Annual Cost CE Tons Contr.$/ton Incr CE

#1 Cansolv $ 17,323,399 0.985 20036 $ 864.62

#2 Acid Plant $ 33,578,725 0.96 19527 $ 1,719.57 -31965.6

#3 Caustic Scrubber $ 16,643,002 0.9 18307 $ 909.11 393.523
On Secondary Hooding

Capital Cost $ 85,000,000 provided by ASARCO

Annualized Cap Cost $ 8,023,399

Operating Cost $ 9,300,000 used high end of estiamte

Total Annual Cost $ 17,323,399

SO2 Controlled 20036 tpy based on 98.5% CE

Cost of control $ 864.62 dollars per ton
On Secondary Hooding

Capital Cost $ 28,000,000 provided by ASARCO

Annualized Cap Cost $ 2,643,002

Operating Cost $ 14,000,000 used high end of estiamte

Sludge Disposal $ 7,000,000 If toxic waste

$ 21,000,000

Total Annual Cost $ 23,643,002

SO2 Controlled 18307 tpy based on 95% CE

Cost of control $ 1,291.48 dollars per ton
On Secondary Hooding

Capital Cost $ 28,000,000 provided by ASARCO

Annualized Cap Cost $ 2,643,002

Operating Cost $ 14,000,000 used high end of estiamte

Sludge Disposal $ - Assumes sludge mass is 5 times SO2 controlled plus acid plant PM, at $60/ton

$ 14,000,000

Total Annual Cost $ 16,643,002

SO2 Controlled 18307 tpy based on 95% CE

Cost of control $ 909.11 dollars per ton
d plus acid plant PM, at $60/ton
For Secondary hood based on 2012 Test numbers

Q 311,287 scfm @ 70 F (upsized 50%)

% SO2 0.23145 Second lowest value from 2012 secondary hood source test, conver

ln cost 2.541893588 from 1984 OAQPS report of NSPS P, page 8-13

cost $12.70 millions of 1981 dollars

CPI Mult 2.57 from Bureau of Labor Statistics CPI Calculator (http://www.bls.gov/

Multiplier 2.5 to be somewhat conservative

$ 163,242,593.67 2013 dollars (doubled based on MECS estimate)

Annualized Cost $ 15,408,946.02 2013 dollars

Catalyst Cost $ 1,842,242.62 Cost of changeout every 2 years, 100% Cs catalyst in 1 and 4

Preheater energy cost $ 16,327,536.25 Doubled based on MECS letter requiring colling and reheating

Annual Variable Cost $ 18,169,778.86

Total annual cost $ 33,578,724.88

Emissions Reduction (tons) 19527 assumed reduction of 96% (provided by MECS) from highest two of 

Cost of control $ 1,719.57 dollars per ton
condary hood source test, converted from ppm to percentage

P, page 8-13

I Calculator (http://www.bls.gov/data/inflation_calculator.htm)

ECS estimate)

100% Cs catalyst in 1 and 4

quiring colling and reheating

ed by MECS) from highest two of past five years in secondary system
SO2 (tpy)

Acid Plant 2nd Hood

Furnace 

vent Fugitives Anode

2011 541 18290 1127 563 36.6

2010 509 20476 1344 1223 38.0

2009 731 20206 1091 1074 33.3

2008 1174 17738 1014 1195 37.1

2007 894 16628 1024 1181 36.7

Baseline 1034 20341 1209 37.5

PM10 (tpy)

Acid Plant 2nd Hood

Furnace 

vent Fugitives Anode

2011 30.6 46.5 12.7 9.9 64.1

2010 49.5 110.5 13.2 11.3 69.9

2009 26.0 29.2 11.6 9.9 62.2

2008 45.6 35.4 12.9 9.7 69.6

2007 27.3 85.4 12.8 9.0 64.0

Baseline 36 70 11 69.8
Data from 2012 CEMS, Secondfary Hood, and Furnace Vent Test by EEMC

