Option 2S 0.009 lbton

SourceFile

BaghouseControl

EquipmentID

ControlDevic

eInstallation

Year

InletGasFlowRat

e_dscfm

NumberO

fCompart

ments

NumberOfBags

OrCartridgesPe

rCompartment

Capital cost 

Estimate

Annualized 

Capital cost

Additional Annual 

O&M

Bag 

Replacement 

cost 

Total Annualized cost 

over current cost 

Capital cost Estimate 

by facility

Annualized 

Capital cost by 

Facility

Annual O&M by 

Facility

Bag Replacement 

cost by Facility

Total Facility 

Annualized cost 

above current 

cost 

Buick RRF CD8-EP08 1967 325,000 14 416 5,625,750 531,031 156,000 349,440 1,036,471

Buick RRF CD27-EP71 2003 60,000 4 256 259,650 24,509 28,800 61,440 114,749

Buick RRF EP-73 27,166 3 352 470,237 44,387 13,039 63,360 120,786

Buick RRF EP-16 33,985 3 352 588,284 55,530 16,313 63,360 135,203 6,943,920 655,457 214,152 537,600 1,407,209 

East Penn S202 30,000 1 384 - 14,400 23,040 37,440 - - 14,400 23,040 37,440 

Exide Frisco HARDLEADBH 1978 25,616 4 216 443,420 41,856 12,296 51,840 105,992

Exide Frisco SPECALLOY 1978 74,382 3 216 1,287,552 121,536 35,703 38,880 196,119

Exide Frisco SOFTLEADBH 1978 52,093 6 288 901,733 85,117 25,005 103,680 213,802

Exide Frisco NewBLAST-Reverb 1969 62,401 5 200 1,080,165 101,960 29,953 60,000 191,912

Exide Frisco FURNFUG ? 113,167 6 288 1,958,924 184,909 54,320 103,680 342,909

Exide Frisco RMSTG ? 91,883 8 288 1,590,491 150,131 44,104 138,240 332,475

Exide Frisco Dryer BH ? 20,000 4 216 - 9,600 51,840 61,440 7,262,286 685,508 210,981 548,160 1,444,649 

Exide Baton Rouge #1 BH 1973 90,000 10 528 1557900 147,055 43,200 316,800 507,055

Exide Baton Rouge #4 BH 1977 45,000 8 288 778,950 73,527 21,600 138,240 233,367

Exide Baton Rouge #5 BH 1979 35,000 3 352 605850 57,188 16,800 63,360 137,348 2,942,700 277,770 81,600 518,400 877,770 

Exide Reading C22 1984 80,000 4 264 1,384,800 130,715 38,400 63,360 232,475

Exide Reading C11 60,000 5 80 1,038,600 98,036 28,800 24,000 150,836

Exide Reading C19 74,945 5 80 1,297,294 122,455 35,974 24,000 182,429

Exide Reading C47 2000 84,000 5 276 1,454,040 137,251 40,320 82,800 260,371 5,174,734 488,458 143,494 194,160 826,112 

Sanders BH 1 1970 90,720 10 288 1,570,363 148,231 43,546 172,800 364,577 1,570,363 148,231 43,546 172,800 364,577 

average 1,327,445

Total 23,894,004 2,255,425 708,172 1,994,160 4,957,757 23,894,004 2,255,425 708,172 1,994,160 4,957,757 

Note: East Penn is not currently within the limit established, however one baghouse had a test with much higher values than previous test. Assume East Penn needs only additional maintenance or bag replacement.

Assumptions:

Annual O&M cost derived from data submitted in survey. Compared with cost of replacing bags at $200/bag for teflon on teflon bag, cost seems reasonable, estimated additional O&M over current is 25%

For cost over current cost of operating a baghouse, estimated that bags would be changed more often than current (2 years vs 5)

Facilities would meet the revised Lead limit for facility wide emissions

Survey data used for flowrate, number of compartments and number of bags 

Facilities listed would need upgrade/ replacement of existing baghouses 

Cost for baghouses were derived from data submitted in survey - Model facility used 

Annualized cost assumes 7% cost of capital, 20 year life

Baghouses selected based on emission rate needed to comply with lb/ton limit

Costs calculated for limit based on 0.009 lb lead emissions per ton product
Option 1S Conc 0.5

