# Polyvinyl Chloride and Copolymers (PVC) Production

Control Cost Estimates Process Vents April 11, 2011

Worksheet Name Cost Summary PV Condenser Cost-MACT Floor FF Cost ACI Cost HCl Scrubber PolyOne TO Costing Chart for PV Condenser

# Polyvinyl Chloride and Copolymers (PVC) Production

Description

Total Capital/Annual Costs for Process Vent Control Equipment Vinyl Chloride Condenser Cost Algorithm Fabric Filter Cost Algorithm Activated Carbon Injection Cost Algorithm Hydrogen Chloride Scrubber Cost Algorithm Inputs/Outputs for Air Compliance Advisor - PolyOne Thermal Oxidizers Chart Supporting Vinyl Chloride Cost Algorithm

### Process Vents Costing Summary (MACT Floor)

Certain Teed Lake Charles 874,964 $ 267,268

$ 7,797

$ 25,069

$ 882,761

$ Formosa Baton Rouge 1,295,725 $ 383,748

$ 16,310

$ 43,057

$ 1,312,035

$ Formosa Delaware Formosa Point Com fort 1,080,270 $ 324,103

$ 12,451

$ 61,604

$ 1,092,721

$ Georgia Gulf Aberdeen Georgia Gulf Plaquem ine 2,401,684 $ 689,912

$ 30,641

$ 122,701

$ 2,432,325

$ Oxy Vinyls Deer Park Oxy Vinyls Pasadena Oxy Vinyls Pedricktown PolyOne Henry PolyOne Pedricktown Shintech Addis Shintech Freeport Shintech Plaquem ine Dow Midland Westlake Calvert City Westlake Geismar 3,991,764 $ 1,130,097

$ 45,533

$ 111,109

$ 4,037,296

$

Bulk 874,964

$ 267,268

$ 7,797

$ 25,069

$ 882,761

$ Dispersion
-

$

-

$

-

$

-

$

-

$ Other 8,769,443

$ 2,527,861

$ 104,935

$ 338,471

$ 8,874,378

$ Industry Total 9,644,407

$ 2,795,129

$ 112,732

$ 363,540

$ 9,757,138

$ Totals Fabric Filter TCI (2010$) TAC ($/yr, 2010) Total DF Cost (Control) Location TCI (2010$) TAC ($/yr, 2010) Company TCI (2010$) AC I

### 292,337

$ 760,527

$ (114,794)

$ 426,805 $ 385,708 $ 79,085

$ 69,036

$ 812,613 $ 1,153,653 $ 282,000

$ 629,409 $ (1,377,272)

$

1,241,205 $
292,337 $ 760,527

$ (114,794)

$

-

$

-

$

-

$

- $

-

$

-

$

-

$

-

$

-

$ 2,866,332 $ 708,494

$ (1,308,236)

$ 1,153,653

$ 282,000

$

-

$ 3,158,669 $ 1,469,021

$ (1,423,030)

$ 1,153,653

$ 282,000

$ -

$ TCI (2010$) Total DF Cost (Control) Condenser

TAC ($/yr, 2010) Thermal Oxidizer HCL Scrubber TCI (2010$) TAC ($/yr, 2010) TCI (2010$) TAC ($/yr, 2010)

### 760,527 $ (114,794)

$ 1,643,288

$ 177,543

$

- $ -

$ 1,312,035

$ 426,805

$

- $ -

$ -

$ -

$

- $ -

$ 1,092,721

$ 385,708

$ 79,085 $ 69,036

$ 79,085

$ 69,036

$ 1,153,653 $ 282,000

$ 3,585,978

$ 1,094,613

$

- $ -

$ 629,409 $ (1,377,272)

$ 629,409

$ (1,377,272)

$

- $ -

$ 173,930 $ -

$ 173,930

$ 173,930 $ 130,855 $ -

$ 130,855

$ 130,855 $

- $ -

$ -

$ -

$

- $ -

$ -

$ -

$

- $ -

$ -

$ -

$

- $ -

$

- $ -

$ -

$ -

$

- $ -

$ 4,037,296

$ 1,241,205

$

- $ 760,527

$ (114,794)

$ 1,643,288

$ 177,543

$ 304,785 $

-

$ 304,785

$

-

$ 304,785

$

- $ 1,862,147

$ (1,026,236)

$ 10,736,525

$ 1,840,096

$ 304,785 $ 2,622,674

$ (836,245)

$ 12,379,813

$ 2,322,423

$ Total VC, HCl, TOH Cost Thermal Oxidizer Facility TAC ($/Yr) Total Capital Cost ($) TAC ($/yr, 2010) TAC ($/yr, 2010)

TCI (2010$)

