber and 

ethylene propylene rubber processes at the Baton Rouge facility. An estimate of the flow rate 

required for the control systems for each source category at the Baton Rouge facility was made 

based on the emission rates of the different source categories. A summary of the differences in 

flow rate and HAP emissions from the flares between the proposal information and the revised 

information are presented in Table 1. 
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Table 1. Comparison of the Proposal and Revised “Front-End” Process Baseline Emissions

Facility and 

Source Category Pollutant

Proposal 

Estimate 

Emissions 

(Tons/yr)

Revised 

Estimate 

Emissions 

(Tons/yr)

Proposal 

Flow Rate 

(ft3

/min)

Revised 

Flow Rate 

(ft3/min)

Baytown Facility, 

Butyl Rubber

Production

Hydrochloric Acid 30.1 24.7

3,500 5,700

Methyl Chloride 0.779 0.779

Hexane 6.53 6.53

1,3 Butadiene 0.001 0.001

Xylenes 0.0002 0.0002

Baton Rouge 

Facility, Butyl 

Rubber

Production

Hydrochloric Acid 76.8 76.9

Methyl Chloride 0.53 0.53 3,500 2,040

Hexane 0.06 0.06

Baton Rouge 

Facility, Ethylene 

Propylene 

Rubber

Production

Hydrochloric Acid 19.8 24.1

3,500 660

Hexane 0.188 0.188

Methyl Chloride 0.53 0.53

Hexane 0.06 0.06

3.2 Back-End Process Emissions

At proposal we evaluated regulatory alternatives for the process back-end for the butyl 

rubber processes at the ExxonMobil facilities in Baytown, TX and Baton Rouge, LA. In the 

proposal, HAP control impacts were estimated using the emissions and flow rates obtained from 

the section 114 letter. After the proposal was published, ExxonMobil clarified the amount of 

back-end emissions that would be controlled, considering emissions capture inefficiency and 

emissions that would be bypassed to the atmosphere during control equipment maintenance 

procedures. ExxonMobil also provided information on the design flow rate that would be 

required for the emissions control systems to control the currently uncontrolled back-end streams 

from the butyl rubber processes at both facilities. The design flow information ExxonMobil 

provided for the Baytown facility included capacity for other processes that could be routed to 

the control equipment. For the purposes of the costs and impact analyses, only the capacity to 

control the butyl rubber processes at the facility were considered. A summary of the differences 

in flow rate and HAP emissions from the back-end processes the proposal information and the 

revised information are presented in Table 2. 
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Table 2. Comparison of the Proposal and Revised “Back-End” Process Vent Baseline Emissions

Facility and Source 

Category Pollutant

Proposal 

Estimate 

Emissions 

(Tons/yr)

Revised 

Estimate 

Emissions 

(Tons/yr)

Proposal 

Flow Rate 

(ft3

/min)

Revised 

Flow Rate 

(ft3/min)

Baytown Facility, 

Butyl Rubber 

Production

Hexane 26.19 25.8 12,780 15,000

Baton Rouge 

Facility, Butyl 

Rubber Production

Hexane 34.7 41.7 27,240 80,000

4.0 COSTS AND EMISSION REDUCTIONS OF REGULATORY ALTERNATIVES

4.1 Front-End Process Vents

As noted in Section 2, two regulatory alternatives were identified to address HCl 

emissions from front-end process vents from the Butyl Rubber and Ethylene Propylene Rubber

Production source categories. The first alternative would ensure that the current levels of HCl 

emissions are maintained. The only impact of this alternative would be costs due to the labor 

associated with the calculations, records, and reports to demonstrate compliance. These costs 

have not changed, other than considering the two butyl rubber production facilities together in 

one revised source category and considering the revised baseline HCl emissions. These costs are 

summarized in Table 3.

Table 3. Revised Estimated Impacts for Front-End Regulatory Alternative 1

Source Category

Revised Baseline

HCl Emissions

(tpy)

Emission 

Reduction 

(tpy)

Capital Costs 

($)

Annual 

Costs ($/yr)

Cost 

Effectiveness 

($/ton)

Butyl Rubber 101.6 0 $0 $2,000 N/A

Ethylene Propylene 

Rubber 24.1 0 $0 $1,000 N/A

The second alternative would require a 99 percent reduction of the HCl created from the 

combustion of chlorinated organic compounds in the flares currently used as control devices for 

organic HAP. For the proposed rule, we estimated the costs of obtaining this level of control 

assuming a direct-flame incinerator would be used followed by an acid gas scrubber. Also, at 

proposal, data on the stream flow rates going to the flare were not available (only the flow rate of 

emissions exiting the flare was obtained by the ICR), and a flow rate of 3,500 standard cubic feet 

per minute (scfm) was assumed for both butyl rubber processes and the ethylene rubber 

processes, based on information submitted by these facilities during development of the MACT 

standards. For the proposed rule, we estimated costs using this information and the standard 
6

EPA Office of Air Quality Planning and Standards (OAQPS) algorithms for thermal incinerators 

and acid-gas scrubbers. 

Based on the information provided by ExxonMobil after the publication of the proposed 

rule, we have performed a revised analysis of the costs and impacts of this proposed alternative. 

Due to the characteristics of the emissions streams to be controlled, including the variable 

concentration of HAP in the stream and the required energy input needed to obtain the desired 

98% thermal destruction of organic HAP, we have revised our analysis to assume a recuperative 

thermal oxidizer would be used. A recuperative thermal oxidizer can reclaim up to 70 percent of 

the heat produced during oxidation for use in pre-heating the combustion air and process gas 

stream, reducing the amount of natural gas needed to heat the stream and reduce the quantity of 

NOx produced. Additionally, ExxonMobil provided information after the proposal indicating 

that additional auxiliary equipment not included in the impacts and cost estimates performed at

proposal would be needed. We believe it is reasonable to assume that equipment such as utility 

piping, piperacks, and piperack modifications would be needed to install additional control 

equipment at an existing facility. We have included the estimated costs submitted by 

ExxonMobil for piperacks and piperack modifications, utility piping, and a new motor control 

center at both the Baytown and Baton Rouge facilities plus a caustic loop at the Baytown facility 

in our revised analysis. In this revised analysis, we also included the revised flow rates shown in

Table 1, which are based on the design flow rates submitted by ExxonMobil during the comment 

period. In the revised analysis we estimated costs using this information and the standard EPA 

OAQPS algorithms for recuperative thermal oxidizers and acid-gas scrubbers. 

Table 4 presents the costs based on the revised analysis of the second regulatory 

alternative requiring 99 percent reduction in HCl emissions. The control costs for the Baytown 

and Baton Rouge butyl rubber sources are totaled to show the average cost of controlling HCl 

emissions from the revised Butyl Rubber Production source category. Details of these costs 

estimates are provided in Attachments 1 and 2.
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Table 4. Revised Estimated Impacts for Front-End Regulatory Alternative 2

Parameter

Butyl Rubber 

Production Source 

Category 

Ethylene 

Propylene Rubber

Source Category

HCl Emissions at Baseline (tpy) 101.6 24.1

Incinerator

 Capital $708,069 $231,440

 Annual $420,412 $116,645

Scrubber

 Capital $640,410 $55,327

 Annual $294,939 $82,726

Auxiliary Equipment

 Capital2 $3,144,111 $1,602,744

 Annual2 $508,412 $241,783

Total

 Capital $4,492,590 $1,889,511

 Annual $1,223,765 $441,154

HCl Emission Reduction (tpy) 100.5 23.8

HCl Cost Effectiveness $12,173 $18,528

HCl after control (tpy) 1.0 0.2

4.2 Back-End Process Operations

As noted in Section 2, there were two regulatory alternatives identified to address backend emissions from the Butyl Rubber Production source category. The first alternative would 

ensure that the current levels of emissions are maintained. The only impact of this alternative 

would be costs due to the labor costs associated with the calculations, records, and reports to 

demonstrate compliance. These costs have not changed, other than considering the two butyl 

rubber production facilities together in one revised source category and considering the revised 

baseline HAP emissions. These costs are summarized in Table 5.
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Table 5. Revised Estimated Impacts for Back-End Regulatory Alternative 1

Source Category

Revised 

Baseline 

Emissions

(tpy)

Emission 

Reduction 

(tpy)

Capital Costs 

($)

Annual 

Costs ($/yr)

Cost 

Effectivenes

s ($/ton)

Butyl Rubber 67.5 0 $0 $2,000 N/A

The second alternative would require a 98 percent reduction in organic HAP emissions 

for currently uncontrolled back-end streams. For the proposed rule, we estimated the costs of 

obtaining this level of control assuming a direct-flame incinerator would be used at the Baytown 

facility, a recuperative thermal oxidizer would be used at the Baton Rouge facility, and assuming

the stream flow rates going to the incinerator were the flow rates of the uncontrolled streams. 

For the proposed rule, we estimated costs using this information and the standard EPA Office of 

Air Quality Planning and Standards algorithms for thermal incinerators. 

Based on the information provided by ExxonMobil after the publication of the proposed 

rule we have performed a revised analysis of the costs and impacts of this proposed alternative. 

Due to the characteristics of the emissions streams to be controlled, including the low HAP 

concentration, high flow rate rates, presence of sticky particulates, potential moisture saturation 

and the amount of energy needed to obtain the desired 98% thermal destruction of organic HAP, 

we have revised our analysis to assume a regenerative thermal oxidizer would be used. A 

regenerative thermal oxidizer can reclaim up to 95% of the heat produced during oxidation for 

use in pre-heating the combustion air and process gas stream, reducing the amount of natural gas 

needed to heat the stream and reduce the quantity of NOx produced. For these processes at these 

facilities, a recuperative thermal oxidizer would require much more fuel combustion and 

generate more NOx than a regenerative thermal oxidizer. Additionally, ExxonMobil provided 

information after the proposal indicating that additional auxiliary equipment would be needed 

that was not included in the impacts and cost estimates performed at proposal. We believe it is 

reasonable to assume that some additional equipment or plant modifications would be needed to 

install additional control equipment at an existing facility. For the back-end processes, we have 

estimated costs associated with the length of ducting required at both the Baytown and Baton 

Rouge facilities in our revised analysis. In this revised analysis, we also included the revised 

flow rates shown in Table 2, which are based on the design flow rates submitted by ExxonMobil 

during the comment period. In the revised analysis we estimated costs using this information 

and the standard EPA OAQPS algorithms for regenerative thermal oxidizers. 

