## 1

TECHNICAL MEMORANDUM

TO: Jodi Howard, U.S. EPA, Sector Policies and Programs Division/Coatings and

Chemicals Group

F ROM: Eastern Research Group, Inc.

DATE: April 13 , 2011

S UBJECT: Costs and Emission Reductions of the Proposed Standards for the

Polyvinyl Chloride and Copolymers (PVC) Production Source Category

1.0 Introduction

The U.S. Environmental Protection Agency (EPA), under section 112 of the Clean Air

Act (CAA), is required to establish national emissions standards for Hazardous Air Pollutants

( NESHAP) emitted from polyvinyl chloride and copolymer (PVC) production facilities. The

complete set of regulated hazardous air pollutants ( HAP ) is listed in CAA section 112(b). The

C AA requires EPA to determine the maximum achievable control technology (MACT) for each

c ategory of sources. To do so, EPA must first determine the minimum stringency “floor”

re quirements. A previous memorandum documents the MACT floor analysis for the production

fa cilities 1



## . The purpose of this memorandum is to present the nationwide costs and nationwide

emission reductions associated with existing sources complying with the MACT floor level of

c ontrol.

1.1 Selection of Controls Needed to Meet MACT Floor Limits

A significant portion of the total cost for industry compliance comes from the cost of

installing new pollution control devices or improving existing pollution control devices for

facilities not currently meeting the MACT floor limits

. Various control technologies were

considered for each facility depending upon which limits that facility needed to meet and how

much emissions improvement or HAP reduction would be needed to meet the limits

.

1.2 Compliance Costs

For each emission point, costs were estimated for existing production facilities for (A) the

emission controls used to comply with the MACT floor limits; and (B) the monitoring, testing,

recordkeeping, and reporting activities used to demonstrate compliance. All costs were

calculated as 2010 dollars.

1.3 Emission Control Costs

The costs for various types of control equipment were estimated depending on the

emission point. For all cost analyses, an annual operating time of 8,400 hours (assuming 336

hours or 2 weeks of downtime) was assumed, where applicable. A twenty year life was assumed

## 2

for any installed equipment. Capital recovery factors (CRF) were calculated using a 7 percent

discount rate. All PVC production facilities were assumed to have adequate space to install

additional emissions control equipment without shutting down the production facility for an

extended period. It was also assumed that connecting any process piping or ductwork could be

performed during scheduled downtime for maintenance, thereby minimizing expected downtime.

1.4 Testing, Monitoring, and Recordkeeping Costs

The total capital investment (TCI) for testing and monitoring equipment, and the total

annual costs (TAC) for conducting testing, monitoring, and completing recordkeeping were

estimated for process vents, stripped resin, wastewater, equipment leaks, and heat exchange

syste ms

. TCI and TAC for testing and monitoring equipment were not estimated for storage

vessels since all of the storage vessels that are currently being used by the PVC industry are

either pressurized vessels or have fixed roofs. For TCI costs, the CRF was again calculated

using a 7 percent discount rate.

1.5 Emission Reductions

Emission reductions for each emission point were estimated as a result of facilities

meeting the MACT floor limits

. Emission reductions were calculated by subtracting the

emissions of facilities at the MACT floor from the facility baseline emissions. The calculation of

baseline emissions is described in a separate memorandum 2



## . If a facility is currently meeting a

MACT floor, then emissions reductions for that facility, at that emission point were assumed to

be zero.

2.0 Process Vents

2.1 Selection of Controls Needed to Meet MACT Floor Limits

Three different control devices to reduce emission concentrations from PVC process

vents were considered. An existing control device may reduce one of the pollutants to below the

MACT floor, but additional control may be required to reduce emissions of other pollutants from

that same process vent. The cost of a refrigerated condenser system was estimated to reduce

vinyl chloride (VC), and total organic HAP from facilities currently using a thermal oxidizer to

control process vent emissions. Total organic HAP accounts for VC and chlorinated

dibenzodioxins and chlorinated dibenzofurans (CDD/CDF), but does not include HCl or any

other non-organic compounds. For facilities using a vent gas absorption system (VGA), the cost

of operating the facility’s backup thermal oxidizer in series with the VGA to control VC , HCl,

and total organic HAP emissions was estimated since the VGA does not reduce the emission

concentrations to the MACT floor levels. To further reduce emissions of chlorinated

dibenzodioxins and chlorinated dibenzofurans, the cost of an activated carbon injection (ACI)

system coupled with a fabric filter was estimated. For facilities only requiring a reduction in

HCl, and not VC or total organic HAP, the cost of a packed bed scrubber system was estimated.

