# ATTACHMENT 1

COST DETAILS FOR FRONT

- END PROCESS VENT CONTROLSTOTAL ANNUAL COST SPREADSHEET PROGRAM--THERMAL INCINERATORSCOST BASE DATE: April 1988 [1]VAPCCI (Third Quarter 2003--FINAL): [2]109.8 109.8 109.8 109.8CE Plant Index Nov 2003403.8 403.8 403.8 403.8CE Plant Index Jan 2010532.9 532.9 532.9 532.9BR HBR EPRCombined HBRAND EPRINPUT PARAMETERScontrolled organic emission, tpy 7.31 0.59 0.188 0.778Process gas flow, scf/s 58.3 58.3 58.3 116.7-- Operating hours, hr/yr 8,000 8,000 8,000 8,000-- Air molecular weight 29 29 29 29-- HAP in emission stream hexane Methyl Cl hexanemethylchloride andhexane-- HAP molecular weight 86.2 50.5 86.2 59.8-- HAP emission rate, lb/yr 731,000 236,000 75,200 311,200lb/hr 91.38 29.50 9.40 38.90-- Other VOC emission rate, lb/yr 0 0 0 0lb/hr 0.00 0.00 0.00 0.00-- VOC molecular weight 100 100 100 100-- HAP heating value, Btu/lb 19,391 5,290 19,391 8,982-- VOC heating value, Btu/lb 0 0 0 0-- HAP concentration, ppmv 1,943 1,071 200 596-- VOC concentration, ppmv 0 0 0 0-- Air flow rate, lb/hr 15,78715,80115,81531,617-- Oxygen content of gas stream, %20.86 20.88 20.90 20.89-- Reference temperature (oF):77 77 77 77-- Inlet gas temperature (oF):95 95 95 95-- Vent gas flowrate (scfm):3,5653,5653,5657,129acfm 3,6843,6843,6847,368-- Inlet gas density (lb/scf):0.0715 0.0715 0.0715 0.0715-- HAP LEL, ppmv 11,000 125,000 11,000 11,000-- Other VOC LEL, ppmv (assumed) 0 0 0 0-- Mixture LEL, ppmv 11,000 125,000 11,000 11,000-- Dilution air for combustion, scfm 0.0000 0.0000 0.0000 0.0000BRHBREPRCombined HBRAND EPR-- Dilution air for safety, scfm0.0000 0.0000 0.0000 0.0000-- Total gas flow to incinerator, scfm3,5653,5653,5657,129-- Primary heat recovery (fraction):0.000.700.700.70-- Waste gas heat content (BTU/scf):7.980.700.820.79-- Waste gas heat content (BTU/lb):111.599.86 11.52 11.04-- Gas heat capacity (BTU/lb-oF):0.2550.255 0.255 0.255-- Combustion temperature (oF):1600160016001600-- Preheat temperature (oF):95114911491149Temperature of flue gas, F1600547547547-- Fuel heat of combustion (BTU/lb):2150221502 21502 21502-- Fuel density (lb/ft3):0.0408 0.0408 0.0408 0.0408DESIGN PARAMETERS-- Auxiliary Fuel Reqrmnt (lb/min):0.2302 1.7464 1.7263 3.4642(scfm):5.642 42.804 42.310 84.907(scf/yr)2,708,123 20,545,762 20,308,970 40,755,193-- Total Gas Flowrate (scfm):3,5703,6083,6077,214CAPITAL COSTSEquipment Costs ($): (For 500 scfm to 50,000 scfm)-- Incinerator:@ 0 % heat recovery:70,672000@ 35 % heat recovery:0000@ 50 % heat recovery:0000@ 70 % heat recovery:0 165,401 165,395 196,691-- Other (auxiliary equipment, etc.):0000Total Equipment Cost--base:70,672 165,401 165,395 196,691' ' ' --escalated:128,090 299,780 299,770 356,492Purchased Equipment Cost ($):138,337 323,763 323,752 385,012Total Capital Investment ($):172,921 404,703 404,690 481,264=========== ============= ================ ============= =======================================ANNUAL COST INPUTSOperating factor (hr/yr):8000800080008000BRHBREPRCombined HBRAND EPROperating labor rate ($/hr):22.5022.50 22.50 22.50Maintenance labor rate ($/hr):24.7524.75 24.75 24.75Operating labor factor (hr/sh):0.50.50.50.5Maintenance labor factor (hr/sh):0.50.50.50.5Electricity price ($/kwh):0.0590.059 0.059 0.059Natural gas price ($/mscf):8.008.008.008.00Annual interest rate (fraction):0.070.070.070.07Control system life (years):15151515Capital recovery factor:0.1098 0.1098 0.1098 0.1098Taxes, insurance, admin. factor:0.040.040.040.04Pressure drop (in. w.c.):5.119.019.019.0ANNUAL COSTSItemCost ($/yr) Cost ($/yr)------------------------------------------------------------------------------------------------Operating labor11,250 11,250 11,250 11,250Supervisory labor1,688 1,688 1,688 1,688Maintenance labor12,375 12,375 12,375 12,375Maintenance materials12,375 12,375 12,375 12,375Natural gas21,665 164,366 162,472 326,042Electricity1,665 6,309 6,308 12,617Overhead22,613 22,613 22,613 22,613Taxes, insurance, administrative6,917 16,188 16,188 19,251Capital recovery18,986 44,434 44,433 52,840------------------------------------------------------------------------------------------------Total Annual Cost109,533 291,598 289,700 471,049[1] Original equipment costs reflect this date.[2] VAPCCI = Vatavuk Air Pollution Control Cost Index (for thermalincinerators) corresponding to year and quarter shown. Originalequipment cost, purchased equipment cost, and total capital investmenthave been escalated to this data via the VAPCCI and control equipment vendor data.TOTAL ANNUAL COST SPREADSHEET PROGRAM--GAS ABSORBERS [1]COST BASE DATE: Third Quarter 1991 [2]VAPCCI (Third Quarter 2003): [3]116.9 116.9 116.9 116.9CE Plant Index Nov 2003403.8 403.8 403.8 403.8CE Plant Index Jan 2010532.9 532.9 532.9 532.9ModelsBR HBR EPR HBR & EPRINPUT PARAMETERS:Stream parameters:Process gas flow, scf/s 59.51 60.13 60.12 120.24-- Process operating hours, hr/yr 8,000 8,000 8,000 8,000-- Inlet waste gas temperature (oF): 1600 547 547 547-- Inlet waste gas pressure (atm.):1111-- Pollutant in waste gas: Hydrogen chloride (HCl)HCl emissions, tpy 30.09 76.8 19.77 96.57-- HCl emissions, lb/yr 60,180 153,600 39,540 193,140-- HCl concentration, ppmv 370 936 241 588-- HCl molecular weight 36.5 36.5 36.5 36.5-- Waste gas molecular weight (lb/lb-mole): 28.85 28.85 28.85 28.85-- Solvent molecular weight (lb/lb-mole): 18 18 18 18-- Inlet waste gas flowrate (acfm): 13,930 6,877 6,876 13,752-- Inlet gas poll. conc., yi (mole fraction): 0.000370398 0.000935644 0.000240888 0.000588307-- Pollutant removal efficiency (fraction): 0.99 0.99 0.99 0.99-- Solvent: Aqueous caustic soda-- Inlet pollutant conc. in solvent:0000-- Inlet waste gas density (lb/ft3): 0.0192 0.0393 0.0393 0.0393-- Solvent density (lb/ft3): 62.4 62.4 62.4 62.4-- Solvent specific gravity:1111-- Waste gas viscosity @ inlet temp. (lb/ft-hr): 0.044 0.044 0.044 0.044-- Solvent viscosity @ inlet temp. (lb/ft-hr): 2.16 2.16 2.16 2.16-- Minimum wetting rate (ft2/hr): 1.3 1.3 1.3 1.3-- Pollutant diffusivity in air (ft2/hr): 0.725 0.725 0.725 0.725-- Pollutant diffusivity in solvent (ft2/hr): 0.000102 0.000102 0.000102 0.000102Packing parameters:-- Packing type: ceramic Raschig rings2" dia 2" dia 2" dia 2" dia-- Packing factor, Fp:65656565-- Packing constant, alpha:3.823.823.823.82-- Packing constant, beta:0.410.410.410.41-- Packing constant, gamma:0.450.450.450.45-- Packing constant, phi:0.0125 0.0125 0.0125 0.0125-- Packing constant, b:0.220.220.220.22-- Packing constant, c:0.240.240.240.24-- Packing constant, j:0.170.170.170.17-- Surface area-to-volume ratio, a (ft2/ft3):28282828-- Packing cost ($/ft3):20202020DESIGN PARAMETERS:-- Material of construction (see list below):[4]1111-- Inlet pollutant