Table 6 presents the costs based on the revised analysis of the second regulatory 

alternative for back-end processes for the revised Butyl Rubber source category requiring 98 

percent reduction in organic HAP emissions. The control costs for the Baytown and Baton 

Rouge butyl rubber sources are totaled to show the average cost of controlling HCl emissions 

from the revised Butyl Rubber Production source category. Details of these costs estimates are 

provided in Attachments 1 and 2.
9

Table 6. Revised Estimated Cost and Emission Reductions for Back-End Regulatory 

Alternative 2

Parameter Butyl Rubber Production 

Source Category

HAP Emissions at Baseline (tpy) 67.5

Incinerator

 Capital $3,318,385

 Annual $1,477,287

Auxiliary Equipment

 Capital $192,360

 Annual $46,870

Total

 Capital $3,510,745

 Annual $1,524,157

HAP Emission Reduction (tpy) 66.2

HAP Cost Effectiveness $23,041

HAP after control (tpy) 1.3

5.0 SECONDARY ENVIRONMENTAL IMPACTS

While the primary impact of the regulatory alternatives is to address HCl emissions on 

the front-end and organic HAP emissions on the back-end, the application of the control 

technologies that would be required under the second regulatory alternatives can also have other 

environmental effects. These impacts can be positive, such as a reduction in non-HAP volatile 

organic compound air emissions; or negative, such as the generation of additional wastewater or 

energy consumption. In this section the secondary impacts on air pollution, water pollution, and 

energy are discussed. The methodologies used to calculate secondary impacts can be found in 

documentation for the MACT standard.1

 1 Memorandum. Estimated Regulatory Alternative Impacts for Elastomer Production Facilities (Polymers and 

Resins I). Norwood, P., EC/R, to Evans, L., EPA/OAQPS/ESD/OCG. May 10, 1995. Contained in Hazardous Air 

Pollutant Emissions from Process Units in the Elastomer Manufacturing Industry--Supplementary Information 

Document for Proposed Standards. EPA-453/R-95-005a. May 1995.
10

Air Pollution

For the two ExxonMobil facilities for which we have performed a revised cost and 

impact analysis, the secondary air pollution impacts are the increased criteria pollutant emissions 

caused by the on-site combustion of organic HAPs and fuels. This combustion results in the 

emission of nitrogenous oxides (NOx), carbon monoxide (CO), particulate matter (PM), and 

sulfur dioxide (SO2). In addition to these five criteria pollutants, emissions of carbon dioxide 

(CO2) are also expected. Table 7 presents the revised estimated secondary air impacts for 

regulatory alternative 2 for the front-end process vents, and Table 8 presents the revised 

estimates for back-end process vents. 

Table 7. Revised Secondary Air Impacts for Front-End Regulatory Alternative 2

Source Category Emissions (tpy)

PM SO2 NOX CO CO2

Butyl Rubber 0.05 0.01 5.2 0.53 1,823

Ethylene Propylene Rubber 0.003 0.001 0.4 0.04 136

Table 8. Revised Secondary Air Impacts for Back-End Regulatory Alternative 2

Source Category Emissions (tpy)

PM SO2 NOX CO CO2

Butyl Rubber 0.18 0.04 63 2 7,111

Water Pollution

The only impact on water pollution for the second regulatory alternatives identified in 

Section 2.0 is associated with the incinerator/scrubber system for control of HCl from the frontend process vents. Control of organic HAP emissions using combustion only does not result in 

any significant increase in wastewater discharge, since no water effluents are generated by a

thermal or recuperative oxidizer. 

In the scrubber control system, water is used to remove the acid gas contained in the 

thermal oxidizer outlet stream. The amount of wastewater generated is equal to the amount of 

water needed by the scrubber to absorb the acid gas leaving the incinerator. It is estimated that 

about 100 million gallons of wastewater will be generated annually from acid scrubbers at Butyl 

Rubber and Ethylene Propylene Rubber Production facilities. The same assumptions were used 

for this analysis as those used in the MACT.2

 Table 9 presents the water pollution impacts from 

front-end regulatory alternative 2.

 2 See footnote 1
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Table 9. Revised Water Pollution Impacts from Front-End Regulatory Alternative 2

Source Category

Flow Rate to 

Scrubber 

(scfm)

Operating 

Hours (hr/yr)

Wastewater 

Treatment Flow 

Rate (1000 gal/yr)

Butyl Rubber 7,000 8,760 89.8

Ethylene Propylene Rubber 955 8,760 8.5

Energy Impacts

The energy demands associated with the control technologies for the second regulatory 

alternatives include the need for additional electricity and natural gas. The total nationwide 

energy demands that would result from implementing regulatory alternative 2 for front-end and 

back-end process vents are presented in Tables 10 and 11, respectively. More details about the 

methodologies used can be found in the MACT documentation.3

 

Table 10. Revised Energy Requirements for Front-End Regulatory Alternative 2

Source 

Category

Incinerator Scrubber

Annual 

Electricity 

Cost

($/yr)

Electricity 

(Kw-hr)

Natural 

Gas Cost 

($/yr)

Natural 

Gas 

(Mscf/yr)

Annual 

Electricity 

Cost

($/yr)

Electricity 

(Kw-hr)

Natural 

Gas Cost 

($/yr)

Natural 

Gas 

(Mscf/yr)

Butyl 

Rubber

Production

$18,207 265,796 $158,913 30,385 $37,758 551,212 0 0

Ethylene 

Propylene 

Rubber

Production

$1,511 22,058 $11,820 2,260 $1,302 19,007 0 0

Table 11. Revised Energy Requirements for Back-End Regulatory Alternative 2

Source Category

Annual 

Electricity Cost

($/yr)

Electricity (Kwhr)Natural Gas 

Cost ($/yr)

Natural Gas 

(Mscf/yr)

Butyl Rubber Production $222,853 3,336,085 $619,874 118,523

 3 See footnote 1
Attachment 1

Capital and Annual Cost Summary Sheets
Proposal Estimate 

($2009)

Revised Estimate 

($2009)

HCl Emissions at Baseline (TPY) 30.1 24.7

Incinerator1

 Capital $172,921 $399,696

 Operating $90,547 $202,152

 Capital Recovery2

$18,986 $43,885

 Annual $109,533 $246,036

Scrubber3

 Capital $496,400 $529,852

 Operating $71,277 $130,334

 Capital Recovery2

$54,502 $58,175

 Annual $125,779 $188,508

Auxiliary4

 Capital $0 $1,541,367

 Operating5

$0 $97,395

 Capital Recovery2

$0 $169,234

 Annual $0 $266,629

Total Costs6

 Capital $669,321 $2,470,915

 Operating $161,824 $429,880

 Capital Recovery2

$73,488 $271,293

 Total Annual $235,312 $701,174

Cost Effectiveness $7,896 $28,674

HCl Emission Reduction (TPY) 29.8 24.5

HCl Emissions After Control (TPY) 0.3 0.2

6

 The revised cost estimate includes the costs for a recuperative thermal oxidizer, HCl scrubber, 

stainless steel piping from the emission source to the oxidizer, one 25 HP pumps, caustic loop, utility 

piping, and a new motor control center.

2

 The capital recovery was calculated using a CRF of 0.10979 (15-year equipment life and 7% 

interest).

3

 The proposal estimate was calculated using the EPA Control Cost Manual (4th edition) for a gas 

absorber. The revised estimate was calculated using the most recent cost methodologies in the EPA 

Control Cost Manual (6th edition) for a gas absorber.

4

 The revised estimate includes auxiliary costs for stainless steel ducting to the control device, a 

caustic loop, utility piping, new motor control center, and one 25 HP pumps.

5

 The operating cost includes taxes, insurance, and the electricity needed to move the gas through 

Baytown BR - Front End

Cost Parameters

Table 1. Capital and Annual Cost Comparisons for Baytown

Butyl Rubber - Front End

1

 The proposal estimate was calculated using the EPA Control Cost Manual for a direct flame thermal 

incinerator and the assumed flow rate in the MACT proposal. The revised estimate was calculated 

using the EPA Control Cost Manual for a recuperative thermal oxidizer w/ 70% heat recovery and the 

estimated process flow rate and HAP emissions from the Exxon data.
Proposal Estimate 

($2009)

Revised Estimate 

($2009)

HCl Emissions at Baseline (TPY) 76.8 76.9

Incinerator1

 Capital $404,703 $308,373

 Operating $247,164 $140,519

 Capital Recovery2

$44,434 $33,858

 Annual $291,598 $174,376

Scrubber3

 Capital $580,177 $110,558

 Operating $90,182 $94,293

 Capital Recovery2

$63,700 $12,139

 Annual $153,882 $106,431

Auxiliary4

 Capital $0 $1,602,744

 Operating5

$0 $65,811

 Capital Recovery2

$0 $175,973

 Annual $0 $241,783

Total Costs6

 Capital $984,880 $2,021,675

 Operating $337,346 $300,622

 Capital Recovery2

$108,134 $221,969

 Total Annual $445,480 $522,591

Cost Effectiveness $5,859 $6,869

HCl Emission Reduction (TPY) 76.0 76.1

HCl Emissions After Control (TPY) 0.8 0.8

Table 2. Capital and Annual Cost Comparisons for Baton Rouge

Butyl Rubber - Front End

Cost Parameters

Baton Rouge BR - Front End

1

 The proposal estimate was calculated using the EPA Control Cost Manual for a direct flame thermal 

incinerator and the assumed flow rate in the MACT proposal. The revised estimate was calculated 

using the EPA Control Cost Manual for a recuperative thermal oxidizer with 70% heat recovery, 3/4 of 

the total HBR and EPR process flow rate, and the HAP emissions from Exxon.

3

 The proposal estimate was calculated using the EPA Control Cost Manual (4th edition) for a gas 

absorber. The revised estimate was calculated using the most recent cost methodologies in the EPA 

Control Cost Manual (6th edition) for a gas absorber.

4

 The revised estimate includes auxiliary costs for stainless steel ducting to the control device, 

piperacks and piperack modifications, auxiliary equipment and piping, utility piping, new motor 

control center, and one 25 HP pump.

5

 The operating cost includes taxes, insurance, and the electricity needed to move the gas through the 

duct.

6

 The revised cost estimate includes the costs for a recuperative thermal oxidizer, HCl scrubber, and 

the cost for stainless steel piping from the emission source to the oxidizer, one 25 HP pump, piperacks 

and piperack modifications, auxiliary equipment and piping, utility piping, and a new motor control 

center. 

2

 The capital recovery was calculated using a CRF of 0.10979 (15-year equipment life and 7% interest).
Proposal Estimate 

($2009) 1

Revised Estimate 

($2009)

HCl Emissions at Baseline (TPY) 106.9 101.6

Total Costs

 Capital $1,654,201 $4,492,590

 Operating $499,170 $730,502

 Capital Recovery $181,622 $493,262

 Total Annual $680,792 $1,223,765

Cost Effectiveness $6,433 $12,173

HCl Emission Reduction (TPY) 105.8 100.5

HCl Emissions After Control (TPY) 1.1 1.0

Table 3. Butyl Rubber Front End Process Vents Total Cost Effectiveness

Cost Parameters

Butyl Rubber Front End Process Vents Baytown 

and Baton Rouge Facilities

Baytown/Baton Rouge Facilities

1

 These combined costs were not presented at proposal, however they were calculated to provide a 

comparison of the combined cost effectiveness of the butyl rubber processes with the revised 

estimate.
Proposal Estimate 

($2009)

Revised Estimate 

($2009)

HCl Emissions at Baseline (TPY) 19.8 24.1

Incinerator1

 Capital $404,690 $231,440

 Operating $245,267 $91,234

 Capital Recovery2

$44,433 $25,411

 Annual $289,700 $116,645

Scrubber3

 Capital $580,194 $55,327

 Operating $70,210 $76,651

 Capital Recovery2

$63,702 $6,075

 Annual $133,912 $82,726

Auxiliary4

 Capital $0 $1,602,744

 Operating5

$0 $65,811

 Capital Recovery2

$0 $175,973

 Annual $0 $241,783

Total Costs6

 Capital $984,884 $1,889,511

 Operating $315,477 $233,695

 Capital Recovery2

$108,135 $207,458

 Total Annual $423,612 $441,154

Cost Effectiveness $21,643 $18,528

HCl Emission Reduction (TPY) 19.6 23.8

HCl Emissions After Control (TPY) 0.2 0.2

Table 4. Capital and Annual Cost Comparisons for Baton Rouge

Ethylene Propylene Rubber - Front End

Cost Parameters

Baton Rouge EPR - Front End

1

 The proposal estimate was calculated using the EPA Control Cost Manual for a direct flame thermal 

incinerator and the assumed flow rate in the MACT proposal. The revised estimate was calculated 

using the EPA Control Cost Manual for a recuperative thermal oxidizer with 70% heat recovery, 1/2 of 

the total HBR and EPR process flow rate, and the EPR HAP emissions from the Exxon data.