2.2 Compliance Cost Methodology and Results

The cost of adding a refrigerated condenser for control of VC , and total organic HAP

emissions from process vents was estimated. The cost algorithm for installing a refrigerated

condenser is presented in Attachment A and is based on algorithms in the OAQPS Air Pollution

## 3

Control Cost Manual 3 

## . For facilities requiring only a reduction in HCl emissions, it was assumed that condensing and removing VC from the control system inlet stream would reduce

some of the HCl emissions in the control system exhaust stream as the amount of chloride ions

available for HCl formation during combustion would be reduced. However, we assumed that

for the single facility that would need only a reduction in HCl and not vinyl chloride, a new or

replacement acid scrubber would be installed at the outlet of their existing thermal oxidizer. The

TCI for the packed bed scrubber was estimated at approximately $1.2 million. The TAC for the

packed bed scrubber was estimated at approximately $282,000 per year. For facilities that

needed both VC and HCl reductions, it was assumed that the reduction in VC being sent to the

thermal oxidizer would remove adequate amounts of chlorinated compounds for the facility to

comply with the HCl MACT floor. The condenser input calculations for VC and total organic

HAP reduction are presented in Attachment B. The refrigerated condenser TCI costs range from

approximately $79 ,000 to $76 1 ,000 , and TAC range from a net savings of approximately $1.4

million/yr to a net cost of $70,000 /yr. Any estimated net savings to a facility is due to an

increased recovery of VC which is the primary feedstock for PVC production. Sources for

specific cost data are documented in Attachment A.

For facilities currently operating a VGA system, the cost of operating the facility’s

backup thermal oxidizer to process the exhaust gas of the VGA outlet was estimated. The Air

Compliance Advisor (ACA) Program, version 7.6, build number 187, was used to estimate

operating costs of a regenerative thermal oxidizer based on facility inputs. The ACA is available

on EPA’s Technology Transfer Network Clean Air Technology Center website 4



## . The output of

the ACA program is presented in Attachment C. The operating TAC ranges from $131,000 per

year to $174,000 per year.

The cost of adding an ACI system to control emissions of CDD/CDF was also estimated.

The cost algorithm for installing an ACI system is presented in Attachment D and is based on

cost equations from the Model Plant Description and Control Cost Report for

hospital/medical/infectious waste incinerators (HMIWI) 5



## . The ACI factor compares the carbon

grain loading originally assumed to achieve 98 percent control of CDD/CDF to the amount of

reduction the unit will need to meet the emission limits. The factor is then used to adjust the

carbon injection rate calculation of the algorithm. The ACI TCI ranges from approximately

$ 8,000 to $46,000, and TAC range from approximately $25,000 per year to $123,000 per year. Sources for specific cost data are documented in Attachment D. If additional vinyl chloride is

recovered by the addition of a new recovery system, a reduction in the amount of dioxin formed

is possible. While we do not know the direct correlation between reducing the amount of

chlorine being sent to be combusted in the thermal oxidizer we do believe that less dioxin is

created. Therefore, the dioxin emissions after additional vinyl chloride recovery may be

overestimated.

To control the particulate matter created by the ACI system, the cost of installing fabric

filters to the process vent emission points was estimated. The cost algorithm for installing a

fabric filter system in presented in Attachment E and is also based on the Model Plant

Description and Control Cost Report for HMIWI 5



## . The fabric filter TCI range from

approximately $875,000 to $4.0 million, and TAC range from approximately $267,000 per year to $1.1 million/yr. Sources for specific cost data are documented in Attachment E.

## 4

Table 2 -1 -A presents a summary of the control equipment TCI and TAC for process

vents as a result of complying with the MACT floor.

2.3 Testing, Monitoring, and Recordkeeping Costs

The initial cost of emissions tests at process vents for VC, HCl, CDD/CDF and total

organic HAP were calculated and annualized. The costs of annual emissions tests at process

vents for VC, CDD/CDF, and total organic HAP were calculated. Cost estimates for US EPA

Method 18, Method 26, Method 23, and Method 25A for VC, HCl, CDD/CDF, and THC

respectively were performed.

For many facilities, measuring THC concentration may prove more practical than

directly measuring total organic HAP. THC continuous emissions monitoring system (CEMS)

data was analyzed for the 5 best performing facilities based on total organic HAP concentration.

The analyses used the MACT floor procedures for process vents outlined in the memorandum

titled MACT Floor Analysis for the Polyvinyl Chloride and Copolymers (PVC) Production

Source Category 1 

## ; however, 30 days of CEMS data was used for each facility and the

compliance average was set to 30 days. A THC concentration of 2.0 parts per million by

volume, on a dry basis corrected to 3 percent oxygen as was determined to be equivalent to the

MACT floor process vent concentration limit for total organic HAP for new and existing

sources. Details of the THC concentration analysis are presented in Attachment N.

The cost algorithm used to estimate TAC of testing on a facility basis is presented in

Attachment F. Testing costs on a facility basis for process vents are presented in Table 2-1 -B.

The industry TAC for process vent testing was estimated at approximately $768,000 per year.

Although facilities will determine traverse points (Method 1), stack velocity (Method 2),

stack gas oxygen content (Method 3 or ANSI/ASME PTC 19.10-1981 ), and stack gas moisture

content (Method 4), it was assumed that the cost of these methods was included in the estimate

for HCl, CDD/CDF, THC, and VC. Although facilities may potentially use a CEMS to

demonstrate compliance, any costs to install, maintain, or demonstrate compliance using a

CEMS have not been estimated.