SourceFile

BaghouseControlE

quipmentID

ControlDevic

eInstallationY

ear Pb Conc

Pb Emissions 

TPY

Anticipated 

Pb Emission 

Reduction

InletGasFlowRat

e_acfm

NumberO

fCompart

ments

NumberOfBags

OrCartridgesPe

rCompartment

Capital cost 

Estimate

Annualized 

Capital cost

Additional 

Annual O&M

Bag 

Replacement 

cost 

Total Annualized cost 

over current cost 

cost Effectiveness $/ton 

HAP

Buick RRF CD8-EP08 1967 1.19 3.46 3.0 325000 14 416 5,625,750 531,031 156,000 349,440 1,036,471

Buick RRF EP-73 1.27 0.43 0.4 27166 3 352 470,237 44,387 13,039 63,360 120,786

Buick RRF EP-16 0.53 0.22 0.2 33985 3 352 588,284 55,530 16,313 63,360 135,203

Exide Frisco Feed Dryer 2007 0.585 0.54 0.4 81197 4 216 - 38,974 51,840 90,814

Exide Baton Rouge #1 BH 1973 1.26 1.49 1.3 90000 10 528 1,557,900 147,055 43,200 316,800 507,055

Exide Baton Rouge EP93-3 0.506 0.34 0.2 44208 3 458 - 21,220 82,419 103,639

Exide Reading C22 1984 0.657 0.39 0.3 80000 4 264 1,384,800 130,715 38,400 63,360 232,475

Sanders BH 1 1970 0.619 0.72 0.5 90720 10 288 1,570,363 148,231 43,546 172,800 364,577

Sanders BH4 0.723 0.31 0.2 35000 3 352 605,850 57,188 16,800 63,360 137,348

 - - 0 0 0

Total 7.9 6.5 11,803,184 1,114,137 387,492 1,226,739 2,728,368 329,752 

 8.3 

Total Metal HAP 

reduction

Assumptions:

Annual O&M cost derived from data submitted in survey. Added to cost of replacing bags at $200/bag for teflon on teflon bag, estimated additional O&M over current is 25%

Option 1S- Concentration limit established at about 0.5 mg/dscm

Facilities listed would need upgrade/ replacement of existing baghouses 

Survey data used for existing baghouses at facilities. 

Cost for baghouses were derived from data submitted in survey - Model facility used 

average lead concentration from all stacks is 0.159, assumption for emission reduction is based on achieving this concentration

For cost over current cost of operating a baghouse, estimated that bags would be changed more often than current (2 years vs 5)

Baghouses chosen for replacement would allow facilities to meet proposed concentration limit 

Annualized cost assumes 7% cost of capital, 20 year life
Option 3S (1.00 0.2)

SourceFile

BaghouseControlE

quipmentID

ControlDevic

eInstallationY

ear Pb Conc

Pb Emissions 

TPY

Emission 

Reduction

InletGasFlowRat

e_acfm

NumberO

fCompart

ments

NumberOfBags

OrCartridgesPer

Compartment

Capital cost 

Estimate

Annualized 

Capital cost Additional Annual O&M

Bag 

Replacement 

cost 

Total Annualized cost 

over current cost 

cost Effectiveness 

$/ton HAP

Buick RRF CD8-EP08 1967 1.19 3.46 3.0 325,000 14 416 5,625,750 531,031 156,000 349,440 1,036,471

Buick RRF EP-73 1.27 0.43 0.4 27,166 3 352 470,237 44,387 13,039 63,360 120,786

Exide Baton Rouge #1 BH 1973 1.26 1.49 1.3 90,000 10 528 1,557,900 147,055 43,200 316,800 507,055

 5.4 4.7 Total 7,653,887 722,473 212,239 729,600 1,664,312 $ 280,690 

reduction 

assuming 

Scenario- 1.0 mg/dscm limit and 0.3 

mg/dscm average Metal HAP 5.92 

Assumptions:

Facilities listed would need upgrade/ replacement of existing baghouses 

Survey data used for existing baghouses at facilities. 