3

 The proposal estimate was calculated using the EPA Control Cost Manual (4th edition) for a gas 

absorber. The revised estimate was calculated using the most recent cost methodologies in the EPA 

4

 The revised estimate includes auxiliary costs for stainless steel ducting to the control device, 

piperacks and piperack modifications, auxiliary equipment and piping, utility piping, new motor 

control center, and one 25 HP pump.

5

 The operating cost includes taxes, insurance, and the electricity needed to move the gas through the 

duct.

6

 The revised cost estimate a thermal oxidizer, scrubber, and the cost for stainless steel piping from 

the emission source to the oxidizer, and one 25 HP pump. 

2

 The capital recovery was calculated using a CRF of 0.10979 (15-year equipment life and 7% interest).
Proposal Estimate 

($2009)

Revised Estimate - 

15,000 scfm ($2009)

Hexane Emissions at Baseline (TPY) 26.2 25.8

Incinerator1

 Capital $234,589 $848,334

 Operating $154,871 $232,415

 Capital Recovery2

$25,757 $93,142

 Annual $180,628 $325,558

Auxiliary3

 Capital $0 $29,020

 Operating4

$0 $4,547

 Capital Recovery2

$0 $3,186

 Annual $0 $7,733

Total Costs5

 Capital $234,589 $877,354

 Operating $154,871 $236,962

 Capital Recovery2

$25,757 $96,329

 Total Annual $180,628 $333,291

Cost Effectiveness $7,035 $13,182

Hexane Emission Reduction (TPY) 25.7 25.3

Hexane Emissions After Control (TPY) 0.524 0.5

5

 The revised cost estimate includes the costs for a regenerative thermal oxidizer, and the cost for 

stainless steel piping from the emission source to the oxidizer. The Exxon capital and annual cost 

estimate includes costs for a regenerative thermal oxidizer, demolition of existing facilities, and 

ducting.

4

 The operating cost includes taxes, insurance, and the electricity needed to move the gas through the 

duct.

2

 The capital recovery was calculated using a CRF of 0.10979 (15-year equipment life and 7% interest).

3

 The revised estimate includes auxiliary costs for stainless steel ducting to the control device.

Table 5. Capital and Annual Cost Comparisons for Baytown

Butyl Rubber - Back End

Cost Parameters

Baytown BR - Back End

1

 The proposal estimate was calculated using the EPA Control Cost Manual for a direct flame thermal 

incinerator and the assumed flow rate in the MACT proposal. The revised estimate was calculated 

using the EPA Control Cost Manual for a regenerative thermal oxidizer and the estimated process flow 
Proposal Estimate 

($2009)

Revised Estimate - 

80,000 scfm ($2009)

Hexane Emissions at Baseline (TPY) 34.7 41.7

Incinerator1

 Capital $951,419 $2,470,051

 Operating $1,502,118 $880,530

 Capital Recovery2

$104,461 $271,198

 Annual $1,606,579 $1,151,729

Auxiliary3

 Capital $0 $163,340

 Operating4

$0 $21,204

 Capital Recovery2

$0 $17,934

 Annual $0 $39,137

Total Costs5

 Capital $951,419 $2,633,391

 Operating $1,502,118 $901,734

 Capital Recovery2

$104,461 $289,132

 Total Annual $1,606,579 $1,190,866

Cost Effectiveness $47,285 $29,141

Hexane Emission Reduction (TPY) 34.0 40.9

Hexane Emissions After Control (TPY) 0.7 0.8

3

 The revised estimate includes auxiliary costs for stainless steel ducting to the control device.

4

 The operating cost includes taxes, insurance, and the electricity needed to move the gas through the 

duct.

5

 The revised cost estimate includes the costs for a thermal oxidizer and stainless steel piping from the 

emission source to the oxidizer. 

Table 6. Capital and Annual Cost Comparisons for Baton Rouge

Halobutyl Rubber - Back End

Cost Parameters

Baton Rouge HBR - Back End

1

 The proposal estimate was calculated using the EPA Control Cost Manual for a direct flame thermal 

incinerator and the assumed flow rate in the MACT proposal. The revised estimate was calculated 

using the EPA Control Cost Manual for a regenerative thermal oxidizer and the estimated process flow 

rate and HAP emissions from the Exxon data.

2

 The capital recovery was calculated using a CRF of 0.10979 (15-year equipment life and 7% interest).
Proposal Estimate 

($2009) 1

Revised Estimate 

($2009)

Hexane Emissions at Baseline (TPY) 60.9 67.5

Total Costs

 Capital $1,186,008 $3,510,745

 Operating $1,656,989 $1,138,696

 Capital Recovery $130,218 $385,461

 Total Annual $1,787,207 $1,524,157

Cost Effectiveness $29,960 $23,041

HCl Emission Reduction (TPY) 59.7 66.2

HCl Emissions After Control (TPY) 1.2 1.3

Table 7. Butyl Rubber Back End Process Vents Total Cost Effectiveness

Baytown/Baton Rouge Facilities

Cost Parameters

Butyl Rubber Back End Process Vents Baytown 

and Baton Rouge Facilities

1

 These combined costs were not presented at proposal, however they were calculated to provide a 

comparison of the combined cost effectiveness of the butyl rubber processes with the revised 

estimate.
Attachment 2

Control Device Capital and Annual Cost Spreadsheets
TOTAL ANNUAL COST SPREADSHEET PROGRAM--RECUPERATIVE THERMAL OXIDIZERS (RCO)

Baton Rouge Ethylene Propylene Rubber Front End

COST BASE DATE: CEPCI 1999 390.6

COST ESCALATION: CEPCI 2009 521.9

INPUT PARAMETERS

ICR (M-07)

-- Gas flowrate (scfm): 641

-- Reference temperature (oF): 77

-- Inlet gas temperature (oF): 203.5

-- Inlet gas density (lb/scf): 0.073901176

-- Primary heat recovery (fraction): 0.7

-- Waste gas heat content (BTU/scf): 4.669

-- Waste gas heat content (BTU/lb): 63.18

-- Gas heat capacity (BTU/lb-oF): 0.255

-- Combustion temperature (oF): 2000

-- Heat loss (fraction): 0.01

-- Exit temperature (oF): 742.45

-- Fuel heat of combustion (BTU/lb): 21502

-- Fuel density (lb/ft3): 0.0408

DESIGN PARAMETERS

Auxiliary Fuel Requirement (lb/min): 0.175938126

 (scfm): 4.312208979

Total Gas Flowrate (scfm): 645.7915281

TOTAL CAPITAL INVESTMENT ($)

(Cost correlations range: 500 to 50,000 scfm, 70% Heat Recovery)

Total Capital Investment - Base $173,214

Total Capital Investment - Escalated $231,440

ANNUAL COST INPUTS

Operating factor (hr/yr): 8760

Operating labor rate ($/hr): 23.38 2009 Technical labor rate

Maintenance labor rate ($/hr): 25.718 Operator labor rate*1.1

Operating labor factor (hr/sh): 0.5

Maintenance labor factor (hr/sh): 0.5

Electricity price ($/kwh): 0.0685

Natural gas price ($/mscf): 5.23

Annual interest rate (fraction): 0.07

Control system life (years): 15

Capital recovery factor: 0.109794625

Taxes, insurance, admin. factor: 0.04

Pressure drop (in. w.c.): 20

ANNUAL COSTS

 Item Cost ($/yr)

-------------------------------------------------------------------------------------------------------------------

Operating labor $12,800.55

Supervisory labor $1,920.08

Maintenance labor $14,080.61

Maintenance materials $14,080.61

Natural gas $11,853.78

Electricity $1,511.30

Overhead $25,729.11

Taxes, insurance, administrative $9,257.62

Capital recovery $25,410.91

-------------------------------------------------------------------------------------------------------------------

Total Annual Cost $116,645
RCO Average Pollutant Heat Content Calculations

Baton Rouge Ethylene Propylene Rubber Front End

Component

NEI Emissions 

(lb/hr)

Molecular 

Weight (lb/lbmole)

Volumetric 

Flow Rate 

(scf/min) -ΔHc (KJ/mole)

Heat of 

Combustion 

(Btu/lb)

Heat of 

Combustion 

(Btu/scf)

Volume 

Fraction of 

Component in 

Exhaust Gas

Vent Heat 

Content 

(Btu/scf)

VOC 44.09 0.0 2220 21,665 2,479 0.00E+00 0

Methane 16.04 0.00 890.4 23,884 994 0.00E+00 0

Ethane 30.07 0.00 1559.9 22,321 1,742 0.00E+00 0

Other HAP 44.09 0.00 2220 21,665 2,479 0.00E+00 0

Hexanes 8.58 86.17 0.639 4194.8 20,946 4,684 9.97E-04 4.67

Methyl Chloride 50.49 0.00 841.8 7,174 940 0.00E+00 0

Air 641 0 0 0 9.99E-01 0

Total 8.58 641 1.00E+00 4.67

Data Source: ICR Emissions rates & estimated flow rate based on Exxon's comments.
TOTAL ANNUAL COST SPREADSHEET PROGRAM--GAS ABSORBERS [1]

Baton Rouge Ethylene Propylene Rubber Front End

COST BASE DATE: CEPCI 1991 361.3

COST ESCALATION: CEPCI 2009 521.9

INPUT PARAMETERS:

Stream parameters:

Inlet waste gas flowrate (scfm): 955

-- Inlet waste gas temperature (oF): 200 Assume gas is cooled to 200 F after incinerator

-- Inlet waste gas pressure (atm.): 1

-- Process operating hours, hr/yr 8760

-- Pollutant in waste gas: HCl

 HCl emissions, tpy 24.05

-- HCl emissions, lb/yr 48100

-- HCl concentration, ppmv 1010.774352

-- HCl molecular weight 36.5

-- Inlet gas poll. conc., yi (mole fraction): 0.001010774

-- Pollutant removal efficiency (fraction): 0.99

-- Absorbent: Aqueous caustic soda

-- Inlet pollutant conc. in absorbent: 0

-- Waste gas molecular weight (lb/lb-mole): 28.85

-- Absorbent molecular weight (lb/lb-mole): 18

-- Inlet waste gas density (lb/ft3): 0.059879618

-- Absorbent density (lb/ft3): 62.4

-- Absorbent specific gravity: 1

-- Waste gas viscosity @ inlet temp. (lb/ft-hr): 0.044

-- Absorbent viscosity @ inlet temp. (lb/ft-hr): 2.16

-- Minimum wetting rate (ft2/hr): 1.3

-- Pollutant diffusivity in air (ft2/hr): 0.725

-- Pollutant diffusivity in absorbent (ft2/hr): 0.000102

Packing parameters:

-- Packing type: 2-in. ceramic Raschig rings

-- Packing factor, Fp: 65

-- Packing constant, alpha: 3.82

-- Packing constant, beta: 0.41

-- Packing constant, gamma: 0.45

-- Packing constant, phi: 0.0125

-- Packing constant, b: 0.22

-- Packing constant, c: 0.24

-- Packing constant, j: 0.17

-- Surface area-to-volume ratio, a (ft2/ft3): 28

-- Packing cost ($/ft3): 20

DESIGN PARAMETERS:

-- Material of construction (see list below):[2] 1

-- Inlet pollutant concentration (free basis): 0.001011797

-- Outlet pollutant concentration (free basis): 1.0118E-05

-- Out. eq. poll. conc. in absorbent., Xo* (op. line): 0.16

-- Theoretical operating line slope (Ls/Gs,min.): 0.006260494

-- Ls/Gs adjustment factor: 1.5

-- Actual operating line slope (Ls/Gs, act.): 0.009390741

-- Gas flowrate, Gs (free basis, lb-moles/hr): 118.8088058

-- Absorbent flowrate, Ls (free basis, lb-mol/hr): 1.115702768

-- Gas flowrate, Gmol,i (lb-moles/hr): 118.9290162

-- Absorbent flowrate, Lmol,i (lb-moles/hr): 1.115702768

-- Outlet actual pollutant conc. in absorbent, Xo: 0.106666667

-- Gas poll. conc. in eq. w/Xo (Yo*): 0.0001

-- Outlet absorbent poll. conc. (mole fract. basis): 0.096385542

-- Gas poll. conc., Yo* (mole fract. basis): 9.999E-05

-- Outlet gas poll. conc., yo (mole fract.): 1.01179E-05

-- Slope of equilibrium line (m): 0.001037396

-- Absorption factor (AF): 9.052222119

-- ABSCISSA (column diameter calculation): 0.000181499

-- ORDINATE (column diameter calculation): 0.206062991

-- Superficial gas flowrate, Gsfr,i (lb/sec-ft2) 0.624401327
-- Flooding factor, f: 0.7

-- Column cross-sectional area, A (ft2): 2.178362187

-- Superficial liquid flowrate (lb/hr-ft2): 9.219150952

-- Minimum liquid flowrate (lb/hr-ft2): 2271.36

-- Column diameter, D (ft2): 1.66540592

-- Number of transfer units, Ntu: 5.045754253

-- Gas film transfer coefficient, Hg (ft): 2.428660928

-- Liquid film transfer coefficient, Hl (ft): 1.06425965

-- Height of a transfer unit (ft): 2.546229811

-- Packing depth (ft): 12.8476499

-- Column total height (ft): 22.4954239

-- Column surface area (ft2): 122.0533897

-- Column gas pressure drop (in. w.c./ft packing): 0.980199783

-- Column liquid pressure drop (ft of H2O): 60

-- Packing volume (ft3): 27.98683473

CAPITAL COSTS:

Equipment costs ($):

-- Gas absorber $14,036

-- Pump (assumes $16/gpm) $158

-- Packing $560

-- Auxiliaries (ductwork, etc.) $0

 -------------

-- Total (base) $14,754

 ' (escalated) $21,312

Purchased Equipment Cost ($): $25,149

Total Capital Investment ($): $55,327

================================================================================== ===========================

ANNUAL COST INPUTS:

Operating factor (hr/yr): 8760

Operating labor rate ($/hr): 23.38

Maintenance labor rate ($/hr): 25.718

Operating labor factor (hr/sh): 0.5

Maintenance labor factor (hr/sh): 0.5

Electricity price ($/kWhr): 0.0685

Absorbent material (caustic) price ($/ton): 300

Absorbent carrier ( water) price ($/1000 gal): 0.2

Wastewater trtmt cost ($/1000 gal): 3.8

Overhead rate (fraction): 0.6

Annual interest rate (fraction): 0.07

Control system life (years): 15

Capital recovery factor (system): 0.109794625

Taxes, insurance, admin. factor: 0.04

 ANNUAL COSTS:

 Item Cost ($/yr) Wt. Factor W.F.(cond.)

------------------------------------------------------------------------------------------------------------------------------------------------ ------------------------

Operating labor $12,801 0.150703105 ----

Supervisory labor $1,920 0.022605466 ----

Maintenance labor $14,081 0.165773416 ----

Maintenance materials $14,081 0.165773416 ----

Electricity $1,302 0.015326597 ----

Absorbent material (caustic) $6,443 0.075854103 ----

Absorbent carrier (water) $15 0.000173924 ----

Wastewater treatment $281 0.003304556 ----

Overhead $25,729 0.302913242 0.807768644

Taxes, insurance, administrative $2,213 0.02605492 ----

Capital recovery $6,075 0.071517255 0.097572175

------------------------------------------------------------------------------------------------ ------------------------ ------------------------

Total Annual Cost $84,939 1 1

NOTES:

[1] This program has been based on data and procedures in Section 5.2, Chapter 1 of the

OAQPS CONTROL COST MANUAL (6th edition).

[2] Enter one of the following: fiberglass-reinforced plastic (FRP)--'1'; 304 stainless steel--'1.4';

 polypropylene--'0.95'; polyvinyl chloride (PVC)--'0.70'.
TOTAL ANNUAL COST SPREADSHEET PROGRAM--STRAIGHT DUCTWORK [1]

Baton Rouge Ethylene Propylene Rubber Front End

ICR

COST BASE DATE: CEPCI 1993 359.2

COST ESCALATION: CEPCI 2009 521.9

INPUT PARAMETERS

-- Inlet stream flowrate (acfm): 2650

-- Duct velocity (ft/min): [4] 2952

-- Duct length (ft): [5] 650

-- Material of construction: [6] 304 SS Sheet

-- Insulation thickness (in.): (text input) [7] 0

-- Duct design: [8] Circ.-spiral

-- Cost equation parameters: [9]

 a: 1.56

 b: 1

-- Cost equation form: [10] 1

-- Control system installation factor: [11] 1.5

 (if no system, enter '0')

-- Fan-motor combined efficiency (fraction): 0.6

DESIGN PARAMETERS

-- Duct diameter (in.): 12.82493303

-- Pressure drop (in. w.c.): [12] 5.735754385

CAPITAL COSTS

Equipment Cost ($)--base: $13,004

 ' ' ' --escalated: $18,895

Purchased Equipment Cost ($): $20,406

Other Purchased Equipment Cost ($):[13] $1,570,000

Total Capital Investment ($): [14] $1,600,610

====================================================================

ANNUAL COST INPUTS

Operating factor (hours/year): 8760

Electricity price ($/kWhr): 0.0685

Annual interest rate (fractional): 0.07

Ductwork economic life (years): 15

Capital recovery factor (system): 0.109794625

Taxes, insurance, admin. factor: 0.04

ANNUAL COSTS

Item Cost ($/yr) Wt.Fact.

------------------------------------------------------------------------------------------------------------------------

Electricity $1,786 0.007394566

Taxes, insurance, administrative $64,024 0.265057691

Capital recovery $175,738 0.727547743

------------------------------------------------------------------------------------------------------------------------

Total Annual Cost $241,549 1

Notes:

[1] Data used to develop this program were taken from 'OAQPS Control Cost Manual', 5th 

edition, Chapter 10. Prices are for CIRCULAR straight ductwork, only.

[2] Base ductwork costs reflect this date.

[3] PPI = Producer Price Index PCU 3444#1 ('Air-conditioning ducts and stove pipe') for year 

and quarter shown. Ductwork equipment cost has been escalated to this date via this PPI.

[4] See 'Manual,' pp. 10-30 to 10-33.

[5] Duct length is a site-specific parameter that can vary from < 10 to > 1000 ft.

[6] Choices available are: carbon steel sheet (galv. CS sh.), stainless steel sheet (304 SS sh.), 

coated carbon steel plate (coat. CS pl.), 304 stainless steel plate (304 SS pl.), polyvinyl chloride 

(PVC), and fiber-reinforced plastic (FRP)

[13] Other purchased equipment cost includes caustic loop, utility piping, and a new motor 

control center

[14] Product of installation factor and Purchased Equipment Cost. Costs are presented both in 

terms of 2nd quarter '93 and above escalation date. Latter costs are based on Producer Price 

Index PCU 3444#1 ('Air-conditioning ducts and stove pipe')

[7] Choices are: 0, 1, and 3.

[8] Choices are: circular spiral (circ.-spiral) and circular longitudinal (circ.-long.)

[9] Equation type and parameters depend on duct material of construction. Parameters 

reflect 2nd quarter 1993 costs. See 'Manual,' pp. 10-44 to 10-49.

[10] Choices are: power function (1) and exponential (2).

[11] Installation factor depends on control device ductwork is supporting. This factor, when 

multiplied by Purchased Equipment Cost, yields Total Capital Investment (TCI). If ductwork is 

installed alone, factor is 1.25 to 1.50. (Default = 1.50.) See 'Manual'.

[12] Pressure drop applies ONLY to circular, spiral-wound galvanized duct with 10 joints per 

100 feet. For pressure drop data for other duct types, see 'Manual,' Chapter 10.
PUMPS

Baton Rouge Ethylene Propylene Rubber Front End

The EPA Control Cost Manual does not have specific cost equations for pumps. 