concentration (free basis) (Yi):3.705352E-04 9.365202E-04 2.409462E-04 5.886530E-04-- Outlet pollutant concentration (free basis) (Yo):0.0000037 0.0000094 0.0000024 0.0000059-- Out. eq. poll. conc. in solv., Xo* (op. line):0.1060.1060.0900.090-- Theoretical operating line slope (Ls/Gs,min.):0.0035 0.0087 0.0027 0.0065-- Ls/Gs adjustment factor:1.51.51.51.5-- Actual operating line slope (Ls/Gs, act.):0.0052 0.0131 0.0040 0.0097-- Gas flowrate, Gs (free basis, lb-moles/hr):5565615611122-- Solvent flowrate, Ls (free basis, lb-mol/hr):2.887.362.2310.90-- Gas flowrate, Gmol,i (lb-moles/hr):5565625611123-- Solvent flowrate, Lmol,i (lb-moles/hr):2.887.362.2310.90-- Outlet actual pollutant conc. in solv., Xo:0.0707 0.0707 0.0600 0.0600-- Gas poll. conc. in eq. with Xo (Yo*):0.000100 0.000100 0.000100 0.000100-- Outlet solv. poll. conc. (mol frac basis,xo):0.0660 0.0660 0.0566 0.0566-- Gas poll. conc., yo* (mole fract. basis):0.000100 0.000100 0.000100 0.000100-- Outlet gas poll. conc., yo (mole fract.):0.0000037 0.0000094 0.0000024 0.0000059-- Slope of equilibrium line (m):0.00151 0.00151 0.00177 0.00177-- Absorption factor (AF)--first calculation:3.438.662.255.50-- ABSCISSA (column diameter calculation):0.00006 0.00021 0.00006 0.00015-- ORDINATE (column diameter calculation):0.2061 0.2061 0.2061 0.2061-- Superficial gas flowrate, Gsfr,i (lb/sec-ft2)0.3534 0.5056 0.5056 0.5056-- Flooding factor, f:0.70.70.70.7-- Column cross-sectional area, A (ft2):17.9965 12.703212.7125.41-- Superficial liq flowrate (lb/hr-ft2) (Lsfr,i):2.8810.433.167.72-- Minimum liquid flowrate (lb/hr-ft2):2,2712,2712,2712,271-- If Superficial liquid flowrate is < minimumneeded, the minimum must be used to calculatetower area and diameter (iteratively):-- guess A iteratively until the two69 108 108 108ORDINATE values below agree, ft2-- recalculate Lmol,i 8,707 13,628 13,628 13,628-- calculate ABSCISSA for Fig. 9.5 0.17138 0.37982 0.37987 0.18993-- calculate Gsfr,i from Eq. 9-21 0.0922 0.0595 0.0595 0.1190-- calculate ORDINATE for Fig. 9.5 using 0.0140 0.0029 0.0029 0.0114eq. 9.54-- calculate ORDINATE from eq. 9-19 0.0975 0.0544 0.0544 0.0912-- Absorption factor--based on min liq flowrate-- Xo 7.58E-11 1.21E-10 3.12E-11 3.81E-11-- xo 7.58E-11 1.21E-10 3.12E-11 3.81E-11-- AF infinity infinity infinity infinity-- Values to use in subsequent calculations-- Lsfr,i 2,271 2,271 2,271 2,271-- A 69 108 108 108-- Gsfr,i 0.0922 0.0595 0.0595 0.1190-- AF infinity infinity infinity infinity-- Column diameter, D (ft): 9.4 11.7 11.7 11.7-- Number of transfer units, Ntu: 4.605 4.604 4.605 4.605-- Gas film transfer coefficient, Hg (ft): 1.959 1.144 1.144 1.520-- Liquid film transfer coefficient, Hl (ft): 1.064 1.064 1.064 1.064-- Height of a transfer unit (ft): 1.959 1.144 1.144 1.520-- Packing depth (ft): 9.019 5.268 5.269 7.000-- Column total height (ft): 25.00 22.15 22.15 24.57-- Column surface area (ft2): 874.1 1031.9 1031.9 1121.2-- Column gas pressure drop (in. w.c./ft packing): 0.067 0.014 0.014 0.054-- Column liquid pressure drop (ft of H2O): 60 60 60 60-- Packing volume (ft3): 622.32 568.96 569.0 756.0CAPITAL COSTS:Equipment costs ($):-- Gas absorber 100,519 118,665 118,668 128,936-- Pump (assumes $16/gpm) 5,011 7,844 7,844 7,844-- Packing 12,446 11,379 11,380 15,120-- Total (base) 117,977 137,887 137,891 151,900' (escalated)191,217 223,489 