Cost for baghouses were derived from data submitted in survey - Model facility used (see tab Baghouse cost)

Annualized cost assumes 7% cost of capital, 20 year life

Annual O&M cost derived from data submitted in survey. Compared with cost of replacing bags at $200/bag for teflon on teflon bag, estimated additional O&M over current is 25%

For cost over current cost of operating a baghouse, estimated that bags would be changed more often than current (2 years vs 5)

Facilities would meet the revised Lead MACT floor for facility wide emissions

average lead concentration from all stacks is 0.159, an alternate assumption for emission reduction is based on achieving this concentration
Option 3F Fugitive Control Cost

Facility

Total Enclosed 

Area Needed ft2

Building 

Capital Cost

New CF to be 

ventilated

Baghouse 

Capital ($)

Total Capital 

cost

Annualized 

Capital cost 

Baghouse + 

building

Baghouse 

Annual 

Operating 

cost($)

Enclosure 

Annual 

operating 

cost

Enclosure 

and 

baghouse 

operating 

cost

Enclosure and 

baghouse total 

Annual cost

Work practice 

estimate

Annual 

Operation and 

Maintenance 

cost (total)

Total Annual 

cost 

Exide Baton Rouge 66,488 2,659,514 1,994,636 3,031,846 5,691,360 537,224 337,093 66,488 403,581 940,805 300,000 703,581 1,240,805

Exide Forest City 29,880 1,195,185 896,389 1,362,511 2,557,696 241,428 151,490 29,880 181,369 422,798 300,000 481,369 722,798

Exide Frisco 51,281 2,051,220 1,538,415 2,338,391 4,389,611 414,348 259,992 51,281 311,273 725,621 300,000 611,273 1,025,621

Exide Reading 65,816 2,632,620 1,974,465 3,001,187 5,633,807 531,792 333,685 65,816 399,500 931,292 300,000 699,500 1,231,292

Doe Run 141,590 5,663,584 4,247,688 6,456,486 12,120,070 1,144,049 717,859 141,590 859,449 2,003,498 300,000 1,159,449 2,303,498

EnviroFocus 20,139 - 300,000 300,000 300,000

Sanders 111,183 4,447,336 3,335,502 5,069,963 9,517,299 898,366 563,700 111,183 674,883 1,573,249 300,000 974,883 1,873,249

Total listed facilities 18,649,459 21,260,383 39,909,842 6,597,262 2,100,000 4,930,055 8,697,262

Total Level 1 facilities 27,328,729 4,517,552 900,000 2,837,913 5,417,552

Total Level 2 facilities 12,581,114 2,079,710 900,000 1,792,142 2,979,710

Level 3 facilities 900000 900,000 900,000

Total All Facilities 39,909,842 3,767,207 2,363,819 466,236 2,830,055 6,597,262 3,000,000 5,830,055 9,597,262

Assumptions:

 Using the reduced footprint methodology, the capital cost of building and baghouse was reduced by up to 40%

Level 2 definition - total facility enclosures vented to baghouse

Level 3 defnition - Level 2 plus additional work practices equivalent to South Coast California rule

No capital cost was estimated for Envirofocus as this facility is currently undergoing an expansion and upgrade. Practices described will meet control level required. 

Unenclosed or partially enclosed facilities would need to enclose area and vent to baghouse

 Unenclosed or partially enclosed faciliites would reduce their facility footprint to the size of an enclosed facility with similar production. 

 Buildings are 30 ft tall

Baghouse cost estimated from data submitted by facilities in survey. EPA cost manual data was significantly higher

Baghouse operating data was submitted in the survey for the control device used to estimate capital cost

 Baghouse operating data verified against cost to replace bags on a bi-annual basis, costs were similar

 Building O&M cost was estimated at $1 / ft sq ft. This cost was estimated using the Air Compliance Advisor program for Permanent Total Enclosures

Building cost was estimated at $40 /ft2. this cost was estimated using two model facilities in the Air Compliance Advisor for Permanent Total Enclosures. 