25-HP Pump $2,134

Total Cost $4,268

Annual interest rate (fraction): 0.07

Control system life (years): 15

Capital recovery factor: 0.109795

Capital recovery $234.30

Data Source: http://www.grainger.com/Grainger/CENTURY-CloseCoupled-Pump-Motor-1XKP3
TOTAL ANNUAL COST SPREADSHEET PROGRAM--REGENERATIVE THERMAL OXIDIZERS (RTO)

Baton Rouge Halobutyl Rubber Back End

COST BASE DATE: CEPCI 1999 390.6

COST ESCALATION: CEPCI 2009 521.9

INPUT PARAMETERS

ICR (V-127 & V-131

-- Gas flowrate (scfm): 80,001

-- Reference temperature (oF): 77

-- Inlet gas temperature (oF): 120

-- Inlet gas density (lb/scf): 0.073901176

-- Primary heat recovery (fraction): 0.95

-- Waste gas heat content (BTU/scf): 0.042

-- Waste gas heat content (BTU/lb): 0.56

-- Gas heat capacity (BTU/lb-oF): 0.255

-- Combustion temperature (oF): 2000

-- Heat loss (fraction): 0.01

-- Exit temperature (oF): 214

-- Fuel heat of combustion (BTU/lb): 21502

-- Fuel density (lb/ft3): 0.0408

DESIGN PARAMETERS

Auxiliary Fuel Requirement (lb/min): 7.79891727

 (scfm): 191.1499331

Total Gas Flowrate (scfm): 80191.85944

TOTAL CAPITAL INVESTMENT ($)

(Cost correlations range: 10,000 to 100,000 scfm)

Total Capital Investment - Base $1,848,634

Total Capital Investment - Escalated $2,470,051

ANNUAL COST INPUTS

Operating factor (hr/yr): 8760

Operating labor rate ($/hr): 23.38 2009 Technical labor rate

Maintenance labor rate ($/hr): 25.718 Operator labor rate*1.1

Operating labor factor (hr/sh): 0.5

Maintenance labor factor (hr/sh): 0.5

Electricity price ($/kwh): 0.0685

Natural gas price ($/mscf): 5.23

Annual interest rate (fraction): 0.07

Control system life (years): 15

Capital recovery factor: 0.109794625

Taxes, insurance, admin. factor: 0.04

Pressure drop (in. w.c.): 20

ANNUAL COSTS

 Item Cost ($/yr)

-------------------------------------------------------------------------------------------------------------------

Operating labor $12,800.55

Supervisory labor $1,920.08

Maintenance labor $14,080.61

Maintenance materials $14,080.61

Natural gas $525,449.76

Electricity $187,667.72

Overhead $25,729.11

Taxes, insurance, administrative $98,802.05

Capital recovery $271,198.35

-------------------------------------------------------------------------------------------------------------------

Total Annual Cost $1,151,729
RTO Average Pollutant Heat Content Calculations

Baton Rouge Halobutyl Rubber Back End

Component

NEI Emissions 

(lb/hr)

Molecular 

Weight (lb/lbmole)

Volumetric 

Flow Rate 

(scf/min) -ΔHc (KJ/mole)

Heat of 

Combustion 

(Btu/lb)

Heat of 

Combustion 

(Btu/scf)

Volume 

Fraction of 

Component in 

Exhaust Gas

Vent Heat 

Content 

(Btu/scf)

VOC 44.09 0.0 2220 21,665 2,479 0.00E+00 0

Methane 16.04 0.00 890.4 23,884 994 0.00E+00 0

Ethane 30.07 0.00 1559.9 22,321 1,742 0.00E+00 0

Other HAP 44.09 0.00 2220 21,665 2,479 0.00E+00 0

Hexanes 9.52 86.17 0.710 4194.8 20,946 4,684 8.87E-06 0.04

Benzene 78.11 0.00 3301.5 18,187 3,687 0.00E+00 0

Toluene 92.13 0.00 3947.9 18,438 4,409 0.00E+00 0

Ethylbenzene 106.16 0.00 4607.1 18,673 5,145 0.00E+00 0

Xylenes 106.16 0.00 4595.2 18,625 5,132 0.00E+00 0

Air 80,000 0 0 0 1.00E+00 0

Total 9.52 80,001 1.00E+00 0.0415

Data Source: ICR Average
TOTAL ANNUAL COST SPREADSHEET PROGRAM--STRAIGHT DUCTWORK [1]

Baton Rouge Halobutyl Rubber Back End

ICR

COST BASE DATE: CEPCI 1993 359.2

COST ESCALATION: CEPCI 2009 521.9

INPUT PARAMETERS

-- Inlet stream flowrate (acfm): 80000

-- Duct velocity (ft/min): [4] 3840

-- Duct length (ft): [5] 720

-- Material of construction: [6] 304 SS Sheet

-- Insulation thickness (in.): (text input) [7] 0

-- Duct design: [8] Circ.-spiral

-- Cost equation parameters: [9]

 a: 1.56

 b: 1

-- Cost equation form: [10] 1

-- Control system installation factor: [11] 1.5

 (if no system, enter '0')

-- Fan-motor combined efficiency (fraction): 0.6

DESIGN PARAMETERS

-- Duct diameter (in.): 61.78310449

-- Pressure drop (in. w.c.): [12] 1.595420621

CAPITAL COSTS

Equipment Cost ($)--base: $69,395

 ' ' ' --escalated: $100,827

Purchased Equipment Cost ($): $108,893

Total Capital Investment ($): [13] $163,340

====================================================================

ANNUAL COST INPUTS

Operating factor (hours/year): 8760

Electricity price ($/kWhr): 0.067

Annual interest rate (fractional): 0.07

Ductwork economic life (years): 15

Capital recovery factor (system): 0.109794625

Taxes, insurance, admin. factor: 0.04

ANNUAL COSTS

Item Cost ($/yr) Wt.Fact.

------------------------------------------------------------------------------------------------------------------------

Electricity $14,670 0.374832949

Taxes, insurance, administrative $6,534 0.166939782

Capital recovery $17,934 0.458227269

------------------------------------------------------------------------------------------------------------------------

Total Annual Cost $39,137 1

Notes:

[1] Data used to develop this program were taken from 'OAQPS Control Cost Manual', 5th 

edition, Chapter 10. Prices are for CIRCULAR straight ductwork, only.

[2] Base ductwork costs reflect this date.

[3] PPI = Producer Price Index PCU 3444#1 ('Air-conditioning ducts and stove pipe') for year 

and quarter shown. Ductwork equipment cost has been escalated to this date via this PPI.

[4] See 'Manual,' pp. 10-30 to 10-33.

[5] Duct length is a site-specific parameter that can vary from < 10 to > 1000 ft.

[6] Choices available are: carbon steel sheet (galv. CS sh.), stainless steel sheet (304 SS sh.), 

coated carbon steel plate (coat. CS pl.), 304 stainless steel plate (304 SS pl.), polyvinyl 

chloride (PVC), and fiber-reinforced plastic (FRP)

[13] Product of installation factor and Purchased Equipment Cost. Costs are presented both 

in terms of 2nd quarter '93 and above escalation date. Latter costs are based on Producer 

Price Index PCU 3444#1 ('Air-conditioning ducts and stove pipe')

[7] Choices are: 0, 1, and 3.

[8] Choices are: circular spiral (circ.-spiral) and circular longitudinal (circ.-long.)

[9] Equation type and parameters depend on duct material of construction. Parameters 

reflect 2nd quarter 1993 costs. See 'Manual,' pp. 10-44 to 10-49.

[10] Choices are: power function (1) and exponential (2).

[11] Installation factor depends on control device ductwork is supporting. This factor, when 

multiplied by Purchased Equipment Cost, yields Total Capital Investment (TCI). If ductwork is 

installed alone, factor is 1.25 to 1.50. (Default = 1.50.) See 'Manual'.

[12] Pressure drop applies ONLY to circular, spiral-wound galvanized duct with 10 joints per 

100 feet. For pressure drop data for other duct types, see 'Manual,' Chapter 10.
TOTAL ANNUAL COST SPREADSHEET PROGRAM--RECUPERATIVE THERMAL OXIDIZERS (RCO)

Baton Rouge Halobutyl Rubber Front End

COST BASE DATE: CEPCI 1999 390.6

COST ESCALATION: CEPCI 2009 521.9

INPUT PARAMETERS

ICR (M-07)

-- Gas flowrate (scfm): 2,015

-- Reference temperature (oF): 77

-- Inlet gas temperature (oF): 203.5

-- Inlet gas density (lb/scf): 0.073901176

-- Primary heat recovery (fraction): 0.7

-- Waste gas heat content (BTU/scf): 1.910

-- Waste gas heat content (BTU/lb): 25.85

-- Gas heat capacity (BTU/lb-oF): 0.255

-- Combustion temperature (oF): 2000

-- Heat loss (fraction): 0.01

-- Exit temperature (oF): 742.45

-- Fuel heat of combustion (BTU/lb): 21502

-- Fuel density (lb/ft3): 0.0408

DESIGN PARAMETERS

Auxiliary Fuel Requirement (lb/min): 0.813503022

 (scfm): 19.93879955

Total Gas Flowrate (scfm): 2035.368605

TOTAL CAPITAL INVESTMENT ($)

(Cost correlations range: 500 to 50,000 scfm, 70% Heat Recovery)

Total Capital Investment - Base $230,793

Total Capital Investment - Escalated $308,373

ANNUAL COST INPUTS

Operating factor (hr/yr): 8760

Operating labor rate ($/hr): 23.38 2009 Technical labor rate

Maintenance labor rate ($/hr): 25.718 Operator labor rate*1.1

Operating labor factor (hr/sh): 0.5

Maintenance labor factor (hr/sh): 0.5

Electricity price ($/kwh): 0.0685

Natural gas price ($/mscf): 5.23

Annual interest rate (fraction): 0.07

Control system life (years): 15

Capital recovery factor: 0.109794625

Taxes, insurance, admin. factor: 0.04

Pressure drop (in. w.c.): 20

ANNUAL COSTS

 Item Cost ($/yr)

-------------------------------------------------------------------------------------------------------------------

Operating labor $12,800.55

Supervisory labor $1,920.08

Maintenance labor $14,080.61

Maintenance materials $14,080.61

Natural gas $54,809.53

Electricity $4,763.24

Overhead $25,729.11

Taxes, insurance, administrative $12,334.93

Capital recovery $33,857.73

-------------------------------------------------------------------------------------------------------------------

Total Annual Cost $174,376
RCO Average Pollutant Heat Content Calculations

Baton Rouge Halobutyl Rubber Front End

Component

NEI Emissions 

(lb/hr)

Molecular 

Weight (lb/lbmole)

Volumetric 

Flow Rate 

(scf/min) -ΔHc (KJ/mole)

Heat of 

Combustion 

(Btu/lb)

Heat of 

Combustion 

(Btu/scf)

Volume 

Fraction of 

Component in 

Exhaust Gas

Vent Heat 

Content 

(Btu/scf)

VOC 44.09 0.0 2220 21,665 2,479 0.00E+00 0

Methane 16.04 0.00 890.4 23,884 994 0.00E+00 0

Ethane 30.07 0.00 1559.9 22,321 1,742 0.00E+00 0

Other HAP 44.09 0.00 2220 21,665 2,479 0.00E+00 0

Hexanes 2.74 86.17 0.204 4194.8 20,946 4,684 1.01E-04 0.47

Methyl Chloride 24.2 50.49 3.08 841.8 7,174 940 1.53E-03 1.44

Air 2,012 0 0 0 9.98E-01 0

Total 26.9 2,015 1.00E+00 1.91

Data Source: ICR Emissions rates & estimated flow rate based on Exxon's comments.
TOTAL ANNUAL COST SPREADSHEET PROGRAM--GAS ABSORBERS [1]

Baton Rouge Halobutyl Rubber Front End

COST BASE DATE: CEPCI 1991 361.3

COST ESCALATION: CEPCI 2009 521.9

INPUT PARAMETERS:

Stream parameters:

Inlet waste gas flowrate (scfm): 3,045

-- Inlet waste gas temperature (oF): 200 Assume gas is cooled to 200 F after incinerator