### Secondary Impacts

Electricity

Required Water Required kW -hr/yr gal/yr FF ACI Condenser TO FF

74,773.49 1,953,202.58 0 207,282.81 0 139,430.23 0 18,985.26 555,579.73 0 1,566,409.61 0 15,602.14 15,602.14

1,056,339.43 0
74,773.49
- 1,953,202.58
- 0

- - - 15,602.14 0 1,958,632.20
- 1,585,394.88 15,602.14 0

### Activated Carbon Required Dust Produced tons/yr tons/yr ACI Condenser TO ACI FF

0 0 1.72 0.69 0 0 6.78 2.36

0 0 0 14.04 1.50

0 0 0 32.95 6.74 0 0 0 0 0 0 0 0 0 26.38 13.04

0 0 0 2 1 0 0 0 0 0 0 0 0 80 24

### Supplem ental Fuel ft3 NG/yr ACI TO

1.72 6.78 14.04 32.95

22,623,149

8,887,788

26.38

2 0 0 8,887,788 80 22,623,149Attachment A - Condenser Cost Algorithm

Refrigerated Condenser Package for PVC and Copolymer Process Vents
Certain Teed Georgia Gulf OxyVinyls Lake Charles Aberdeen Pasadena -- Inlet stream flowrate (DSCMM): 5.7 0.1 15.1 -- Inlet stream flowrate (scfm): (Qin) =DSCMM/35.31 200 4 535 -- Inlet stream temperature (oC): 65 16 18 -- Inlet stream temperature (oF): (Tin) =oC*1.8+32 148 61 65 -- VOC to be condensed: Vinyl chloride Vinyl chloride Vinyl chloride -- VOC inlet volume fraction:(Yvoc,in) =ppm/1E6 0.096 0.485 0.188 -- Required VOC removal (fraction): (n) 0.937 0.835 0.660 -- Antoine equation constants for VOC: [4] A: 6.497 6.497 6.497 B: 783.400 783.400 783.400 C: 230.010 230.010 230.010 -- VOC heat of condensation (BTU/lb-mole): (ΔHvoc,r) 10080 10080 10080 -- VOC heat capacity (BTU/lb-mole-oF): (Cp,voc) 11.655 11.655 11.655 -- Coolant specific heat (BTU/lb-oF): Cp,cool 0.650 0.650 0.650 -- VOC boiling point (oF): (Tboil) 7 7 7 -- VOC critical temperature (oR): (Tc) 773 773 773 -- VOC molecular weight (lb/lb-mole): (MWvoc) 63 63 63 -- VOC condensate density (lb/gal): 8.15 8.15 8.15 -- Air heat capacity (BTU/lb-mole-oF): (Cp,air) 6.95 6.95 6.95 DESIGN PARAMETERS: -- Outlet VOC partial pressure (mm Hg): (Pvoc) =760*(Yvoc,in*(1-n)/(1-Yvoc,in*n)) 5.0 102.2 55.4 -- Condensation temperature, Tc (oF): (Tcon) =(B/(A-log10(Pvoc))-C)*1.8+32 -138.7 -67.8 -85.4 (oR): =Tcon+460 321.3 392.2 374.6 -- VOC flowrate in (lb-moles/hr): (Mvoc,in) =Qin*Yvoc,in*60/392 2.93 0.29 15.39 -- VOC flowrate out (lb-moles/hr): (Mvoc,out) =Mvoc,in*(1-n) 0.185 0.048 5.232 -- VOC condensed (lb-moles/hr): (Mvoc,con) =Mvoc,in-Mvoc,out 2.745 0.245 10.156 (lb/hr): (Lb/hrvoc,con) =Mwvoc*Mvoc,con 171.6 15.3 634.7 -- VOC heat of condensation @ Tc (BTU/lb-mole): (ΔHvoc) =(ΔHvoc,r)*[(1-Tcon/Tc)/(1-Tboil/Tc)]^0.38 11679 10946 11135 -- Enthalpy change, condensed VOC (BTU/hr): (ΔHcon) =Mvoc,con[ΔHvoc+Cp,voc(Tin-Tcon) 41244 3052 130918 -- Enthalpy change, uncondensed VOC (BTU/hr):(ΔHuncon) =Mvoc,out*Cp,voc*(Tin-Tcon) 618 73 9186 -- Enthalpy change, air (BTU/hr): (ΔHnoncon) =Cp,air*(Tin-Tcon)*(Qin*60/392-Mvoc,in) 55128 280 69622 -- Condenser heat load (BTU/hr): (Hload) =ΔHcon+Δhuncon+ΔHnoncon 96990 3405 209726 -- Heat transfer coefficient, U (BTU/hr-ft2-oF): Estimate from