 The higher cost estimate of the two faciliites in $/ft2 was used to estimate all facilities 

 Not enough facility specific information on cost to retrofit was available for an alternate retrofit cost

 Cost data for a building was submitted by Quemetco, CA in January 2011. This cost was not considered in the analysis as the cost was very high compared to other estimates
Option 1F &2F

Facility

Total Enclosed 

Area Needed ft2

Building 

Capital Cost

New CF to be 

ventilated

Baghouse 

Capital ($)

Total Capital 

cost

Annualized 

Capital cost 

Baghouse + 

building

Baghouse 

Annual 

Operating 

cost($)

Enclosure 

Annual 

operating 

cost

Enclosure and 

baghouse 

operating 

cost

Enclosure and 

baghouse total 

Annual cost

Work practice 

estimate

Annual 

Operation and 

Maintenance 

cost (total)

Ambient 

Monitoring 

Cost

Total Annual 

cost 

Exide Baton Rouge 66,488 2,659,514 1,994,636 3,031,846 5,691,360 537,224 337,093 66,488 403,581 940,805 300,000 703,581 23,128 1,240,805

Exide Forest City 29,880 1,195,185 896,389 1,362,511 2,557,696 241,428 151,490 29,880 181,369 422,798 300,000 481,369 23,128 722,798

Exide Frisco 51,281 2,051,220 1,538,415 2,338,391 4,389,611 414,348 259,992 51,281 311,273 725,621 300,000 611,273 23,128 1,025,621

Exide Reading 65,816 2,632,620 1,974,465 3,001,187 5,633,807 531,792 333,685 65,816 399,500 931,292 300,000 699,500 23,128 1,231,292

Doe Run 141,590 5,663,584 4,247,688 6,456,486 12,120,070 1,144,049 717,859 141,590 859,449 2,003,498 300,000 1,159,449 23,128 2,303,498

EnviroFocus 20,139 - 300,000 300,000 23,128 300,000

Sanders 111,183 4,447,336 3,335,502 5,069,963 9,517,299 898,366 563,700 111,183 674,883 1,573,249 300,000 974,883 23,128 1,873,249

Total listed facilities 18,649,459 21,260,383 39,909,842 6,597,262 2,100,000 4,930,055 161,896 8,697,262

Total Level 1 facilities 27,328,729 4,517,552 900,000 2,837,913 69,384 5,417,552

Total Level 2 facilities 12,581,114 2,079,710 900,000 1,792,142 69,384 2,979,710

Level 3 facilities 900000 900,000 161,896 900,000

Total All Facilities 39,909,842 3,767,207 2,363,819 466,236 2,830,055 6,597,262 3,000,000 5,830,055 323,792 9,597,262

Assumptions:

 Using the reduced footprint methodology, the capital cost of building and baghouse was reduced by up to 40%

Level 2 definition - total facility enclosures vented to baghouse

Level 3 defnition - Level 2 plus additional work practices equivalent to South Coast California rule

Unenclosed or partially enclosed facilities would need to enclose area and vent to baghouse

 Unenclosed or partially enclosed faciliites would reduce their facility footprint to the size of an enclosed facility with similar production. 

Baghouse cost estimated from data submitted by facilities in survey. EPA cost manual data was significantly higher

Baghouse operating data was submitted in the survey for the control device used to estimate capital cost

 Baghouse operating data verified against cost to replace bags on a bi-annual basis, costs were similar

No capital cost was estimated for Envirofocus as this facility is currently undergoing an expansion and upgrade. Practices described will meet control level required. 

 Buildings are 30 ft tall

 Building O&M cost was estimated at $1 / ft sq ft. This cost was estimated using the Air Compliance Advisor program for Permanent Total Enclosures

Building cost was estimated at $40 /ft2. this cost was estimated using two model facilities in the Air Compliance Advisor for Permanent Total Enclosures. 

 The higher cost estimate of the two faciliites in $/ft2 was used to estimate all facilities 

 Not enough facility specific information on cost to retrofit was available for an alternate retrofit cost

 Cost data for a building was submitted by Quemetco, CA in January 2011. This cost was not considered in the analysis as the cost was very high compared to other estimates
Secondary Lead Control Cost Incremental Improvement with increase in afterburner temperature

Control of THC / Dioxin-Furan

Facility

Furnace 

Type

Blast Furnace Flow 

rate requiring 

control (scfm)