-- Inlet waste gas pressure (atm.): 1

-- Process operating hours, hr/yr 8760

-- Pollutant in waste gas: HCl

 HCl emissions, tpy 76.85

-- HCl emissions, lb/yr 153700

-- HCl concentration, ppmv 1012.975821

-- HCl molecular weight 36.5

-- Inlet gas poll. conc., yi (mole fraction): 0.001012976

-- Pollutant removal efficiency (fraction): 0.99

-- Absorbent: Aqueous caustic soda

-- Inlet pollutant conc. in absorbent: 0

-- Waste gas molecular weight (lb/lb-mole): 28.85

-- Absorbent molecular weight (lb/lb-mole): 18

-- Inlet waste gas density (lb/ft3): 0.059879618

-- Absorbent density (lb/ft3): 62.4

-- Absorbent specific gravity: 1

-- Waste gas viscosity @ inlet temp. (lb/ft-hr): 0.044

-- Absorbent viscosity @ inlet temp. (lb/ft-hr): 2.16

-- Minimum wetting rate (ft2/hr): 1.3

-- Pollutant diffusivity in air (ft2/hr): 0.725

-- Pollutant diffusivity in absorbent (ft2/hr): 0.000102

Packing parameters:

-- Packing type: 2-in. ceramic Raschig rings

-- Packing factor, Fp: 65

-- Packing constant, alpha: 3.82

-- Packing constant, beta: 0.41

-- Packing constant, gamma: 0.45

-- Packing constant, phi: 0.0125

-- Packing constant, b: 0.22

-- Packing constant, c: 0.24

-- Packing constant, j: 0.17

-- Surface area-to-volume ratio, a (ft2/ft3): 28

-- Packing cost ($/ft3): 20

DESIGN PARAMETERS:

-- Material of construction (see list below):[2] 1

-- Inlet pollutant concentration (free basis): 0.001014003

-- Outlet pollutant concentration (free basis): 1.014E-05

-- Out. eq. poll. conc. in absorbent., Xo* (op. line): 0.16

-- Theoretical operating line slope (Ls/Gs,min.): 0.006274143

-- Ls/Gs adjustment factor: 1.5

-- Actual operating line slope (Ls/Gs, act.): 0.009411215

-- Gas flowrate, Gs (free basis, lb-moles/hr): 378.8188653

-- Absorbent flowrate, Ls (free basis, lb-mol/hr): 3.565145852

-- Gas flowrate, Gmol,i (lb-moles/hr): 379.2029888

-- Absorbent flowrate, Lmol,i (lb-moles/hr): 3.565145852

-- Outlet actual pollutant conc. in absorbent, Xo: 0.106666667

-- Gas poll. conc. in eq. w/Xo (Yo*): 0.0001

-- Outlet absorbent poll. conc. (mole fract. basis): 0.096385542

-- Gas poll. conc., Yo* (mole fract. basis): 9.999E-05

-- Outlet gas poll. conc., yo (mole fract.): 1.01399E-05

-- Slope of equilibrium line (m): 0.001037396

-- Absorption factor (AF): 9.07195787

-- ABSCISSA (column diameter calculation): 0.000181895

-- ORDINATE (column diameter calculation): 0.206062991

-- Superficial gas flowrate, Gsfr,i (lb/sec-ft2) 0.624401327
-- Flooding factor, f: 0.7

-- Column cross-sectional area, A (ft2): 6.945652608

-- Superficial liquid flowrate (lb/hr-ft2): 9.239250643

-- Minimum liquid flowrate (lb/hr-ft2): 2271.36

-- Column diameter, D (ft2): 2.973798844

-- Number of transfer units, Ntu: 5.044689149

-- Gas film transfer coefficient, Hg (ft): 2.428660928

-- Liquid film transfer coefficient, Hl (ft): 1.06425965

-- Height of a transfer unit (ft): 2.545974044

-- Packing depth (ft): 12.84364763

-- Column total height (ft): 23.82438151

-- Column surface area (ft2): 236.4697461

-- Column gas pressure drop (in. w.c./ft packing): 0.980199783

-- Column liquid pressure drop (ft of H2O): 60

-- Packing volume (ft3): 89.20751468

CAPITAL COSTS:

Equipment costs ($):

-- Gas absorber $27,194

-- Pump (assumes $16/gpm) $504

-- Packing $1,784

-- Auxiliaries (ductwork, etc.) $0

 -------------

-- Total (base) $29,483

 ' (escalated) $42,588

Purchased Equipment Cost ($): $50,254

Total Capital Investment ($): $110,558

================================================================================== ===========================

ANNUAL COST INPUTS:

Operating factor (hr/yr): 8760

Operating labor rate ($/hr): 23.38 2009 Technical labor rate

Maintenance labor rate ($/hr): 25.718 Operator labor rate*1.1

Operating labor factor (hr/sh): 0.5

Maintenance labor factor (hr/sh): 0.5

Electricity price ($/kWhr): 0.0685

Absorbent material (caustic) price ($/ton): 300

Absorbent carrier ( water) price ($/1000 gal): 0.2

Wastewater trtmt cost ($/1000 gal): 3.8

Overhead rate (fraction): 0.6

Annual interest rate (fraction): 0.07

Control system life (years): 15

Capital recovery factor (system): 0.109794625

Taxes, insurance, admin. factor: 0.04

 ANNUAL COSTS:

 Item Cost ($/yr) Wt. Factor W.F.(cond.)

------------------------------------------------------------------------------------------------------------------------------------------------ ------------------------

Operating labor $12,801 0.115472473 ----

Supervisory labor $1,920 0.017320871 ----

Maintenance labor $14,081 0.12701972 ----

Maintenance materials $14,081 0.12701972 ----

Electricity $4,150 0.037433505 ----

Absorbent material (caustic) $20,588 0.185722334 ----

Absorbent carrier (water) $47 0.000425838 ----

Wastewater treatment $897 0.008090925 ----

Overhead $25,729 0.23209967 0.618932454

Taxes, insurance, administrative $4,422 0.039893272 ----

Capital recovery $12,139 0.109501671 0.149394944

------------------------------------------------------------------------------------------------ ------------------------ ------------------------

Total Annual Cost $110,854 1 1

NOTES:

[1] This program has been based on data and procedures in Section 5.2, Chapter 1 of the

OAQPS CONTROL COST MANUAL (6th edition).

[2] Enter one of the following: fiberglass-reinforced plastic (FRP)--'1'; 304 stainless steel--'1.4';

 polypropylene--'0.95'; polyvinyl chloride (PVC)--'0.70'.
TOTAL ANNUAL COST SPREADSHEET PROGRAM--STRAIGHT DUCTWORK [1]

Baton Rouge Halobutyl Rubber Front End

ICR

COST BASE DATE: CEPCI 1993 359.2

COST ESCALATION: CEPCI 2009 521.9

INPUT PARAMETERS

-- Inlet stream flowrate (acfm): 2650

-- Duct velocity (ft/min): [4] 2952

-- Duct length (ft): [5] 650

-- Material of construction: [6] 304 SS Sheet

-- Insulation thickness (in.): (text input) [7] 0

-- Duct design: [8] Circ.-spiral

-- Cost equation parameters: [9]

 a: 1.56

 b: 1

-- Cost equation form: [10] 1

-- Control system installation factor: [11] 1.5

 (if no system, enter '0')

-- Fan-motor combined efficiency (fraction): 0.6

DESIGN PARAMETERS

-- Duct diameter (in.): 12.82493303

-- Pressure drop (in. w.c.): [12] 5.735754385

CAPITAL COSTS

Equipment Cost ($)--base: $13,004

 ' ' ' --escalated: $18,895

Purchased Equipment Cost ($): $20,406

Other Purchased Equipment Cost ($):[13] $1,570,000

Total Capital Investment ($): [14] $1,600,610

====================================================================

ANNUAL COST INPUTS

Operating factor (hours/year): 8760

Electricity price ($/kWhr): 0.0685

Annual interest rate (fractional): 0.07

Ductwork economic life (years): 15

Capital recovery factor (system): 0.109794625

Taxes, insurance, admin. factor: 0.04

ANNUAL COSTS

Item Cost ($/yr) Wt.Fact.

------------------------------------------------------------------------------------------------------------------------

Electricity $1,786 0.007394566

Taxes, insurance, administrative $64,024 0.265057691

Capital recovery $175,738 0.727547743

------------------------------------------------------------------------------------------------------------------------

Total Annual Cost $241,549 1

Notes:

[1] Data used to develop this program were taken from 'OAQPS Control Cost Manual', 5th 

edition, Chapter 10. Prices are for CIRCULAR straight ductwork, only.

[2] Base ductwork costs reflect this date.

[3] PPI = Producer Price Index PCU 3444#1 ('Air-conditioning ducts and stove pipe') for year 

and quarter shown. Ductwork equipment cost has been escalated to this date via this PPI.

[4] See 'Manual,' pp. 10-30 to 10-33.

[5] Duct length is a site-specific parameter that can vary from < 10 to > 1000 ft.

[6] Choices available are: carbon steel sheet (galv. CS sh.), stainless steel sheet (304 SS sh.), 

coated carbon steel plate (coat. CS pl.), 304 stainless steel plate (304 SS pl.), polyvinyl chloride 

(PVC), and fiber-reinforced plastic (FRP)

[13] Other purchased equipment cost includes caustic loop, utility piping, and a new motor 

control center

[14] Product of installation factor and Purchased Equipment Cost. Costs are presented both in 

terms of 2nd quarter '93 and above escalation date. Latter costs are based on Producer Price 

Index PCU 3444#1 ('Air-conditioning ducts and stove pipe')

[7] Choices are: 0, 1, and 3.

[8] Choices are: circular spiral (circ.-spiral) and circular longitudinal (circ.-long.)

[9] Equation type and parameters depend on duct material of construction. Parameters 

reflect 2nd quarter 1993 costs. See 'Manual,' pp. 10-44 to 10-49.

[10] Choices are: power function (1) and exponential (2).

[11] Installation factor depends on control device ductwork is supporting. This factor, when 

multiplied by Purchased Equipment Cost, yields Total Capital Investment (TCI). If ductwork is 

installed alone, factor is 1.25 to 1.50. (Default = 1.50.) See 'Manual'.

[12] Pressure drop applies ONLY to circular, spiral-wound galvanized duct with 10 joints per 

100 feet. For pressure drop data for other duct types, see 'Manual,' Chapter 10.
PUMPS

Baton Rouge Halobutyl Rubber Front End

The EPA Control Cost Manual does not have specific cost equations for pumps. 