OAQPS Manual 20 20 20 -- Log-mean temperature difference (oF): Tlm =(Tin-Tcon-25)/ln((Tin-Tcon-10)/15) 89.9 50.2 56.1 -- Condenser surface area (ft2): (Acon) =Hload/U*Tlm 54.0 3.4 186.8 -- Coolant flowrate (lb/hr): =Hload/(Cp,cool*(Tcon-15+25)-(Tcon-15)) 5969 210 12906 -- Refrigeration capacity (tons): (R) =Hload/1200 8.08 0.28 17.48 -- Electricity requirement (kW/ton) [6]: (kW ) =-9E-06(Tcon)^3 - 0.0004(Tcon)2 - 0.0331(Tcon) + 3.560 24.45 6.77 9.07 CAPITAL COSTS Equipment Costs ($): -- Refrigeration unit/single-stage (< 10 tons): (Rss<10) =exp(9.83-0.014Tcon+0.340lnR) 263,481 31,283 0 -- Refrigeration unit/single-stage (> 10 tons): (Rss>10) =exp(9.26-0.007Tcon+0.627lnR) 0 0 114,840 -- Multistage refrigeration unit: (Mru) exp(9.73-0.012Tcon+0.584lnR) 300,831 18,176 248,966 Total equipment cost ($)--base: (ECp) =1.25*MAX(Rss<10,Rss>10,Mru) 376,039 39,103 311,208 Cost Index a. 2010 CE Equip (Feb Final) CE Equipment index (Feb 2010 Final) 641.1 641.1 641.1 b. 1990 CE Equip (Oct Final) CE Equipment index (Oct 1990 Final) 394 394 394 ' ' ' ' --escalated: (ECpe) =(ECp)*(FebFinal/OctFinal) 612,341 63,676 506,770 Purchased Equipment Cost ($): (PECp) =ECpe*1.08 661,328 68,770 547,312 Total Capital Investment ($): (TCI) =PECp*1.15 760,527 79,085 629,409 INPUT PARAMETERS: EquationRefrigerated Condenser Package for PVC and Copolymer Process Vents
Certain Teed Georgia Gulf OxyVinyls Lake Charles Aberdeen Pasadena INPUT PARAMETERS: Equation ANNUAL COST INPUTS: Operating factor (hr/yr): (OF) 8400 8400 8400 Operating labor rate ($/hr): (LR) 34.60 34.60 34.60 Maintenance labor rate ($/hr): (MR) 38.06 38.06 38.06 Operating labor factor (hr/sh): (OLF) 1/2 hour per 8 hour shift 0.50 0.50 0.50 Maintenance labor factor (hr/sh): (MLF) 1/2 hour per 8 hour shift 0.50 0.50 0.50 Electricity price ($/kW hr): (EP) 0.0700 0.0700 0.0700 Recovered VOC value ($/lb)[5]: (Rvoc) 0.31 0.31 0.31 Annual interest rate (fraction): (Int) 0.07 0.07 0.07 Control system life (years): (EL) 20 20 20 Capital recovery factor: (CRF) =Int*(1+Int)^EL/((1+Int)^EL-1) 0.0944 0.0944 0.0944 Taxes, insurance, admin. factor: (TaxF) 0.04 0.04 0.04 ANNUAL COSTS: Item Cost ($/yr) Cost ($/yr) Cost ($/yr) Operating labor =OF/8*OLF*LR 18,165 18,165 18,165 Supervisory labor =.15*Operating Labor 2,725 2,725 2,725 Maintenance labor =OF/8*MLF*MR 19,982 19,982 19,982 Maintenance materials 100% of maintenance labor 19,982 19,982 19,982 Electricity =EP*OF*kW *R/0.85 136,724 1,329 109,649 Overhead =.60*(Operating Labor+Supervisory Labor+Maint Labor+Maint Materials) 36,512 36,512 36,512 Taxes, insurance, administrative =TaxF*TCI 30,421 3,163 25,176 Capital recovery =CRF*TCI 71,788 7,465 59,412 Total Annual Cost (without credits) (TACwoc) =sum of all annual costs 336,298 109,322 291,601 Recovery credits (RC) =-Rvoc*OF*Lb/hrvoc,con (451,092) (40,286) (1,668,873) Total Annual Cost (with credits) =TACwoc+RC (114,794) 69,036 (1,377,272) NOTES:

---------- 1. Base equipment costs reflect Third Quart 1990 2. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2008 National Industry-Specific Occupational Employment and Wage Estimates 3. Electricity cost: Energy Information Administration. Average Industrial Retail Price of Electricity: October 2009. 4. Antoine constants listed in OAQPS Manual 5. ICIS, http://www.icis.com/v2/chemicals/9076567/vinyl-chloride/pricing.html, October 20, 2010. (Avg. $690/tonne = $0.313/lb) 6. Polynomial of best fit based on Table 2.5 OAQPS Control Cost Manual Section 3.1 Chapter 2.Attachment E1 - Fabric Filter
Fabric Filter Cost Algorithm Parameters/Costs Equation Certain Teed Lake Charles Formosa Baton Rouge Formosa Point Comfort Georgia Gulf Plaquemine Westlake Geismar Industry Total A. Parameters 1. Annual operating hours, hr/yr (H) 8400 8400 8400 8400 8400 2. Exhaust gas flow rate, dscfm (Q) 1213 4150 2646 11869 22968 3. PM concentration, gr/dscf (PM) assumed from original costing alg. 1.58E-02 1.58E-02 1.58E-02 1.58E-02 1.58E-02 4. Water vapor in gas from incinerator (10% by weight) a. lb/min = Q / (385 ft3/lb-mol) x (29 lb/lb-mol) x moisture content (0.10) 9.1 31.3 19.9 89.4 173.0 b. scfm = (lb/min) / (18 lb/lb-mol) x (385 ft3/lbmol) 195 669 426 1,912 3,700 5. Enthalpy change in quench (1800 ° F to 300 ° F) a. Dry gas from incinerator, Btu/lb air = [7.010 x (300 ° F - 77 ° F) - 7.554 x (1800 ° F - 77 ° F)] / (29 lb/lb-mol) 395 395 395 395 395 b. Water vapor from incinerator, Btu/lb water vapor = [8.154 x (300 ° F - 77 ° F) - 9.215 x (1800 ° F - 77 ° F)] / (18 lb/lb-mol) 781 781 781 781 781 c. Total gas stream, Btu/yr = [(Btu/lb air) x Q / (385 ft3/lb-mol) x (29 lb/lb-mol) x (60 min/hr) x H] + [(Btu/lb water vapor) x Q x (0.00753 lb water vapor/ft3) x (60 min/hr) x H] 2.18E+10 7.45E+10 4.75E+10 2.13E+11 4.12E+11

d. Cooling water i. Heat of vaporization at 77 ° F, Btu/lb 1,050 1,050 1,050 1,050 1,050 ii. Sensible heat for vapor, Btu/lb 85 85 85 85 85 iii. Total, Btu/lb water 1,135 1,135 1,135 1,135 1,135 6. Cooling water evaporated, lb/yr a. lb/yr = [enthalpy change (total gas stream, Btu/yr)] / [enthalpy change (cooling water, Btu/lb)] 1.92E+07 6.57E+07 4.19E+07 1.88E+08 3.63E+08

b. scfm = [cooling water evaporated (lb/yr)] / (18 lb/lb-mol) x (385 ft3/lb-mol) / (H * 60 min/hr) 814 2,786 1,776 7,969 15,421
7. Actual gas flow into fabric filter, acfm (AQ) = [Q + (water vapor in gas from incinerator, scfm) + (water vapor added in quench, i.e., cooling water evaporated, scfm)] x [(300 ° F + 460 ° F)/528 ° R] 3,199 10,946 6,979 31,308 60,584