223,495 246,200Purchased Equipment Cost ($): 225,636 263,717 263,725 290,516Total Capital Investment ($): 496,400 580,177 580,194 639,136======================================================= ============ ============ ============ANNUAL COST INPUTS:Operating factor (hr/yr): 8,000 8,000 8,000 8,000Operating labor rate ($/hr): 22.5 22.5 22.5 22.5Maintenance labor rate ($/hr): 24.75 24.75 24.75 24.75Operating labor factor (hr/sh): 0.0 0.0 0.0 0.0Maintenance labor factor (hr/sh): 0.5 0.5 0.5 0.5Electricity price ($/kWhr): 0.059 0.059 0.059 0.059Caustic price ($/ton): 300 300 300 300Solvent (water) price ($/1000 gal): 0.2 0.2 0.2 0.2Wastewater trtmt cost ($/1000 gal): 3.80 3.80 3.80 3.80Overhead rate (fraction): 0.6 0.6 0.6 0.6Annual interest rate (fraction): 0.07 0.07 0.07 0.07Control system life (years): 15 15 15 15Capital recovery factor (system): 0.1098 0.1098 0.1098 0.1098Taxes, insurance, admin. factor: 0.04 0.04 0.04 0.04ANNUAL COSTS:Item Cost ($/yr) Cost ($/yr) Cost ($/yr) Cost ($/yr)------------------------------------------------------------Operating labor0000Supervisory labor0000Maintenance labor 12,375 12,375 12,375 12,375Maintenance materials 12,375 12,375 12,375 12,375Electricity 1,283 477 478 1,290Caustic 10,076 25,718 6,620 32,339Solvent (water) 23 59 15 74Wastewater treatment 439 1,120 288 1,409Overhead 14,850 14,850 14,850 14,850Taxes, insurance, administrative 19,856 23,207 23,208 25,565Capital recovery 54,502 63,700 63,702 70,174-------------------------------------------------Total Annual Cost 125,779 153,882 133,912 170,451

# ATTACHMENT 2

COST DETAILS FOR BACK

- END PROCESS VENT CONTROLSTOTAL ANNUAL COST SPREADSHEET PROGRAM--THERMAL INCINERATORSCOST BASE DATE: April 1988 [1]VAPCCI (Third Quarter 2003--FINAL): [2]109.8 109.8 109.8 109.8 109.8CE Plant Index Nov 2003403.8 403.8 403.8 403.8 403.8CE Plant Index Jan 2010532.9 532.9 532.9 532.9 532.9Butyl HalobutylEpichlorohydrinNeoprene NBRINPUT PARAMETERSOrganic emission, tpy 26.19 34.67 35.97 23.112 1.74Process gas flow, scf/s 213.0 454.0 309.0 1466.0 3561.0-- Operating hours, hr/yr 8,000 8,000 8,000 8,000 8,000-- Air molecular weight 29 29 29 29 29-- HAP in emission stream hexane hexane toluenechloroprene/toluene1,3-Butadiene/Acrylonitrile-- HAP molecular weight 86.2 86.2 92.13 91.1 53.5-- HAP emission rate, lb/yr 52,380 69,340 71,940 46,224 3,480lb/hr 6.55 8.67 8.99 5.78 0.44-- Other VOC emission rate, lb/yr0000 0lb/hr 0.00 0.00 0.00 0.00 0.00-- VOC molecular weight 100 100 100 100 100-- HAP heating value, Btu/lb 19,391 19,391 17,601 17,601 19,236-- VOC heating value, Btu/lb0000 0-- HAP concentration, ppmv 38 24 34 5 0-- VOC concentration, ppmv0000 0-- Air flow rate, lb/hr 57,757123,10883,788397,532965,632-- Oxygen content of gas stream, %20.90 20.90 20.90 20.90 20.90-- Reference temperature (oF):77 77 77 77 77-- Inlet gas temperature (oF):95 95 95 95 95-- Vent gas flowrate (scfm):13,01627,74418,88389,586217,610acfm 13,45328,67419,51692,589224,904-- Inlet gas density (lb/scf):0.0715 0.0715 0.0715 0.0715 0.0715-- HAP LEL, ppmv 11,000 125,000 11,000 11,000 11,000-- Other VOC LEL, ppmv (assumed)0000 0-- Mixture LEL, ppmv 11,000 125,000 11,000 11,000 11,000-- Dilution air for combustion, scfm 0.0000 0.0000 0.0000 0.0000 0.0000-- Dilution air for safety, scfm 0.0000 0.0000 0.0000 0.0000 0.0000-- Total gas flow to