The cost of a fabric filter monitoring system was also estimated for each facility required

to reduce CDD/CDF concentrations. The TCI for each monitoring system was estimated to be

$20,300 for an industry wide total of $101,500 . The TAC for each monitoring system was

estimated to be $3,300 for an industry wide total of $16,500 . The cost algorithm for installing a

fabric filter monitoring system in presented in Attachment E and is also based on the Revised

Testing and Monitoring Options and Costs for Medical Waste Incinerators (MWI’s)—

Me thodology and Assumptions Memorandum for HMIWI 6 

## . It was assumed that the cost to

comply with the “Fabric Filter Bag Leak Detection Guidance 11 

## ” is covered by the cost algorithm

for installing and operating a fabric filter monitoring system.

The cost of a packed bed scrubber monitoring system was also estimated for the facility

required to reduce HCl, but not VC or total organic HAP. The TCI for the monitoring system

was estimated to be $23,000, and the TAC for the monitoring system was estimated to be $5,300

## 5

per year. The cost algorithm for installing a packed bed scrubber monitoring system in presented

in Attachment O and is also based on the Revised Testing and Monitoring Options and Costs for

Medical Waste Incinerators (MWI’s)— Methodology and Assumptions Memorandum for

HMIWI 6



## .

A flat rate of $18,281 was assumed for recordkeeping and reporting for process vents and

all other emission points for each PVC production facility. The facility cost estimate included

allocations to understand the recordkeeping and monitoring requirements, operating parameter

monitoring, and compliance report preparation. The algorithm for recordkeeping and monitoring

costs is presented in Attachment G and testing, monitoring and recordkeeping costs on a facility

basis are presented in Table 2-1

- B.

## 6 Table 2 -1

- A. Summary of Control Equipment Costs for Process Vents

Company/Facility Fabric Filter ACI Condenser Packed Bed Scrubber Thermal Oxidizer Total Control Costs for

Process Vents

TCI ($) TAC ($/yr) TCI ($) TAC

($/yr) T CI ($) TAC ($/yr) TCI ($) TAC ($/yr) TCI ($) TAC

($/yr) TCI ($) TAC ($/yr)

Certain Teed

- Lake

Charles 874,964 267,268 7,797 25,069 760,527 (114,794)

- - - - 1,643,288 177,543

Dow

- Midland

- - - - - - - - - - - -

Formosa

- Baton

Rouge 1,295,725 383,7 48 16,310 43,057

- - - - - - 1,312,035 426,805

Formosa

- Point

Comfort 1,080,270 324,103 12,451 61,604

- - - - - - 1,092,721 385,708

Formosa

- Delaware

- - - - - - - - - - - -

Georgia Gulf

- Aberdeen - - - - 79,085 69,036

- - - - 79,085 69,03 6

Georgia Gulf

- Plaquemine 2,401,684 689,912 30,641 122,701

- - 1,153,653 282,000

- - 3,585,978 1,094,613

OxyVinyls

- Pasadena - - - - 629,409 (1,377,272)

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

OxyVinyls

- Deer

Park - - - - - - - - - - - -

OxyVinyls

- Pedric ktown - - - - - - - - - - - -

PolyOne

- Henry

- - - - - - - - - 173,930

- 173,930

PolyOne

- Pedricktown - - - - - - - - - 130,855

- 130,855

Shintech

- Freeport

- - - - - - - - - - - -

Shintech

- Plaquemine - - - - - - - - - - - -

Shintec h

- Addis

- - - - - - - - - - - -

Westlake

- Calvert

City - - - - - - - - - - - -

Westlake

- Geismar 3,991,764 1,130,097 45,533 111,109

- - - - - - 4,037,296 1,241,205

Total * 9,644,407 2,795,129 112,732 363,540 1,469,021 (1,423,030) 1,153, 653 282,000

- 304,785 12,379,813 2,322,423



### *Totals may not add exactly due to rounding.

* This table and several of the other tables within this memo include GACT costs and emission reductions.

## 7 Table 2 -1

- B. Summary of Testing, Recordkeeping, and Monitoring Costs for Process Vents

Company/Facility Fabric Filter

Monitoring System Packed Bed Scrubber

Monitoring System Performance

Testing Cost Recordkeeping

and Reporting

Cost Total Monitoring, Reporting, and

Recordkeeping Costs for Process Vents

TCI ($) T AC ($/yr) TCI ($) TAC

($/yr) TAC ($/yr) TAC ($/yr) TCI ($) TAC ($/yr)