8. Operating labor rate, $/hr (LR) $34.60 $34.60 $34.60 $34.60 $34.60 9. Electricity cost, $/kWh (EC) $0.07 $0.07 $0.07 $0.07 $0.07 10. Water cost, $/1,000 gal (WC) $0.20 $0.20 $0.20 $0.20 $0.20 11. Compressed air cost, $/1,000 ft3(CAC) $0.24 $0.24 $0.24 $0.24 $0.24 12. Dust disposal cost, $/ton (DDC) $34.29 $34.29 $34.29 $34.29 $34.29 13. Capital recovery factors = [i x (1 + i)a] / [(1 + i)a - 1], where i = interest rate, a = equipment life a. Bag CRF, 2-yr life, 7% interest 0.55309 0.55309 0.55309 0.55309 0.55309 b. Cage CRF, 4-yr life, 7% interest 0.29523 0.29523 0.29523 0.29523 0.29523 c. Equipment CRF, 20-yr life, 7% interest 0.09439 0.09439 0.09439 0.09439 0.09439 14. Cost index a. 2010 CE Equip (Feb Final) 641.1 641.1 641.1 641.1 641.1 b. 1989 CE Equip (Oct Final) 392.6 392.6 392.6 392.6 392.6 B. Total Capital Investment 1. $ = (47.0 x Q + 306,720) x (1.4 retrofit cost factor) x (525.4/357.5) $874,964 $1,295,725 $1,080,270 $2,401,684 $3,991,764 $9,644,407 2. $/dscfm = $ / Q $721.42 $312.24 $408.28 $202.34 $173.79Fabric Filter Cost Algorithm Parameters/Costs Equation Certain Teed Lake Charles Formosa Baton Rouge Formosa Point Comfort Georgia Gulf Plaquemine Westlake Geismar Industry Total C. Direct Annual Operating Costs, $/yr 1. Electricity = (0.746 kW/hp) x hp (0.0072 x Q + 3.20) x H x EC $4,995 $13,846 $9,314 $37,113 $70,563 3. Evaporative cooler water = (0.1007 x Q + 23.1506) gal/min x (60 min/hr) x H x WC $14,645 $44,456 $29,191 $122,815 $235,475 4. Operating labor = (1 hr/shift) x (1 shift/8 hr) x H x LR $36,330 $36,330 $36,330 $36,330 $36,330 5. Supervisory labor = 0.15 x (operating labor) $5,450 $5,450 $5,450 $5,450 $5,450 6. Maintenance labor = (0.5 hr/shift) x (1 shift/8 hr) x H x (LR x 1.1) $19,982 $19,982 $19,982 $19,982 $19,982 7. Maintenance materials = 0.02 x TCI $17,499 $25,914 $21,605 $48,034 $79,835 8. Compressed air = AQ x (2 ft3air/1,000 ft3filtered) x (60 min/hr) x H x CAC $774 $2,648 $1,688 $7,574 $14,656 9. Dust disposal = (PM gr/dscf x Q x 60 min/hr x 1 lb/7,000 gr) x (1 ton/2,000 lb) x H x DDC $24 $81 $52 $231 $447
10. Bag replacement a. Bag cost = AQ x ($2.5/ft2 ) x (525.4/317.4) x (1.08 taxes and freight ratio)/(3.5 ft/min G/C ratio) $4,085 $13,978 $8,912 $39,979 $77,363
b. Bag replacement labor cost = AQ x (0.15 hr/bag)/(18 ft2bag area)/(3.5 ft/min G/C ratio) x LR $264 $902 $575 $2,579 $4,991 c. Bag replacement cost = Bag CRF x [(total bag cost) + (bag replacement labor cost)] $2,405 $8,230 $5,247 $23,539 $45,549 11. Cage replacement a. Number of bags = AQ/(3.5 ft/min G/C ratio)/(18 ft2bag area) $51 $174 $111 $497 $962 b. Cage replacement labor cost = bag replacement labor cost $264 $902 $575 $2,579 $4,991 c. Cage replacement cost = Cage CRF x [single-cage cost (4.941+ 0.163 x 18 ft2bag area) x (number of bags) x (525.4/317.4) + (cage replacement labor cost)] $273 $935 $596 $2,674 $5,174

D. Indirect Annual Costs, $/yr 1. Overhead = 0.6 x (labor + maintenance materials) $47,556 $52,605 $50,020 $65,877 $84,958 2. Property taxes, insurance, and administration = 0.04 x TCI $34,999 $51,829 $43,211 $96,067 $159,671 3. Capital recovery = Equipment CRF x (TCI - bag replacement cost - cage replacement cost) $82,338 $121,442 $101,418 $224,228 $372,006

E. Total Annual Cost 1. $/yr = Direct Annual Costs + Indirect Annual Costs $267,268 $383,748 $324,103 $689,912 $1,130,097 $2,795,129 2. ($/yr) / dscfm = ($/yr) / Q $220.37 $92.47 $122.49 $58.13 $49.20 Sources: 1. Cost equations: Hospital/Medical/Infectious Waste Incinerators (HMIWI) [EPA-HQ-OAR-2006-0534] Model Plant Description and Cost Report (II-A-112); and Dry Injection Fabric Filter Cost Memorandum (IV-B-32). 2. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2008 National Industry-Specific Occupational Employment and Wage Estimates 3. Electricity cost: Energy Information Administration. Average Industrial Retail Price of Electricity: October 2009. 4. Water cost: Air Compliance Advisor, version 7.5. 5. Compressed air cost: P2Pays.org. Energy Tips – Compressed Air. Compressed Air Tip Sheet #1. August 2004. 6. Dust disposal cost: NSWMA’s 2005 Tip Fee Survey 7. Assumed a PM concentration of 1.58E-2 gr/dscf as a result of the ACI.Attachment D 