Existing 

Afterburner 

Operating Temp 

(deg F) - if no 

AB, Furnace 

Temp

Existing AB 

residence time

Temp 

increase 

required 

(deg F) Fuel cost 

Doe Run Mixed 10,000 500 - - -

East penn Co-located

EnviroFocus Blast

Exide Baton Rouge Reverb

Exide Baton Rouge Blast 21,505 700 3 100 $ 78,966.36

Exide Forest City Blast

Exide Frisco Mixed 24,000 1,525 1 75 $ 66,096.00

Exide Muncie Co-located

Exide Reading Co-located

Exide Vernon Mixed

Gopher Eagan Co-located

Quemetco (CA) Reverb

Quemetco (IN) Reverb

RSR Reverb

RSR Rotary

Sanders Blast 16,000 1,300 3 100 $ 58,752.00

Sanders Blast 16,000 1,300 3 100 $ 58,752.00

$ 262,566

Assumptions

A 10% reduction in D/F and organics is possible with improved operating practices and increase in afterburner temperature of 100 deg F

Beyond the floor MACT for Blast furnaces would require 1600 degree afterburner to achieve control of dioxins

$/MM BTU Nat Gas 4

Assumed the existing afterburner would remain in place. Additional afterburner fuel cost to increase temperature 100 deg F
Secondary Lead Control Cost Beyond the floor option for controlling Blast Furnaces

Control of THC / Dioxin-Furan

Facility

Furnace 

Type

Blast Furnace Flow 

rate requiring 

control (scfm)

Existing 

Afterburner 

Operating Temp 

(deg F) - if no 

AB, Furnace 

Temp

Existing 

AB 

residence 

time

New AB 

required 

(Y/N)

AB Installed 

cost

Temp 

increase 

required 

(deg F) Fuel cost Electricity (KWH)

Electricity 

$/yr

Annual Capital 

Cost O&M cost

Indirect 

Operating cost

Total Annual 

O&M

Annual cost - 

total

Doe Run Mixed 10000 500 0 Yes 1,040,310 1100 403,920 839,800 57,526 98,198 13,688 49,825 524,959 623,157

East penn Co-located No

EnviroFocus Blast No

Exide Baton Rouge Reverb No

Exide Baton Rouge Blast 21505 700 3 Yes 1,259,788 900 710,697 1,805,990 123,710 118,915 13,688 58,604 906,699 1,025,614

Exide Forest City Blast No

Exide Frisco Mixed 24000 1525 1 Yes 1,294,838 75 66,096 2,015,520 138,063 122,224 13,688 60,006 277,853 400,076

Exide Muncie Co-located No

Exide Reading Co-located No

Exide Vernon Mixed No

Gopher Eagan Co-located No

Quemetco (CA) Reverb No

Quemetco (IN) Reverb No

RSR Reverb No

RSR Rotary No

Sanders Blast 16000 1300 2.5 Yes 1,170,019 300 176,256 1,343,680 92,042 110,441 13,688 55,013 336,999 447,440

Sanders Blast 16000 1300 2.5 Yes 1,170,019 300 176,256 1,343,680 92,042 110,441 13,688 55,013 336,999 447,440

 5,934,974 1,533,225 503,384 560,220 68,438 278,461 2,383,508 2,943,728

Assumptions

Beyond the floor MACT for Blast furnaces would require 1600 degree afterburner to achieve control of co-located furnaces

$/KWH 0.0685

$/MM BTU Nat Gas 4

Labor cost / hr 25

Electricity KWH calculated from equation in http://www.epa.gov/ttn/catc/dir1/cs3-2ch2.pdf

corrected for density of air at 600 deg F

Assumed the existing afterburner would remain in place. Additional afterburner fuel cost to increase temperature to 1600 deg F

Used afterburner cost data submitted in Section 114 survey for three afterburner installations to estimate base capital cost. Used highest of 3 total installed cost

Derived new equation to account for flow rate - modeled after equation 2.32 in EPA cost estimation manual for Incinerators

Operating cost approach developed from EPA cost manual for incinerators.

Used afterburner operating cost data submitted in Section 114 survey as a reference. Cost is similar to that calculated in this sheet. 