Certain Teed

- Lake Charles 20,300 3,300

- - 48,030 18,281 20,300 69,611

Dow

- Midland

- - - - 48,030 18,281

- 66,311

Formosa

- Baton Rouge 20,300 3,300

- - 48,030 18,281 20,300 69,611

For mosa

- Point Comfort 20,300 3,300

- - 48,030 18,281 20,300 69,611

Formosa

- Delaware

- - - - 48,030 18,281

- 66,311

Georgia Gulf

- Aberdeen

- - - - 48,030 18,281

- 66,311

Georgia Gulf

- Plaquemine 20,300 3,300 23,000 5,300 48,030 18,281 43,300 74,911

OxyViny ls

- Pasadena

- - - - 48,030 18,281

- 66,311

OxyVinyls

- Deer Park

- - - - 48,030 18,281

- 66,311

OxyVinyls

- Pedricktown

- - - - 18,281

- 18,281

PolyOne

- Henry

- - - - 48,030 18,281

- 66,311

PolyOne

- Pedricktown

- - - - 48,030 18,281

- 66,311

Shintech

- Fre eport

- - - - 48,030 18,281

- 66,311

Shintech

- Plaquemine

- - - - 48,030 18,281

- 66,311

Shintech

- Addis

- - - - 48,030 18,281

- 66,311

Westlake

- Calvert City

- - - - 48,030 18,281

- 66,311

Westlake

- Geismar 20,300 3,300

- - 48,030 18,281 20,300 69,611

Total * 101,500 16,500 23,000 5,300 768,487 310,777 124,500 1,101,064



### *Totals may not add exactly due to rounding.

## 8

2.4 Emission Reduction Methodology and Results

The average HAP concentration values used to calculate baseline annual emissions 2 

## for

every process vent at each facility were compared with the MACT floor emissions limits.

Percentages to quantify the amount of improvement needed for the facility to meet the limits

were calculated. Table 2-2 contains the baseline HAP concentration values used for each facility

and the percentage improvement required to meet the MACT floor emissions limits for process

vents. Reductions of VC, HCl,CDD/CDF and total organic HAP for process vents were

estimated at each facility as a result of all facilities complying with the MACT floor standard.

Reductions were estimated at 8.5E-02 tons per year of VC, 33 tons per year of HCl, 2.45E-08

tons per year of CDD/CDF, and 2.26 tons per year of total organic HAP.

MACT floor emission rates for VC , and CDD/CDF were estimated using the procedure

described in the memorandum Estimation of Baseline Emissions from Existing Polyvinyl

Chloride and Copolymer Manufacturing Units Section 3.1 2 

## except that the emissions

concentration was replaced with the MACT floor limit concentration value. Emissions

reductions were then calculated by subtracting the MACT floor emission rate from the baseline

emission rate.

Total organic HAP emission reductions were calculated using a different methodology

than VC and CDD/CDF. The calculation accounted for reductions of VC required by the MACT

floor limits. The reduction of VC results in a reduction of total organic HAP, but a total organic

HAP reduction does not necessarily result in a VC reduction. Therefore, VC reductions were

estimated and then subtracted from the baseline total organic HAP emission. Additional total

organic HAP reductions were calculated if the VC reduction was not sufficient to achieve the

total organic HAP emission limit. To perform the calculation, the percent reduction from the

baseline total organic HAP concentration to the MACT floor limit was calculated. Then, the

percent reduction of total organic HAP due to VC reduction was calculated. If the percent

reduction of total organic HAP from VC was less than the percent reduction required to meet the

MACT floor, the additional tons per year of total organic HAP reduction required to meet the

MACT floor were calculated.

Reductions for HCl were calculated differently than VC, CDD/CDF, or total organic

HAP. If a facility was required to reduce both VC, a ratio was used to determine the amount of

HCl reduction as a result of the VC reduction. First, the mass flow ratio of VC to HCl in the

baseline thermal oxidizer outlet was determined. Then, the VC mass flow emission from the

thermal oxidizer was calculated at the MACT floor limit. The ratio was then multiplied by the

new VC mass flow rate to determine the new HCl mass flow rate. If a facility was only required

to reduce HCl, then it was assumed that installation of a new or replacement acid gas scrubber

would achieve a 98 percent reduction. Reductions by facility for VC , HCl, CDD/CDF and total

organic HAP are presented in Table 2 -3

.