### Activated Carbon Injection Model Costs Parameters/Costs Equation Certain Teed Lake Charles Formosa Baton Rouge Formosa Point Comfort Georgia Gulf Plaquemine Westlake Geismar Industry Total A. Parameters 1. Annual operating hours, hr/yr (H) 8400 8400 8400 8400 8400 2. Exhaust gas flow rate, dscfm (Q) 1213 4150 2646 11869 22968 3. Operating labor rate, $/hr (LR) $34.60 $34.60 $34.60 $34.60 $34.60 4. Activated carbon cost, $/lb (ACC) $1.38 $1.38 $1.38 $1.38 $1.38 5. Dust disposal cost, $/ton (DDC) $34.29 $34.29 $34.29 $34.29 $34.29 6. Capital recovery factor, 20-yr equipment life, 7% interest (CRF) = [i x (1 + i) a] / [(1 + i) a - 1], where i = interest rate, a = equipment life 0.09439 0.09439 0.09439 0.09439 0.09439 7. Cost index a. 2010 CE Equip (Feb Final) 641.1 641.1 641.1 641.1 641.1 b. 1990 CE Equip (Oct Final) 393.7 393.7 393.7 393.7 393.7 8. ACI Adjustment Factor (AF) =% Reduction required / 98 0.27 0.31 0.99 0.52 0.22 B. Total Capital Investment 1. $ = 4,500 x (Q/1,976) 0.6x (1.2 retrofit factor) x (575.4/361.3) $7,797 $16,310 $12,451 $30,641 $45,533 $112,732 2. $/dscfm = $ / Q $6.43 $3.93 $4.71 $2.58 $1.98 C. Direct Annual Costs, $/yr 1. Operating labor = (0.25 hr/8-hr shift) x H x LR $9,083 $9,083 $9,083 $9,083 $9,083 2. Supervisory labor = 0.15 x (operating labor) $1,362 $1,362 $1,362 $1,362 $1,362 3. Maintenance = 0.2 x TCI $1,559 $3,262 $2,490 $6,128 $9,107 4. Activated carbon = 0.00127 x Q x H x ACC x AF $4,755 $18,702 $38,754 $90,936 $72,803 5. Dust disposal = 0.00127 x Q x (1 ton/2,000 lb) x H x DDC x AF $59 $232 $481 $1,130 $904 D. Indirect Annual Costs, $/yr 1. Overhead = 0.6 x (labor + maintenance materials) $7,203 $8,224 $7,761 $9,944 $11,731 2. Property taxes, insurance, and administration = 0.04 x TCI $312 $652 $498 $1,226 $1,821 3. Capital recovery = CRF x TCI $736 $1,540 $1,175 $2,892 $4,298 E. Total Annual Cost 1. $/yr = Direct Annual Costs + Indirect Annual Costs $25,069 $43,057 $61,604 $122,701 $111,109 $363,540 2. ($/yr) / dscfm = ($/yr) / Q $20.67 $10.38 $23.28 $10.34 $4.84 Note: Factor of 1.27 x 10 -3for activated carbon is based on injecting carbon at a rate to achieve a carbon concentration of 338 mg/dscm (achieving reductions of 90% for Hg, 98% for CDD/CDF). Sources: 1. Cost equations: Hospital/Medical/Infectious Waste Incinerators (HMIWI) [EPA-HQ-OAR-2006-0534] Model Plant Description and Cost Report (II-A-112). 2. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2007 National Industry-Specific Occupational Employment and Wage Estimates. 3. Activated carbon cost: The Innovation Group. Chemical Profiles: Carbon, Activated. 2002. Assumed 20% price increase based on online information from Norit, an activated carbon vendor. 4. Dust disposal cost: NSWMA’s 2005 Tip Fee Survey.

# Packed Bed Scrubber Costs

Parameters/Costs Equation A. Parameters 2. Temperature into quench, F (T1) 3. Temperature out of PB to ID fan, F (T2) 4. Annual operating hours, hr/yr (H) 5. Exhaust gas flow rate, dscfm (Qd) 6. Assumed moisture content in gas entering quench, % (M) 7. Exhaust gas flow rate, scfm (Qw) = (Qd) / (1 - M/100) 8. W ater added in quench, scfm (Qh) = ((7.010 x (T1 - 77 ° F) - 6.958 x (T2 - 77 ° F)) x 0.9 + (8.154 x (T1 - 77 ° F) - 8.064 x (T2 - 77 ° F)) x 0.1) x (lb-mole/385 scf) x Qw / (1,160 Btu/lb) / (18 lb/lb-mole) x (0.7302 ft3



### - atm/lb-mol- ° R) x 528 ° R / 1 atm 9. Actual flow out of PB, acfm (Qa) = (Qw + Qh) x (460 ° F + T2)/(528 ° R) 10. HCl or SO2 concentration, (max ppm vd) 11. Operating labor rate, $/hr (LR) 12. Electricity

cost, $/kW h (EC) 13. Caustic cost, $/ton (CC) 14. Sewage disposal cost, $/1,000 gal (SDC) 15. W ater cost, $/1,000 gal (W C) 16. Assumed pressure drop through control system, inches of water (ΔP) 17. Surface area-to-volume ratio for 1" dia. Ceramic Raschig rings, ft2