Cost estimated using Air Compliance Advisor (EPA cost manual program), values significantly higher than these costs. Elected to use industry supplied data as the base
Summary of WESP Control Cost by Facility

Facility WESP ACFM Capital cost Estimate

Annualized Capital 

cost Operating Cost

Total Annualized 

Cost 

Doe Run 446,428 46,623,434 4,400,922 2,331,172 6,732,094

East penn 167,436 25,885,878 2,443,444 1,294,294 3,737,738

EnviroFocus 79,986 16,617,415 1,568,566 830,871 2,399,437

Exide Baton Rouge 203,901 29,134,304 2,750,072 1,456,715 4,206,787

Exide Forest City 95,362 18,466,254 1,743,084 923,313 2,666,396

Exide Frisco 253,113 33,169,760 3,130,991 1,658,488 4,789,479

Exide Muncie 224,391 30,857,250 2,912,706 1,542,862 4,455,569

Exide Reading 286,727 35,746,589 3,374,225 1,787,329 5,161,555

Exide Vernon 251,490 33,041,957 3,118,927 1,652,098 4,771,025

Gopher Eagan 325,023 38,539,167 3,637,825 1,926,958 5,564,783

Quemetco (CA) 94,556 18,000,000

Quemetco (IN) 115,468 20,712,408 1,955,105 1,035,620 2,990,725

RSR 145,133 23,758,174 2,242,604 1,187,909 3,430,512

Sanders 245,173 32,541,498 3,071,687 1,627,075 4,698,762

Total 403,094,087 36,350,158 19,254,704 55,604,862

WESP ACFM Furnace Only ACFM

Doe Run 446,428 266,855

East Penn 167,436 42,601

EnviroFocus 79,986 35,550

Exide Baton Rouge 203,901 126,340

Exide Forest City 95,362 95,362

Exide Frisco 253,113 52,001

Exide Muncie 224,391 26,497

Exide Reading 286,727 88,779

Exide Vernon 251,490 127,105

Gopher Eagan 325,023 106,060

Quemetco CA 94,556 94,556

Quemetco IN 115,468 48,692

RSR 145,133 113,211

Sanders 245,173 191,322

 2,934,187 1,414,930
Activated Carbon 

Injection Model Costs

Unit-specific field Unit-specificUfineildt-specific field Unit-specific fieldUnit-specific field

Facility/Unit ID Capital Investment 

Facility name

Annual 

operating 

Exhaust gas flow 

rate (Q)

Operating 

labor rate 

Activated carbon 

cost (ACC)

Dust disposal cost 

(DDC)

Capital recovery factor, 20-yr 

equipment life, 7% interest (CRF)

Cost Index 

2008

Cost Index 

1990

ACI Adjustment 

Factor (AF)

ACI Adjustment 

Factor (AF) Total Unit cost

hr/yr dscfm $/hr $/lb $/ton for HG control for D/F control $ $/dscfm

FacilityID

= [i x (1 + i)a] / [(1 + i)a - 1], where i = 

interest rate, a = equipment life

= 4,500 x (Q/1,976)0.6 x (1.2 

retrofit factor) x (575.4/361.3) = $ / Q

Doe Run 8500 266855 $51.26 $1.38 $42.14 0.09439 575.4 361.3 1.00 $163,226 $0.61

East Penn 8500 42601 $51.26 $1.38 $42.14 0.09439 575.4 361.3 1.00 $54,284 $1.27

EnviroFocus 8500 35550 $51.26 $1.38 $42.14 0.09439 575.4 361.3 1.00 $48,700 $1.37

Exide Baton Rouge 8500 126340 $51.26 $1.38 $42.14 0.09439 575.4 361.3 1.00 $104,219 $0.82

Exide Forest City 8500 95362 $51.26 $1.38 $42.14 0.09439 575.4 361.3 1.00 $88,034 $0.92

Exide Frisco 8500 52001 $51.26 $1.38 $42.14 0.09439 575.4 361.3 1.00 $61,183 $1.18

Exide Muncie 8500 26497 $51.26 $1.38 $42.14 0.09439 575.4 361.3 1.00 $40,826 $1.54

Exide Reading 8500 88779 $51.26 $1.38 $42.14 0.09439 575.4 361.3 1.00 $84,335 $0.95

Exide Vernon 8500 127105 $51.26 $1.38 $42.14 0.09439 575.4 361.3 1.00 $104,597 $0.82

Gopher Eagan 8500 106060 $51.26 $1.38 $42.14 0.09439 575.4 361.3 1.00 $93,833 $0.88