## 9 Table 2 -2. Percent Improvement Needed for Facilities to Meet Process Vent Limits

Compa ny /Facility VC

Limit: 3.2E

- 01 ppmvd @ 3%

O 2 

### HCl

Limit: 150 ppmvd @ 3%

O 2 

### CDD/CDF (TEQ)

Limit: 0. 2.3E

- 02 ng/dscm

@ 3% O 2 

### Total Organic HAP

Limit: 12 ppmvd @ 3%

O 2 

### Facility

Baseline

(ppmvd ) Percent

Improvement

Needed Facility

Baseline

( ppmvd ) Percent

Imp rovement

Needed Facility

Baseline

(ng/dscm ) Percent

Improvement

Needed Facility

Baseline

( ppmvd ) Percent

Improvement

Needed

CertainTeed

- Lake Charles 5.24 93.9 104.12

- 3.11E

- 02 26.1 76.0 84.2

Formosa

- Delaware City 2.45E

- 01

- 121.33

- 2.70E

- 03

- 2.86

- PolyOne

- Henry 2.18 85.3 5.30E

- 01

- NR

- 9724 99.9

PolyOne

- Pedricktown 2.66 88.0 1.32

- NR

- 25173 99.95

Westlake

- Calvert City 1.29E

- 05

- 2.53E

- 01

- 9.21E

- 03

- 6.43

-

Formosa

- Point Comfort

- PVC Unit 1.86E

- 04

- 2.83E

- 01

- 9.08E

- 01 97.5 1.1 4

-

Westlake

- Geismar 7.31E

- 04

- 4.06E

- 01

- 2.91E

- 02 21.1 4.31

- OxyVinyls

- Deer Park 1.08E

- 03

- NR

- 5.06E

- 03

- 3.51

- Georgia Gulf

- Plaquemine 2.35E

- 03

- 184.26 18.6 4.69E

- 02 51.0 1.73

-

Formosa

- Baton Rouge 3.31E

- 03

- 10.88

- 3.29E

- 02 3 0.1 3.26

-

Dow

- Midland 4.51E

- 03

- NR

- 1.68E

- 03

- 3.36E

- 01

-

Shintech

- Freeport 5.00E

- 03

- 1.20E

- 01

- 1.16E

- 02

- 2.16E

- 01

-

Shintech

- Addis 2.43E

- 01

- 8.47E

- 02

- 1.73E

- 02

- 11.9

- OxyVinyls

- Pasadena 9.71E

- 01 67.1 359.74 58.3 7.76E

- 03

- 17.9 33.0

Georgia Gulf

- Aberdeen 2.00 84.0 156.78 4.3 4.72E

- 03

- 14.1 14.7

Shintech

- Plaquemine 2.43E

- 01

- 8.47E

- 02

- 1.73E

- 02

- 11.9

-

VC – Vinyl chloride

HCl – Hydrogen chloride

CDD/CDF - Chlorinated dibenzodioxin and chlorinated dibenzofuran

TEQ - Toxic Equivalency

HAP – Hazardous air pollutant

ppmvd – Parts per million on a dry volume basis corrected to 3 percent oxygen

ng/dscm – Nanograms per dry standard cubic meter corrected to 3 percent oxygen

NR – Not reported by facility

## 10

Table 2 -3. Process Vent Emission Reductions as a Result of Emissions Limits

Company/ Facility Emission Reduction ( Tons per Year )

VC HCl CDD/CDF Total

Organic

HAP

CertainTeed

- Lake Charles 5.49E

- 02 6.12E

- 01 3.44E

- 11 8.80E

- 01



### Dow

– Midland

- - - -



### Formosa

- Delawar e City

- - - -



### Formosa

- Point Comfort

- - 2.04E

- 08

-



### Formosa

- Baton Rouge

- - 4.06E

- 10

-



### Georgia Gulf

- Plaquemine

- 29.2 2.52E

- 09

-



### Georgia Gulf

- Aberdeen 1.91E

- 02 8.74E

- 01

- 2.91E

- 02



### OxyVinyls

- Deer Park

- - - -



### OxyVinyls

– Pasadena 1.09E

- 02 2. 29

- 8.97E

- 02



### PolyOne

– Henry 9.55E

- 05

- - 9.10E

- 01



### PolyOne

– Pedricktown 1.81E

- 05

- - 3.50E

- 01



### Shintech

– Freeport

- - - -



### Shintech

– Addis

- - - -



### Shintech

- Plaquemine

- - - -



### Westlake

- Calvert City

- - - -



### Westlake

– Geismar

- - 1.18E

- 09

-



### TOT AL * 8.50E

- 02 33.0 2.45E

- 08 2.26

*Totals may not add exactly due to roundingVC – Vinyl Chloride

HCl – Hydrogen chloride

CDD/CDF – Chlorinated dibenzodioxin and chlorinated dibenzofurans

HAP - Hazardous air pollutant



## 3.0 Stripped Resin

3.1 Selection of Controls Needed to Meet MACT Floor Limits

Average HAP concentration values used to calculate baseline annual emissions 2



## originating from residual HAP remaining in stripped resin(s) were compared with the MACT

floor limits for residual HAP in stripped resin(s). The percent improvement needed for a facility

to meet the limits was then calculated. Tables 3-1 through 3 -3 contain the baseline HAP

concentration values used for each facility and the percentage improvement required to meet the

residual HAP stripped resin limits.