### /ft3

### (SAV) 18. Minim umpacking wetting rate, ft2

### /hr (W R) 19. W ater density, lb/ft3

### (W d) 20. W ater circulation flow rate, lb/hr-ft2 

### (Gs) = SAV x W d x W R 21. Estimated column cross-sectional area from separate analysis, ft2

### (A) 22. W ater circulation rate, gpm (GPM) = Gs x A x (1 hr/60 min) x (1 gal/8.33 lb) 23. W ater head, ft of water (Head) 24. W astewater (blowdown) flow, gpm (B) = (HCl/1000000) x (Qd) x (lb-mole/385 ft3 

### ) x (1 lb-mole NaCl/1 lb-mole HCl) x (58.2 lb NaCl/lb-mole NaCl) x (1 lb wastewater/0.1 lb NaCl) x (1 gal/8.33 lb) 25. Capital recovery

factor, 15-yr equipm ent life, 7% interest (CRF) = [i x (1 + i) a

### ] / [(1 + i) a 

### - 1], where i = interest rate, a = equipment life 26. Chemical Engineering plant cost index a. Feb. 2010 CE b. 1989

### B. Total Capital Investment

1. $ = (27.6 x Qd + 109,603) x (525.4/357.5) x (1.4 retrofit factor) 2. $/dscfm = $ / Qd C. Direct Annual Costs, $/yr 1. Operating labor = (if Qa < 20,000, then 0, otherwise 0.5 hr/shift) x H x LR 2. Supervisory

labor = 0.15 x (operating labor) 3. Maintenance labor = (0.5 hr/8-hr shift) x H x (LR x 1.1) 4. Maintenance materials = 0.02 x TCI 5. Electricity = (0.000181 x Qa x ΔP x H x EC) + (0.000289 x GPM x Head x H x EC) 6. Caustic = HCl x (3.117E-9 ) x Q x H x CC 7. Sewage disposal = B x (60 min/hr) x H x SDC 8. Makeup water = (B + Qh x (lb-mole/385 scf) x (18 lb/lbmo le) x (gal/8.33 lb)) x (60 min/hr) x H x W C D. Indirect Annual Costs, $/yr 1. Overhead = 0.6 x (labor + maintenance materials) 2. Property

taxes, insurance, and adm inistration = 0.04 x TCI 3. Capital recovery = CRF x TCI E. Total Annual Cost 1. $/yr = Direct Annual Costs + Indirect Annual Costs 2. ($/yr) /dscfm = ($/yr) / Qd Sources: 1. Cost equations: Hospital/Medical/Infectious W aste Incinerators (HMIW I) [EPA-HQ-OAR-2006-0534]-Model Plant Description and Cost Report (II-A-112); and W et Scrubber Cost Memorandum (IV-B-30). 2. Operating labor rate: Bureau of Labor Statistics, Occupational Employme nt Statistics, May 2008 National Industry-Specific Occupational Employme nt and W age Estimates. 3. Electricity

cost: Energy

Information Administration. Average Industrial Retail Price of Electricity: October 2009. 4. Caustic cost: Purchasing.com. Caustic soda price hike is on the horizon. August 29, 2007. 5. Sewage disposal cost, water cost: Air Compliance Advisor, version 7.5.

Electricity

($/yr) Electricity

costs ($/kw-hr) Electricity

usage (Mw-hr/yr)

Makeup water ($/yr) Water cost ($/1,000 gal) water usage (gal/yr)

### Georgia Gulf Plaquemine

1 68 68 8,400 11,871 2 12,142 0

12,141 184.26 $34.60 $0.07 $357 $3.80 $0.20 15 58

1 62.4 4,705 19.2

181 60 0.397

0.10979

539.1 357.5

### $1,153,653 $97.18
$0 $0 $19,982 $23,073 $19,843 $20,418 $0 $40

$25,833 $46,146 $126,665
$282,000 $23.76
1. Cost equations: Hospital/Medical/Infectious W aste Incinerators (HMIW I) [EPA-HQ-OAR-2006-0534]-Model Plant Description and Cost Report (II-A-112); and W et Scrubber Cost Memorandum (IV-B-30). 2. Operating labor rate: Bureau of Labor Statistics, Occupational Employme nt Statistics, May 2008 National Industry-Specific 3. Electricity

cost: Energy

Information Administration. Average Industrial Retail Price of Electricity: October 2009. 4. Caustic cost: Purchasing.com. Caustic soda price hike is on the horizon. August 29, 2007.