25-HP Pump $2,134

Total Cost $4,268

Annual interest rate (fraction): 0.07

Control system life (years): 15

Capital recovery factor: 0.109795

Capital recovery $234.30

Data Source: http://www.grainger.com/Grainger/CENTURY-CloseCoupled-Pump-Motor-1XKP3
TOTAL ANNUAL COST SPREADSHEET PROGRAM--REGENERATIVE THERMAL OXIDIZERS (RTO)

Baytown Butyl Rubber Back End

COST BASE DATE: CEPCI 1999 390.6

COST ESCALATION: CEPCI 2009 521.9

INPUT PARAMETERS

ICR (BPBFINISH)

-- Gas flowrate (scfm): 15,000

-- Reference temperature (oF): 77

-- Inlet gas temperature (oF): 105

-- Inlet gas density (lb/scf): 0.073901176

-- Primary heat recovery (fraction): 0.95

-- Waste gas heat content (BTU/scf): 0.137

-- Waste gas heat content (BTU/lb): 1.85

-- Gas heat capacity (BTU/lb-oF): 0.255

-- Combustion temperature (oF): 2000

-- Heat loss (fraction): 0.01

-- Exit temperature (oF): 199.75

-- Fuel heat of combustion (BTU/lb): 21502

-- Fuel density (lb/ft3): 0.0408

DESIGN PARAMETERS

Auxiliary Fuel Requirement (lb/min): 1.405360682

 (scfm): 34.44511477

Total Gas Flowrate (scfm): 15034.88331

TOTAL CAPITAL INVESTMENT ($)

(Cost correlations range: 10,000 to 100,000 scfm)

Total Capital Investment - Base $634,909

Total Capital Investment - Escalated $848,334

ANNUAL COST INPUTS

Operating factor (hr/yr): 8760

Operating labor rate ($/hr): 23.38 2009 Technical labor rate

Maintenance labor rate ($/hr): 25.718 Operator labor rate*1.1

Operating labor factor (hr/sh): 0.5

Maintenance labor factor (hr/wk): 0.5

Electricity price ($/kwh): 0.0685

Natural gas price ($/mscf): 5.23

Annual interest rate (fraction): 0.07

Control system life (years): 15

Capital recovery factor: 0.109794625

Taxes, insurance, admin. factor: 0.04

Pressure drop (in. w.c.): 20

ANNUAL COSTS

 Item Cost ($/yr)

-------------------------------------------------------------------------------------------------------------------

Operating labor $12,800.55

Supervisory labor $1,920.08

Maintenance labor $14,080.61

Maintenance materials $14,080.61

Natural gas $94,685.76

Electricity $35,185.15

Overhead $25,729.11

Taxes, insurance, administrative $33,933.35

Capital recovery $93,142.49

-------------------------------------------------------------------------------------------------------------------

Total Annual Cost $325,558
RTO Average Pollutant Heat Content Calculations

Baytown Butyl Rubber Back End

Component

NEI Emissions 

(lb/hr)

Molecular 

Weight (lb/lbmole)

Volumetric 

Flow Rate 

(scf/min) -ΔHc (KJ/mole)

Heat of 

Combustion 

(Btu/lb)

Heat of 

Combustion 

(Btu/scf)

Volume 

Fraction of 

Component in 

Exhaust Gas

Vent Heat 

Content 

(Btu/scf)

VOC 44.09 0.0 2220 21,665 2,479 0.00E+00 0

Methane 16.04 0.00 890.4 23,884 994 0.00E+00 0

Ethane 30.07 0.00 1559.9 22,321 1,742 0.00E+00 0

Other HAP 44.09 0.00 2220 21,665 2,479 0.00E+00 0

Hexanes 5.88 86.17 0.438 4194.8 20,946 4,684 2.92E-05 0.137

Benzene 78.11 0.00 3301.5 18,187 3,687 0.00E+00 0

Toluene 92.13 0.00 3947.9 18,438 4,409 0.00E+00 0

Ethylbenzene 106.16 0.00 4607.1 18,673 5,145 0.00E+00 0

Xylenes 106.16 0.00 4595.2 18,625 5,132 0.00E+00 0

Air 15,000 0 0 0 1.00E+00 0

Total 5.88 15,000 1.00E+00 0.137

Data Source: ICR Emissions rates & Exxon control device design flow rate.
TOTAL ANNUAL COST SPREADSHEET PROGRAM--STRAIGHT DUCTWORK [1]

Baytown Butyl Rubber Back End

ICR

COST BASE DATE: CEPCI 1993 359.2

COST ESCALATION: CEPCI 2009 521.9

INPUT PARAMETERS

-- Inlet stream flowrate (acfm): 15000

-- Duct velocity (ft/min): [4] 3960

-- Duct length (ft): [5] 300

-- Material of construction: [6] 304 SS Sheet

-- Insulation thickness (in.): (text input) [7] 0

-- Duct design: [8] Circ.-spiral

-- Cost equation parameters: [9]

 a: 1.56

 b: 1

-- Cost equation form: [10] 1

-- Control system installation factor: [11] 1.5

 (if no system, enter '0')

-- Fan-motor combined efficiency (fraction): 0.6

DESIGN PARAMETERS

-- Duct diameter (in.): 26.34440427

-- Pressure drop (in. w.c.): [12] 1.921025267

CAPITAL COSTS

Equipment Cost ($)--base: $12,329

 ' ' ' --escalated: $17,914

Purchased Equipment Cost ($): $19,347

Total Capital Investment ($): [13] $29,020

====================================================================

ANNUAL COST INPUTS

Operating factor (hours/year): 8760

Electricity price ($/kWhr): 0.0685

Annual interest rate (fractional): 0.07

Ductwork economic life (years): 15

Capital recovery factor (system): 0.109794625

Taxes, insurance, admin. factor: 0.04

ANNUAL COSTS

Item Cost ($/yr) Wt.Fact.

------------------------------------------------------------------------------------------------------------------------

Electricity $3,386 0.437870428

Taxes, insurance, administrative $1,161 0.150106741

Capital recovery $3,186 0.412022832

------------------------------------------------------------------------------------------------------------------------

Total Annual Cost $7,733 1

Notes:

[1] Data used to develop this program were taken from 'OAQPS Control Cost Manual', 5th 

edition, Chapter 10. Prices are for CIRCULAR straight ductwork, only.

[2] Base ductwork costs reflect this date.

[3] PPI = Producer Price Index PCU 3444#1 ('Air-conditioning ducts and stove pipe') for year 

and quarter shown. Ductwork equipment cost has been escalated to this date via this PPI.

[4] See 'Manual,' pp. 10-30 to 10-33.

[5] Duct length is a site-specific parameter that can vary from < 10 to > 1000 ft.

[6] Choices available are: carbon steel sheet (galv. CS sh.), stainless steel sheet (304 SS sh.), 

coated carbon steel plate (coat. CS pl.), 304 stainless steel plate (304 SS pl.), polyvinyl 

chloride (PVC), and fiber-reinforced plastic (FRP)

[13] Product of installation factor and Purchased Equipment Cost. Costs are presented both 

in terms of 2nd quarter '93 and above escalation date. Latter costs are based on Producer 

Price Index PCU 3444#1 ('Air-conditioning ducts and stove pipe')

[7] Choices are: 0, 1, and 3.

[8] Choices are: circular spiral (circ.-spiral) and circular longitudinal (circ.-long.)

[9] Equation type and parameters depend on duct material of construction. Parameters 

reflect 2nd quarter 1993 costs. See 'Manual,' pp. 10-44 to 10-49.

[10] Choices are: power function (1) and exponential (2).

[11] Installation factor depends on control device ductwork is supporting. This factor, when 

multiplied by Purchased Equipment Cost, yields Total Capital Investment (TCI). If ductwork is 

installed alone, factor is 1.25 to 1.50. (Default = 1.50.) See 'Manual'.

[12] Pressure drop applies ONLY to circular, spiral-wound galvanized duct with 10 joints per 

100 feet. For pressure drop data for other duct types, see 'Manual,' Chapter 10.
TOTAL ANNUAL COST SPREADSHEET PROGRAM--RECUPERATIVE THERMAL OXIDIZERS (RCO)

Baytown Butyl Rubber Front End

COST BASE DATE: CEPCI 1999 390.6

COST ESCALATION: CEPCI 2009 521.9

INPUT PARAMETERS

ICR (FS12)

-- Gas flowrate (scfm): 5,707

-- Reference temperature (oF): 77

-- Inlet gas temperature (oF): 203.5

-- Inlet gas density (lb/scf): 0.073901176

-- Primary heat recovery (fraction): 0.7

-- Waste gas heat content (BTU/scf): 4.744

-- Waste gas heat content (BTU/lb): 64.19

-- Gas heat capacity (BTU/lb-oF): 0.255

-- Combustion temperature (oF): 2000

-- Heat loss (fraction): 0.01

-- Exit temperature (oF): 742.45

-- Fuel heat of combustion (BTU/lb): 21502

-- Fuel density (lb/ft3): 0.0408

DESIGN PARAMETERS

Auxiliary Fuel Requirement (lb/min): 1.545232283

 (scfm): 37.87334027

Total Gas Flowrate (scfm): 5744.557504

TOTAL CAPITAL INVESTMENT ($)

(Cost correlations range: 500 to 50,000 scfm, 70% Heat Recovery)

Total Capital Investment - Base $299,140

Total Capital Investment - Escalated $399,696

ANNUAL COST INPUTS

Operating factor (hr/yr): 8760

Operating labor rate ($/hr): 23.38 2009 Technical labor rate

Maintenance labor rate ($/hr): 25.718 Operator labor rate*1.1

Operating labor factor (hr/sh): 0.5

Maintenance labor factor (hr/sh): 0.5

Electricity price ($/kwh): 0.0685

Natural gas price ($/mscf): 5.23

Annual interest rate (fraction): 0.07

Control system life (years): 15

Capital recovery factor: 0.109794625

Taxes, insurance, admin. factor: 0.04

Pressure drop (in. w.c.): 20

ANNUAL COSTS

 Item Cost ($/yr)

-------------------------------------------------------------------------------------------------------------------

Operating labor $12,800.55

Supervisory labor $1,920.08

Maintenance labor $14,080.61

Maintenance materials $14,080.61

Natural gas $104,109.57

Electricity $13,443.61

Overhead $25,729.11

Taxes, insurance, administrative $15,987.85

Capital recovery $43,884.51

-------------------------------------------------------------------------------------------------------------------

Total Annual Cost $246,036
RCO Average Pollutant Heat Content Calculations

Baytown Butyl Rubber Front End

Component

NEI Emissions 

(lb/hr)

Molecular 

Weight (lb/lbmole)

Volumetric 

Flow Rate 

(scf/min) -ΔHc (KJ/mole)

Heat of 

Combustion 

(Btu/lb)

Heat of 

Combustion 

(Btu/scf)

Volume 

Fraction of 

Component in 

Exhaust Gas

Vent Heat 

Content 

(Btu/scf)

VOC 44.09 0.0 2220 21,665 2,479 0.00E+00 0

Methane 16.04 0.00 890.4 23,884 994 0.00E+00 0

Ethane 30.07 0.00 1559.9 22,321 1,742 0.00E+00 0

Other HAP 44.09 0.00 2220 21,665 2,479 0.00E+00 0

Hexanes 74.5 86.17 5.552 4194.8 20,946 4,684 9.73E-04 4.56

Methyl Chloride 8.89 50.49 1.13 841.8 7,174 940 1.98E-04 0.186

1,3-Butadiene 0.0114 54.09 0.00 0 0 0 2.37E-07 0

Xylenes 0.00228 106.16 0.00 4595.2 18,625 5,132 2.42E-08 0.000124

Vent Gas 5,700 0 0 0 9.99E-01 0

Total 83.4 5,707 1.00E+00 4.74

Data Source: ICR Emissions rates & estimated flow rate based on Exxon's comments.
TOTAL ANNUAL COST SPREADSHEET PROGRAM--GAS ABSORBERS [1]