## 11

Table 3-1. Stripped Resin Limits, Baseline Concentrations, and Required Facility

Improvements

– Bulk Resin

Company /Facility VC

Limit: 7.1 ppmw Total HAP

Limit: 170 ppmw

Facility

Baseline

( ppmw ) Percent

Improvement

Needed Facility

Baseline

( ppmw ) Percent

Improvement

Needed



## CertainTeed

– Lake Charles 7.10

- 167

-

VC – Vinyl chloride

HAP – Hazardous air pollutant

ppmw – parts per million by weight



## Table 3-2. Stripped Resin Limits, Baseline Concentrations, and Required Facility

Improvements

– Dispersion Resin

Compan y/Facility VC

Limit: 55 ppmw Total HAP

Limit: 110 ppmw

Facility

Baseline

( ppmw ) Percent

Improvement

Needed Facility

Baseline

( ppmw ) Percent

Improvement

Needed



## Formosa

– Delaware City 67. 4 18.4 214 48.5

PolyOne

– Henry 42.8

- 42.8

-

PolyOne

– Pedricktown 28.5

- 43.1

-

VC – Vinyl chloride

HAP – Hazardous air pollutant

ppmw – parts per million by weight

## 12

Table 3-3. Stripped Resin Limits, Baseline Concentrations, and Required Facility

Improvements

– All Other Resin Types

Company VC

L imit: 0.48 ppmw Total HAP

Limit: 76 ppmw

Facility

Baseline

(ppmw) Percent

Improvement

Needed Facility

Baseline

(ppmw) Percent

Improvement

Needed

Dow

- Midland 7.16 93.3 95 .1 20.1

Formosa

– Baton Rouge 5

. 91 E

- 01 18.8 40 .0 0

Formosa

– Point Comfort 1

. 51 E

- 01 0 19 .2 0

Georgia Gulf

- Aberdeen 18.7 97.4 237 67.9

Georgia Gulf

- Plaquemine 21.4 97.8 241 68.5

OxyVinyls

– Deer Park 1

. 99 E

- 01 0 11.9 0

OxyVinyls

- Pasadena 2.83 83.0 77 .1 1.5 3

OxyVinyls

- Pedricktown 2.52 80.9 39 .4 0

Shintech

- Addis 5.79E

- 01 1 7.1 69 .3 0

Shintech

- Freeport 7

. 72 E

- 01 37.8 68.5 0

Shintech

- Plaquemine 5.40E

- 01 11.1 69.0 0

Westlake

– Calvert City 29. 4 98.4 258 70.5

Westlake

- Geismar 8.26 94.2 11 .4 0

VC – Vinyl chloride

HAP – Hazardous air pollutant

ppmw – parts per million by weight



## To estimate the cost for industry to meet the residual HAP resin limits, the cost of

additional steam in existing stripping units was estimated.

3.2 Compliance Cost Methodology and Results

The cost of using additional steam, during a continuous or batch stripping operation, to

reduce residual HAP concentrations in the resin slurry was estimated. The cost algorithm for

calculating the additional required steam is presented in Attachment H and is based on the cost

algorithm for wastewater stripper steam requirements used for the development of the Hazardous

Organic National Emission Standards for Hazardous Air Pollutants (HON) 7



## . For facilities that

do not currently meet the MACT floor, the TAC for additional steam range from $403,327 per year to $2,861, 572 per year. Source specific cost data are noted in Attachment H.

Table 3 -4 presents a summary of the TAC for resins as a result of complying with the

MACT floor.

Table 3 -4

. Annual Cost of Additional Steam

## 13 Company/Facility Total Annual Cost

of Additio nal Steam

($/yr)

Certain Teed

- Lake Charles 0

Dow

– Midland 615,407

Formosa

- Baton Rouge 1,762,963

Formosa

- Delaware City 403,327

Formosa

- Point Comfort 0

Georgia Gulf

– Aberdeen 591,903

Georgia Gulf

– Plaquemine 2,861,572

OxyVinyls

- Deer Park 0

OxyVinyls

– Pasadena 2,800,621

OxyVinyls

– Pedricktown 553,807

PolyOne

– Henry 0

PolyOne

– Pedricktown 0

Shintech

– Addis 1,438,860

Shintech

– Freeport 711,840

Shintech

– Plaquemine 730,691

Westlake

- Calvert City 689,404

Westlake

– Geismar 949 ,970

TOTAL * 14,110,366

$/yr – dollars per year

*Totals may not add exactly due to rounding



## 3.3 Testing, Monitoring, and Recordkeeping Costs

Industry wide testing costs for stripped resin were estimated at approximately $393,000

per year. An average test cost of $301 was assumed for US EPA Method 8260B. Since VC is

currently analyzed “in-house” using Method 107, no additional cost for Method 107 was

estimated. The cost algorithm is presented in Attachment I and facility specific costs are

summarized in Table 3 -5. Source specific cost data are noted in Attachment I.

## 14

Table 3-5

. Annual Costs of Stripped Resin Testing, Monitoring, and Recordkeeping

Company/ Facility Total Annual Cost of

Resin Testing ($/yr.)

Certain Teed

- Lake Charles 21,806

Formosa

- Bato n Rouge 21,806

Formosa

- Delaware 21,806

Formosa

- Point Comfort 21,806

Georgia Gulf

– Aberdeen 21,806

Georgia Gulf

- Plaquemine 21,806

OxyVinyls

- Deer Park 21,806

OxyVinyls

– Pasadena 21,806

OxyVinyls

- Pedricktown 21,806

PolyOne

– Henry 43,6 12 a



### PolyOne

– Pedricktown 21,806

Shintech

- Addis 21,806

Shintech

– Freeport 21,806

Shintech

– Plaquemine 21,806

Dow

– Midland 21,806

Westlake

- Calvert City 21,806

Westlake

- Geismar 21,806

TOTAL * 392,511

$/yr – dollars per year

a 

### PolyOne Henry is required to test both suspension and dispersion resin types.

*Totals may not add exactly due to rounding



## 3.4 Emission Reduction Methodology and Results

Annual emissions reductions of VC and total HAP were calculated as a result of meeting

the MACT floor limit for residual HAP contained in the stripped resin. VC reductions were

estimated at approximately 130 tons per year and total HAP reductions were estimated at

approximately 853 tons per year.