incinerator, scfm 13,01627,74418,88389,586217,610Butyl HalobutylEpichlorohydrinNeoprene NBR-- Primary heat recovery (fraction):0.000.700.700.700.70-- Waste gas heat content (BTU/scf):0.160.100.140.020.00-- Waste gas heat content (BTU/lb):2.201.371.890.260.01-- Gas heat capacity (BTU/lb-oF):0.255 0.255 0.255 0.2550.255-- Combustion temperature (oF):16001600160016001600-- Preheat temperature (oF):951149114911491149Temperature of flue gas, F1600547547547547-- Fuel heat of combustion (BTU/lb):21502 21502 21502 2150221502-- Fuel density (lb/ft3):0.0408 0.0408 0.0408 0.04080.0408DESIGN PARAMETERS-- Auxiliary Fuel Reqrmnt (lb/min):0.8405 14.3929 9.7624 46.8135 113.8957(scfm):20.601 352.767 239.275 1147.391 2791.561(scf/yr)9,888,518 169,328,023 114,852,012 550,747,516 1,339,949,075-- Total Gas Flowrate (scfm):13,03728,09619,12290,733220,401CAPITAL COSTSEquipment Costs ($): (For 500 scfm to 50,000 scfm)-- Incinerator:@ 0 % heat recovery:95,8750000@ 35 % heat recovery:0000 0@ 50 % heat recovery:0000 0@ 70 % heat recovery:0 276,311 250,968 370,405 462,422-- Other (auxiliary equipment, etc.):0000 0Total Equipment Cost--base:95,875 276,311 250,968 370,405 462,422' ' ' --escalated:173,770 500,799 454,867 671,341 838,117Purchased Equipment Cost ($):187,671 590,943 491,257 792,182 988,979Total Capital Investment ($):234,589 951,419 614,071 1,275,414 1,592,255=========== ============ ================ ============= =====================================================ANNUAL COST INPUTSOperating factor (hr/yr):80008000800080008000Operating labor rate ($/hr):22.50 22.50 22.50 22.5022.50Maintenance labor rate ($/hr):24.75 24.75 24.75 24.7524.75Operating labor factor (hr/sh):0.50.50.50.50.5Maintenance labor factor (hr/sh):0.50.50.50.50.5Butyl HalobutylEpichlorohydrinNeoprene NBRElectricity price ($/kwh):0.059 0.059 0.059 0.0590.059Natural gas price ($/mscf):8.008.008.008.008.00Annual interest rate (fraction):0.070.070.070.070.07Control system life (years):1515151515Capital recovery factor:0.1098 0.1098 0.1098 0.10980.1098Taxes, insurance, admin. factor:0.040.040.040.040.04Pressure drop (in. w.c.):5.119.019.019.019.0ANNUAL COSTSItemCost ($/yr) Cost ($/yr)--------------------------------------------------------------------------------------------------------------Operating labor11,250 11,250 11,250 11,250 11,250Supervisory labor1,688 1,688 1,688 1,688 1,688Maintenance labor12,375 12,375 12,375 12,375 12,375Maintenance materials12,375 12,375 12,375 12,375 12,375Natural gas79,108 1,354,624 918,816 4,405,980 10,719,593Electricity6,080 49,137 33,442 158,683 385,458Overhead22,613 22,613 22,613 22,613 22,613Taxes, insurance, administrative9,384 38,057 24,563 51,017 63,690Capital recovery25,757 104,461 67,422 140,034 174,821--------------------------------------------------------------------------------------------------Total Annual Cost180,628 1,606,579 1,104,543 4,816,013 11,403,862Emission Reduction (tpy) 25.7 34.0 35.3 22.6 1.7Cost Effectiveness ($/ton) $7,038 $47,285 $31,334 $212,630 $6,687,697[1] Original equipment costs reflect this date.[2] VAPCCI = Vatavuk Air Pollution Control Cost Index (for thermalincinerators) corresponding to year and quarter shown. Originalequipment cost, purchased equipment cost, and total capital investmenthave been escalated to this data via the VAPCCI and control equipment vendor data.