Baytown Butyl Rubber Front End

COST BASE DATE: CEPCI 1991 361.3

COST ESCALATION: CEPCI 2009 521.9

INPUT PARAMETERS:

Stream parameters:

Inlet waste gas flowrate (scfm): 7,000

-- Inlet waste gas temperature (oF): 200 Assume gas is cooled to 200 F after incinerator

-- Inlet waste gas pressure (atm.): 1

-- Process operating hours, hr/yr 8760

-- Pollutant in waste gas: HCl

 HCl emissions, tpy 24.7

-- HCl emissions, lb/yr 49400

-- HCl concentration, ppmv 141.6254874

-- HCl molecular weight 36.5

-- Inlet gas poll. conc., yi (mole fraction): 0.000141625

-- Pollutant removal efficiency (fraction): 0.99

-- Absorbent: Aqueous caustic soda

-- Inlet pollutant conc. in absorbent: 0

-- Waste gas molecular weight (lb/lb-mole): 28.85

-- Absorbent molecular weight (lb/lb-mole): 18

-- Inlet waste gas density (lb/ft3): 0.059879618

-- Absorbent density (lb/ft3): 62.4

-- Absorbent specific gravity: 1

-- Waste gas viscosity @ inlet temp. (lb/ft-hr): 0.044

-- Absorbent viscosity @ inlet temp. (lb/ft-hr): 2.16

-- Minimum wetting rate (ft2/hr): 1.3

-- Pollutant diffusivity in air (ft2/hr): 0.725

-- Pollutant diffusivity in absorbent (ft2/hr): 0.000102

Packing parameters:

-- Packing type: 2-in. ceramic Raschig rings

-- Packing factor, Fp: 65

-- Packing constant, alpha: 3.82

-- Packing constant, beta: 0.41

-- Packing constant, gamma: 0.45

-- Packing constant, phi: 0.0125

-- Packing constant, b: 0.22

-- Packing constant, c: 0.24

-- Packing constant, j: 0.17

-- Surface area-to-volume ratio, a (ft2/ft3): 28

-- Packing cost ($/ft3): 20

DESIGN PARAMETERS:

-- Material of construction (see list below):[2] 1

-- Inlet pollutant concentration (free basis): 0.000141646

-- Outlet pollutant concentration (free basis): 1.41646E-06

-- Out. eq. poll. conc. in absorbent., Xo* (op. line): 0.16

-- Theoretical operating line slope (Ls/Gs,min.): 0.000876432

-- Ls/Gs adjustment factor: 1.5

-- Actual operating line slope (Ls/Gs, act.): 0.001314648

-- Gas flowrate, Gs (free basis, lb-moles/hr): 871.6075494

-- Absorbent flowrate, Ls (free basis, lb-mol/hr): 1.145856897

-- Gas flowrate, Gmol,i (lb-moles/hr): 871.7310087

-- Absorbent flowrate, Lmol,i (lb-moles/hr): 1.145856897

-- Outlet actual pollutant conc. in absorbent, Xo: 0.106666667

-- Gas poll. conc. in eq. w/Xo (Yo*): 0.0001

-- Outlet absorbent poll. conc. (mole fract. basis): 0.096385542

-- Gas poll. conc., Yo* (mole fract. basis): 9.999E-05

-- Outlet gas poll. conc., yo (mole fract.): 1.41645E-06

-- Slope of equilibrium line (m): 0.001037396

-- Absorption factor (AF): 1.267257067

-- ABSCISSA (column diameter calculation): 2.54088E-05

-- ORDINATE (column diameter calculation): 0.206062991

-- Superficial gas flowrate, Gsfr,i (lb/sec-ft2) 0.624401327
-- Flooding factor, f: 0.7

-- Column cross-sectional area, A (ft2): 15.98094446

-- Superficial liquid flowrate (lb/hr-ft2): 1.290626107

-- Minimum liquid flowrate (lb/hr-ft2): 2271.36

-- Column diameter, D (ft2): 4.510828134

-- Number of transfer units, Ntu: 14.6299482

-- Gas film transfer coefficient, Hg (ft): 2.428660928

-- Liquid film transfer coefficient, Hl (ft): 1.06425965

-- Height of a transfer unit (ft): 3.268474473

-- Packing depth (ft): 47.81761222

-- Column total height (ft): 74.3557018

-- Column surface area (ft2): 1085.67026

-- Column gas pressure drop (in. w.c./ft packing): 0.980199783

-- Column liquid pressure drop (ft of H2O): 60

-- Packing volume (ft3): 764.1706052

CAPITAL COSTS:

Equipment costs ($):

-- Gas absorber $124,852

-- Pump (assumes $16/gpm) $1,161

-- Packing $15,283

-- Auxiliaries (ductwork, etc.) $0

 -------------

-- Total (base) $141,296

 ' (escalated) $204,103

Purchased Equipment Cost ($): $240,842

Total Capital Investment ($): $529,852

================================================================================== ===========================

ANNUAL COST INPUTS:

Operating factor (hr/yr): 8760

Operating labor rate ($/hr): 23.38

Maintenance labor rate ($/hr): 25.718

Operating labor factor (hr/sh): 0.5

Maintenance labor factor (hr/sh): 0.5

Electricity price ($/kWhr): 0.0685

Absorbent material (caustic) price ($/ton): 300

Absorbent carrier ( water) price ($/1000 gal): 0.2

Wastewater trtmt cost ($/1000 gal): 3.8

Overhead rate (fraction): 0.6

Annual interest rate (fraction): 0.07

Control system life (years): 15

Capital recovery factor (system): 0.109794625

Taxes, insurance, admin. factor: 0.04

 ANNUAL COSTS:

 Item Cost ($/yr) Wt. Factor W.F.(cond.)

------------------------------------------------------------------------------------------------------------------------------------------------ ------------------------

Operating labor $12,801 0.067904392 ----

Supervisory labor $1,920 0.010185659 ----

Maintenance labor $14,081 0.074694831 ----

Maintenance materials $14,081 0.074694831 ----

Electricity $33,608 0.178283909 ----

Absorbent material (caustic) $6,617 0.035102384 ----

Absorbent carrier (water) $15 8.04854E-05 ----

Wastewater treatment $288 0.001529222 ----

Overhead $25,729 0.136487827 0.363967539

Taxes, insurance, administrative $21,194 0.112430325 ----

Capital recovery $58,175 0.308606135 0.42103646

------------------------------------------------------------------------------------------------ ------------------------ ------------------------

Total Annual Cost $188,508 1 1

NOTES:

[1] This program has been based on data and procedures in Section 5.2, Chapter 1 of the

OAQPS CONTROL COST MANUAL (6th edition).

[2] Enter one of the following: fiberglass-reinforced plastic (FRP)--'1'; 304 stainless steel--'1.4';

 polypropylene--'0.95'; polyvinyl chloride (PVC)--'0.70'.
TOTAL ANNUAL COST SPREADSHEET PROGRAM--STRAIGHT DUCTWORK [1]

Baytown Butyl Rubber Front End

ICR

COST BASE DATE: CEPCI 1993 359.2

COST ESCALATION: CEPCI 2009 521.9

INPUT PARAMETERS

-- Inlet stream flowrate (acfm): 5700

-- Duct velocity (ft/min): [4] 3936

-- Duct length (ft): [5] 4800

-- Material of construction: [6] 304 SS Sheet

-- Insulation thickness (in.): (text input) [7] 0

-- Duct design: [8] Circ.-spiral

-- Cost equation parameters: [9]

 a: 1.56

 b: 1

-- Cost equation form: [10] 1

-- Control system installation factor: [11] 1.5

 (if no system, enter '0')

-- Fan-motor combined efficiency (fraction): 0.6

DESIGN PARAMETERS

-- Duct diameter (in.): 16.28921774

-- Pressure drop (in. w.c.): [12] 53.61309855

CAPITAL COSTS

Equipment Cost ($)--base: $121,974

 ' ' ' --escalated: $177,222

Purchased Equipment Cost ($): $191,399

Other Purchased Equipment Cost ($):[13] $1,250,000

Total Capital Investment ($): [14] $1,537,099

====================================================================

ANNUAL COST INPUTS

Operating factor (hours/year): 8760

Electricity price ($/kWhr): 0.0685

Annual interest rate (fractional): 0.07

Ductwork economic life (years): 15

Capital recovery factor (system): 0.109794625

Taxes, insurance, admin. factor: 0.04

ANNUAL COSTS

Item Cost ($/yr) Wt.Fact.

------------------------------------------------------------------------------------------------------------------------

Electricity $35,911 0.134922381

Taxes, insurance, administrative $61,484 0.231003648

Capital recovery $168,765 0.634073971

------------------------------------------------------------------------------------------------------------------------

Total Annual Cost $266,160 1

Notes:

[1] Data used to develop this program were taken from 'OAQPS Control Cost Manual', 5th 

edition, Chapter 10. Prices are for CIRCULAR straight ductwork, only.

[2] Base ductwork costs reflect this date.

[3] PPI = Producer Price Index PCU 3444#1 ('Air-conditioning ducts and stove pipe') for year 

and quarter shown. Ductwork equipment cost has been escalated to this date via this PPI.

[4] See 'Manual,' pp. 10-30 to 10-33.

[5] Duct length is a site-specific parameter that can vary from < 10 to > 1000 ft.

[6] Choices available are: carbon steel sheet (galv. CS sh.), stainless steel sheet (304 SS sh.), 

coated carbon steel plate (coat. CS pl.), 304 stainless steel plate (304 SS pl.), polyvinyl chloride 

(PVC), and fiber-reinforced plastic (FRP)

[13] Other purchased equipment cost includes caustic loop, utility piping, and a new motor 

control center

[14] Product of installation factor and Purchased Equipment Cost. Costs are presented both in 

terms of 2nd quarter '93 and above escalation date. Latter costs are based on Producer Price 

Index PCU 3444#1 ('Air-conditioning ducts and stove pipe')

[7] Choices are: 0, 1, and 3.

[8] Choices are: circular spiral (circ.-spiral) and circular longitudinal (circ.-long.)

[9] Equation type and parameters depend on duct material of construction. Parameters 

reflect 2nd quarter 1993 costs. See 'Manual,' pp. 10-44 to 10-49.

[10] Choices are: power function (1) and exponential (2).

[11] Installation factor depends on control device ductwork is supporting. This factor, when 

multiplied by Purchased Equipment Cost, yields Total Capital Investment (TCI). If ductwork is 

installed alone, factor is 1.25 to 1.50. (Default = 1.50.) See 'Manual'.

[12] Pressure drop applies ONLY to circular, spiral-wound galvanized duct with 10 joints per 

100 feet. For pressure drop data for other duct types, see 'Manual,' Chapter 10.
PUMPS

Baytown Butyl Rubber Front End

The EPA Control Cost Manual does not have specific cost equations for pumps. 

25-HP Pump $2,134

Total Cost $4,268

Annual interest rate (fraction): 0.07

Control system life (years): 15

Capital recovery factor: 0.109795

Capital recovery $468.60

Data Source: http://www.grainger.com/Grainger/CENTURY-CloseCoupled-Pump-Motor-1XKP3