VC and total HAP MACT floor emission rates were estimated using the procedure

described in the memorandum titled Estimation of Baseline Emissions from Existing Polyvinyl

Chloride and Copolymer Manufacturing Units Section 3.2 2 

## , except that the baseline

concentrations for VC and total HAP were replaced with the MACT floor limit concentration

values. Emissions reductions were then calculated by subtracting the MACT floor emission rate

from the baseline emission rate. Reductions by facility for VC and total HAP are presented in

Table 3 -6

.

## 15

Table 3-6

. Percent Reduction Needed for Facilities to Meet Stripped Resin Limits and

Estimated Emission Reductions

Company/ Facility P ercent Reduction Needed to

Meet Limit s Emission Reduction

( Tons per Year )

VC Total HAP VC Total HAP

Certain Teed

- Lake Charles 0 0 0 0

Dow

– Midland 93.4 20.2 4.6 4 13.3

Formosa

- Baton Rouge 20.4 0 2

. 38 E

- 01 2

. 38 E

- 01

Formosa

- Delaware City 18.7 53.1 3.52 31.8

Formosa

- Point Comfort 0 0 0 0

Georgia Gulf

- Aberdeen 97.5 67.9 12.3 108

Georgia Gulf

- Plaquemine 97.8 68.5 68.2 538

OxyVinyls

- Deer Park 0 0 0 0

OxyVinyls

- Pasadena 83.4 1.5 3 7.43 7.43

OxyVinyls

- Pedricktown 81.3 0 1.27 1.27

PolyOne

– Henry 0 0 0 0

PolyOne

- Pedricktown 0 0 0 0

Shintech

– Addis 18.7 0 1

. 75 E

- 01 1

. 75 E

- 01

Shintech

– Freeport 39.0 0 2

. 41 E

- 01 2

. 41 E

- 01

Shint ech

- Plaquemine 12.8 0 5

. 69 E

- 02 5

. 69 E

- 02

Westlake

- Calvert City 98.4 70.5 22.8 144

Westlake

– Geismar 94.3 0 8.36 8.36

TOTAL 130 853

VC – Vinyl chloride

HAP – Hazardous air pollutant

*Totals may not add exactly due to rounding

## 16

Table 3 -7

. Summary of Emission Reductions for Stripped Resin Subcategories

Company/ Facility Emission Reduction

(T ons per Y ear)

VC Total HAP

Certain Teed

- Lake Charles 0 0

Bulk Resin Subtotal 0 0

Formosa

- Delaware City 3.52 31.8

PolyOne

– Henry 0 0

PolyOne

- Pedrickto wn 0 0

Dispersion Resin Subtotal 3.52 31.8

Formosa

- Point Comfort 0 0

Georgia Gulf

- Aberdeen 12.3 108

Georgia Gulf

- Plaquemine 68.2 538

OxyVinyls

- Deer Park 0 0

OxyVinyls

- Pasadena 7.43 7.43

OxyVinyls

- Pedricktown 1.27 1.27

Dow

– Midland 4.6 4 13.3

Formosa

- Baton Rouge 2

. 38 E

- 01 2

. 38 E

- 01

Shintech

– Addis 1

. 75 E

- 01 1

. 75 E

- 01

Shintech

– Freeport 2

. 41 E

- 01 2

. 41 E

- 01

Shintech

- Plaquemine 5

. 69 E

- 02 5

. 69 E

- 02

Westlake

- Calvert City 22.8 144

Westlake

– Geismar 8.36 8.36

Other Resin Subtotal 126 821

TOTAL * , All Subcategories 130 853

*Totals may not add exactly due to rounding



## 4.0 Storage Vessels

4.1 Selection of Controls Needed to Meet MACT Floor Limits, Costs, and Emission

Reductions

Current industry work practices, as discussed in previous memoranda 1



## , co nstitute the

MACT Floor for storage vessels; therefore, costs associated with improvement of emissions

from storage, unloading, and transfer were not calculated. No additional emissions reductions

from storage vessels would result from facilities complying with the MACT floor.

## 17

5.0 Heat Exchange Systems

5.1 Selection of Controls Needed to Meet MACT Floor Limits

The MACT floor for heat exchange systems is comprised of a leak action level more stringent that 40 CFR Part 61, subpart F, and an equipment leak program. It was assumed that a

more stringent testing and monitoring program would eliminate all baseline emissions.

5.2 Compliance Cost Methodology and Results

It was assumed that no additional control equipment will be necessary to meet the MACT

floor; therefore, no additional control equipment cost estimation was performed. The cost

estimation for additional sampling, monitoring, and repair is described in Section 5.3

.