Quemetco CA 8500 94556 $51.26 $1.38 $42.14 0.09439 575.4 361.3 1.00 $87,586 $0.93

Quemetco IN 8500 48692 $51.26 $1.38 $42.14 0.09439 575.4 361.3 1.00 $58,816 $1.21

RSR 8500 113211 $51.26 $1.38 $42.14 0.09439 575.4 361.3 1.00 $97,579 $0.86

Sanders 8500 191322 $51.26 $1.38 $42.14 0.09439 575.4 361.3 1.00 $133,685 $0.70

$1,220,904
Activated Carbon 

Injection Model Costs

Unit-specific field

Facility/Unit ID

Facility name

FacilityID

Doe Run

East Penn

EnviroFocus

Exide Baton Rouge

Exide Forest City

Exide Frisco

Exide Muncie

Exide Reading

Exide Vernon

Gopher Eagan

Quemetco CA

Quemetco IN

RSR

Sanders

Direct Annual Indirect Annual Total Annual Cost

Operating labor

Supervisory 

labor Maintenance

Activated 

carbon Dust disposal Overhead

Property taxes, insurance, and 

administration Capital recovery Total cost

$/yr $/yr $/yr $/yr $/yr $/yr $/yr $/yr $/yr ($/yr) / dscfm

= (0.25 hr/8-hr 

shift) x H x LR

= 0.15 x 

(operating 

labor) = 0.2 x TCI

= 0.00127 x Q x 

H x ACC x AF

= 0.00127 x Q x (1 ton/2,000 

lb) x H x DDC x AF

= 0.6 x (labor + 

maintenance 

materials) = 0.04 x TCI = CRF x TCI

= Direct Annual Costs + 

Indirect Annual Costs = ($/yr) / Q

$13,616 $2,042 $32,645 3975365.621 60696.34321 $28,982 $6,529 $15,407 $4,135,284 $15.50

$13,616 $2,042 $10,857 634631.3571 9689.625141 $15,909 $2,171 $5,124 $694,041 $16.29

$13,616 $2,042 $9,740 529596.8707 8085.946424 $15,239 $1,948 $4,597 $584,865 $16.45

$13,616 $2,042 $20,844 1882095.145 28736.04689 $21,901 $4,169 $9,838 $1,983,241 $15.70

$13,616 $2,042 $17,607 1420617.25 21690.14889 $19,959 $3,521 $8,310 $1,507,363 $15.81

$13,616 $2,042 $12,237 774664.0971 11827.66125 $16,737 $2,447 $5,775 $839,346 $16.14

$13,616 $2,042 $8,165 394725.0397 6026.707672 $14,294 $1,633 $3,854 $444,356 $16.77

$13,616 $2,042 $16,867 1322542.192 20192.72753 $19,515 $3,373 $7,961 $1,406,110 $15.84

$13,616 $2,042 $20,919 1893496.889 28910.13003 $21,947 $4,184 $9,873 $1,994,989 $15.70

$13,616 $2,042 $18,767 1579986.426 24123.41594 $20,655 $3,753 $8,857 $1,671,800 $15.76

$13,616 $2,042 $17,517 1408610.188 21506.82366 $19,905 $3,503 $8,268 $1,494,969 $15.81

$13,616 $2,042 $11,763 725369.5932 11075.02705 $16,453 $2,353 $5,552 $788,224 $16.19

$13,616 $2,042 $19,516 1686515.588 25749.91554 $21,104 $3,903 $9,211 $1,781,658 $15.74

$13,616 $2,042 $26,737 2850138.001 43516.23744 $25,437 $5,347 $12,619 $2,979,453 $15.57

$22,305,698
AmbMonitoring Cost

Cost

Annual cost 

per monitor

Number of 

monitors / 

site

Total 

Annual cost

Total cost14 facilities

Ambient Lead Monitoring (lab analysis) per test 127 7725.8 2 15452 216,323

Ambient Monitoring Equipment Annual Lease 2500 2500 2 5000 70,000

Labor to collect and ship samples, analyze data 22 1338.3 2 2677 37,473

Total monitoring cost 23,128 323,797

Ambient monitors tested once every 6 days

References: 

Table 3.5 - Additional Testing and Monitoring Costs, Primary Lead Smelting Technical Support document