$19,843 $0.07 297.06

$40 $0.20 199,235

### 1. Cost equations: Hospital/Medical/Infectious W aste Incinerators (HMIW I) [EPA-HQ-OAR-2006-0534]-Model Plant Description and Cost Report (II-A-112); and W et Scrubber Cost Memorandum (IV-B-30).Ai r Compliance Advisor Input/Output for Vent Gas Absorption Exhaust to Thermal Oxidizer Henry Pedricktow n

Program Inputs Hours of Operation (per year) 8400 8400 Total TO Inlet Flow Rate (DSCFM) 500 500 Stream Temperature (K) 293 293 Program Outputs Min % O2 Required 19.8 19.8 Op. Temp (F) 2200 2200 Auxiliary Air Req (CFM) 2045.45 499.99 Min Fuel Req (CFM) 1 1 Auxiliary Fuel Req (CFM) 45 18 Auxiliary Fuel Cost ($/yr) $68,548 $26,930 Equipment Cost [1] $225,860 $178,813 Auxiliary Equipment Cost 0 0 Total Equipment Cost $225,860 $178,831 Instrumentation Cost $0 $0 Sales Tax $6,776 $5,364 Freight Cost $11,293 $8,941 Purchased Equipment Cost $243,929 $193,118 Foundation Cost $19,514 $15,449 Equipment Erection Cost $34,150 $27,037 Electrical Cost $9,757 $7,725 Piping Cost $4,879 $3,862 Insulation Cost $2,439 $1,931 Painting Cost $2,439 $1,931 Direct Installation Cost $73,179 $57,935 Total Direct Capital Cost $317,108 $251,053 Engineering Cost $24,393 $19,312 Field Cost $12,197 $9,656 Contractor Cost $24,393 $19,312 Start Up Cost $4,879 $3,862 Performance Test Cost $2,439 $1,931 Contingencies Cost $7,318 $5,794 Total Indirect Capital Cost $75,618 $59,867 Total Capital Investment, $2008 (TCI2008) $392,726 $310,919 2008 - CE Equip - Oct Final [4] 720.00 720.00 2010 - CE Equip - Feb Final [4] 641.10 641.10 Total Capital Investment, $2010 (TCI2010) `=TCI2008*641.1/720 $349,690 $276,847 Operating Labor $18,152 $18,152 Supervisory Labor $2,723 $2,723 Maintenance Labor $19,968 $19,968 Maintenance Materials $19,968 $19,968 Replacement Parts $0 $0 Utilities $69,640 $28,022 Electricity [2] $1,092 $1,092 Total Direct Annual Cost $130,450 $88,832 Overhead $36,486 $36,486 Administrative Charges $7,855 $6,218 Property Taxes
- - Insurance
- - Capital Recovery Factor
- - Capital Recovery
- - Total Indirect Annual Cost `=Overhead+Admin Charges $44,341 $42,704 Recovery Credit $0 $0 PolyOne Equation ParametersHenry Pedricktow n PolyOne Equation Parameters Total Annualized Cost (2008 Dollars) ` =Indirect Annual Cost + Direct Annual Cost $174,791 $131,537

- - 2010 Cost Calculations

- - Overhead (2010 Dollars) [3] `=.6*(Op. Labor + Maint. Labor + Maint. Materials + Super. Labor) $36,486.1 $36,486.1 Administrative Charges (2010 Dollars) [3] `=0.02*TCI2010 $6,993.80 $5,536.95 Property Taxes (2010 Dollars)
- - Insurance (2010 Dollars)
- - Capital Recovery Factor
- - Capital Recovery (2010 Dollars)
- - Total Indirect Annual Cost (2010 Dollars) `=Overhead+Admin Charges $43,480 $42,023 Recovery Credit
- - Total Annualized Cost (2010 Dollars) ` =Total Direct Annual Costs + Total Indirect Annual Costs (2010 Dollars) $173,930 $130,855 1. Does not include auxiliary equipment 2. Represented as subpart of Utilities 3. US EPA OAQPS Air Pollution Control Cost Manual - 6th Edition (EPA 452/B-02-001) Section 3 - VOC Controls, Section 3.2 VOC Destruction Controls, Chapter 2 - Incinerators, Table 2.10 4. Chemical Engineering Equipment Cost IndexElectricity Requirement (kW/ton) vs. Condensation Temperature (oF)

----------------------------------------------------------------------------------------------------- -100 11.7 -50 5.0 -20 4.7 20 2.2 40 1.3



### y = -9E

0 2 4 6 8 10 12 14

- 120
- 100
-80
-60
-40
-20 0 20

### 9E
-06x3



### - 0.0004x2



### - 0.0331x + 3.5609

R2 = 0.9894

40 60 Series1 Poly. (Series1)