Secondary Hood

Test Date 9/10/2012

Time SO2 ppmvd %H2O ADCFM T (F) SDCFM

09:23-09:43 3,066.1 3.22 214,478 131 192,341

09:55-10:16 2,108.5 4.32 233,759 137 207,525

10:35-10:56 2,629.3 3.06 230,391 162 196,314

11:13-11:34 5,309.8 4.52 228,332 169 192,394

11:47-12:08 2,966.2 3.28 233,163 192 189,534

12:20-12:41 5,208.0 3.78 225,362 193 182,912

13:01-13:22 2,754.6 3.25 228,867 203 182,956

13:38-13:59 2,708.5 3.07 228,577 196 184,673

14:08-14:29 2,314.5 2.56 226,900 192 184,443

14:42-15:03 5,779.8 4.08 250,330 196 202,248

Max 5,779.8 4.52 250,330 203 207,525

Average 3,484.5 3.51 230,016 177 191,534

Min 2,108.5 2.56 214,478 131 182,912

Design Value 2,314.5 3.51 250,330 177.10 207,525

Acid Plant

Test Date 9/13/2012

Time SO2 ppmvd %H2O ADCFM T (F) SDCFM

07:52-08:22 58.9 0.64 111711 309 76,992

08:38-09:08 52.5 2.16 152872 303 106,189

09:16-09:46 67.1 1.08 174800 300 121,900

10:01-10:31 61.5 0.61 159667 302 111,054

10:40:11:10 144.3 <0.5 158662 309 109,351

11:20-11:50 189.8 <0.5 168804 320 114,700

12:00-12:30 186.3 0.61 161851 338 107,495

12:41-13:11 106.9 <0.5 153669 350 100,549

13:21-13:51 256.6 <0.5 186298 349 122,049

14:01-14:31 150.7 <0.5 182830 360 118,171

Max 256.6 2.16 186,298 360 122,049

Average 127.5 1.02 161,116 324 108,845

Min 52.5 0.61 111,711 300 76,992
Catalyst Volume Cost

K-Cat

Cs-Cat

Existing Acid Plant Cost (standard Cat)

Pass Loading (L) Capacity (L) Loading (L) Capacity (L)

1 70,700 105,980 $289,870.00 $434,518.00

2 84,900 120,180 $348,090.00 $492,738.00

3 84,900 120,180 $348,090.00 $492,738.00

4 113,200 148,480 $464,120.00 $608,768.00

$1,450,170.00 $2,028,762.00

Annual Cost $725,085.00

delta

New Acid Plant 

Volume mult. 1.76 scfm secondary/scfm primary

Cost (standard Cat)

Pass Loading (L) Capacity (L) Loading (L) Capacity (L)

1 124,410 186,493 $510,082.88 $764,619.29

2 149,398 211,480 $612,532.34 $867,068.75

3 149,398 211,480 $612,532.34 $867,068.75

4 199,198 261,280 $816,709.79 $1,071,246.19

$2,551,857.35 $3,570,002.97

Annual Cost $1,275,928.67
from 2011 Sales Proposal

$4.10 per liter

$7.60 per liter

Cost (Cs-Cat in 1 and 4)

Loading (L) Capacity (L)

$537,320.00 $805,448.00

$348,090.00 $492,738.00

$348,090.00 $492,738.00

$860,320.00 $1,128,448.00

$2,093,820.00 $2,919,372.00

$1,046,910.00

$321,825.00

Cost (Cs-Cat in 1 and 4)

Loading (L) Capacity (L)

$945,519.48 $1,417,343.07

$612,532.34 $867,068.75

$612,532.34 $867,068.75

$1,513,901.07 $1,985,724.65

$3,684,485.23 $5,137,205.21

$1,842,242.62
Specific Heat of Air 1 J/(g-K)

Specific Heat of Air 0.2388 Btu/(lb-R)

Desity air @ 70F 0.07429 lb/ft^3

avg Flow in secondary 191,534 scfm

avg mass flow in secondary 14229.07 lb/min

avg Temp in secondary 177.10 F

Temp needed in catalyst 735 F 

delta T 558 F or R

Energy finput required 113.78 MMBtu/hr

Assuming 80% heat transfer eff. 142.23 MMBtu/hr @ 80% efficiency heat conversion

Energy content of natural gas 1050 MMBtu/MMscf

Natural gas needed per hour 0.135 MMscf/hr

Potential annual natural gas requirement 1186.59 MMscf/yr

Cost of natural gas $6.88 per 1000 scf

Hourly natural gas cost $931.94

potential annual natural gas cost $8,163,768.12

Nox emission factor 50 lb/MMscf

Potential Annual NOx emissions 29.66 tpy
t conversion
0.000948 Btu/J

453.59 g/lb

0.555556 K/R
interest rate 0.07

n 20 years

CRF 0.094393