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
nd 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 Comfort $ 1,080,270 $ 324,103 $ 12,451 $ 61,604 $ 1,092,721

Georgia Gulf Aberdeen

Georgia Gulf Plaquemine $ 2,401,684 $ 689,912 $ 30,641 $ 122,701 $ 2,432,325

OxyVinyls Deer Park

OxyVinyls Pasadena

OxyVinyls Pedricktown

PolyOne Henry

PolyOne Pedricktown

Shintech Addis

Shintech Freeport

Shintech Plaquemine

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$)

ACI
$ 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)

HCL Scrubber Thermal Oxidizer

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

Thermal Oxidizer Total VC, HCl, TOH Cost

Facility TAC ($/Yr) Total Capital Cost 

($) TAC ($/yr, 2010) TCI (2010$) TAC ($/yr, 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
Supplemental 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 22,623,149
Attachment 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: Equation
Refrigerated 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 ($/kWhr): (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 $173.79
Fabric 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 ft3

 air/1,000 ft3 filtered) 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 ft2

 bag 

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 ft2

 bag 

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 ft2 bag 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 CharlesFormosa 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)0.6 x (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 10-3 for 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. Water 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 

ppmvd)

11. Operating labor rate, $/hr (LR)

12. Electricity cost, $/kWh (EC)

13. Caustic cost, $/ton (CC)

14. Sewage disposal cost, $/1,000 gal 

(SDC)

15. Water cost, $/1,000 gal (WC)

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. Minimum packing wetting rate, 

ft2/hr (WR)

19. Water density, lb/ft3 (Wd)

20. Water circulation flow rate, lb/hr-ft2 

(Gs)

= SAV x Wd x WR

21. Estimated column cross-sectional 

area from separate analysis, ft2 (A)

22. Water circulation rate, gpm (GPM) = Gs x A x (1 hr/60 min) x (1 gal/8.33 lb)

23. Water head, ft of water (Head)

24. Wastewater (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 

equipment 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/lbmole) x (gal/8.33 lb)) x (60 min/hr) x H x WC

D. Indirect Annual Costs, $/yr

1. Overhead = 0.6 x (labor + maintenance materials)

2. Property taxes, insurance, and 

administration

= 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 Waste Incinerators (HMIWI) [EPA-HQ-OAR-2006-0534]-Model Plant Description 

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. 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

A-HQ-OAR-2006-0534]-Model Plant Description and Cost Report (II-A-112); and Wet Scrubber Cost Memorandum (IV-B-30).

tatistics, May 2008 National Industry-Specific

Price of Electricity: October 2009.

gust 29, 2007.

$19,843

$0.07

297.06

$40

$0.20

199,235

um (IV-B-30).
Air Compliance Advisor Input/Output for Vent Gas Absorption Exhaust to Thermal Oxidizer

Henry Pedricktown

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 Parameters Equation
Henry Pedricktown

PolyOne Parameters Equation

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 Index
Electricity 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)