5.3 Testing, Monitoring, and Recordkeeping Costs

The cost of a more stringent testing, monitoring, and repair program for heat exchangers

using was estimated using the following assumptions; sampling and analysis of each cooling

tower was estimated to cost $7,600 per year per cooling tower. It was assumed that a sampling

and testing method such as Method 8021B or the “Air Stripping Method” would be used by

facilities to sample and analyze cooling towers 12



## . It was assumed that each cooling tower would

require 1 repair event per year at $4,300 per event. Detailed cost information on a per facility

basis is presented in Table 5 -1

. Attachment J contains the analysis used to estimate the costs

presented in Table 5-1. The TAC for heat exchange system sampling and analysis, along with

repair events was estimated at approximately $309,000 per year. Fo r simplicity, the cost of

additional testing and monitoring as a result of delay or repair was not estimated. Sampling and

analysis comprise 64 percent of the cost; the balance, repair events.

## 18

Table 5-1. Summary of Testing and Monitoring Costs for Heat Exchange Systems

Company/Facility Sampling

and

Analysis Costs to

Repair Number

of

Cooling

Towers Repairs Sampling

and

Analysis Costs to

Repair Total

Annual

Costs

($/yr

tower) ($/event

tower) (event/yr) ($/yr) ($/yr) ($/yr)

CertainTeed

- Lake Charles 7 ,600 4,300 2 2 15,200 8,600 23,800

Formosa

- Baton Rouge 7,600 4,300 1 1 7,600 4,300 11,900

Formosa

- Delaware City 7,600 4,300 2 2 15,200 8,600 23,800

Formosa

- Point Comfort 7,600 4,300 1 1 7,600 4,300 11,900

Georgia Gulf

– Aberde en 7,600 4,300 4 4 30,400 17,200 47,600

Georgia Gulf

– Plaquemine 7,600 4,300 2 2 15,200 8,600 23,800

OxyVinyls

- Deer Park 7,600 4,300 3 3 22,800 12,900 35,700

OxyVinyls

– Pasadena 7,600 4,300 2 2 15,200 8,600 23,800

OxyVinyls

– Pe dricktown 7,600 4,300 1 1 7,600 4,300 11,900

PolyOne

– Henry 7,600 4,300 1 1 7,600 4,300 11,900

PolyOne

– Pedricktwon 7,600 4,300 1 1 7,600 4,300 11,900

Shintech

– Addis 7,600 4,300 1 1 7,600 4,300 11,900

Shintech

– Freeport 7,600 4,300 1 1 7,600 4,300 11,900

Shintech

– Plaquemine 7,600 4,300 1 1 7,600 4,300 11,900

Dow

– Midland 7,600 4,300 1 1 7,600 4,300 11,900

Westlake

- Calvert City 7,600 4,300 1 1 7,600 4,300 11,900

Westlake

– Geismar 7,600 4,300 1 1 7, 600 4,300 11,900

TOTAL *

- - 26 26 197,600 111,800 309,400



### $/yr – Dollars per year

$/yr-tower – Dollars per year per cooling tower

$/event-tower – Dollars per repair event per cooling tower

event/yr – event per year

*Totals may not add exactly due to rounding



## 5.4 Emission Reduction Methodology and Results

It was assumed that all of the baseline emissions from heat exchange systems (cooling

towers) 2 

## would be eliminated by the testing, monitoring, and repair program. Therefore, it was

estimated that all the baseline emissions, estimated in a separate memorandum 2



## , 5. 26 tons per

year of VC and 34.6 tons per year of total volatile organic compounds (VOC), would be reduced

as a result of the MACT floor for heat exchange systems. Table 5-2 presents a summary of heat

exchange system emission reductions on a facility basis.

## 19 Table 5 -2

. Estimated Emission Reductions from Heat Exchange Systems

Company/Facility Emission Reduction

( Tons per Year )

VC Total VOC

Certain Teed

- Lake Charles 2.03E

- 01 1.33

Dow

- Mi dland 6.40E

- 02 4.21E

- 01

Formosa

- Baton Rouge 2.90E

- 02 1.91E

- 01

Formosa

- Delaware City 1.07E

- 01 7.02E

- 01

Formosa

- Point Comfort 2.11 13.9

Georgia Gulf

- Aberdeen 1.07E

- 01 7.02E

- 01

Georgia Gulf

- Plaquemine 8.30E

- 01 5.46

OxyVinyls

- Deer Park 3.20E

- 01 2.11

OxyVinyls

- Pasadena 2.75E

- 01 1.81

OxyVinyls

- Pedricktown 1.78E

- 01 1.17

PolyOne

- Henry 5.20E

- 01 3.42

PolyOne

- Pedricktown 1.33E

- 03 8.77E

- 03

Shintech

- Addis 5.98E

- 03 3.94E

- 02

Shintech

- Freeport 4.80E

- 03 3.16E

- 02

Shintech

- Plaquemine 5.7 7E

- 03 3.80E

- 02

Westlake

- Calvert City 3.04E

- 01 2.00

Westlake

- Geismar 0.195 1.29

TOTAL * 5.26 34.6

VC – Vinyl chloride

VOC – Volatile organic compound

*Totals may not add exactly due to rounding



## 6.0 Equipment Leaks

6.1 Selection of Controls Needed to Meet MACT Floor Limits

The cost of compliance with the control level 2 leak detection and repair (LDAR)

requirements of the National Emissions Standards for Equipment Leaks, subpart UU of 40 CFR

part 63 was estimated. The cost of each facility installing electronic monitoring to detect

releases of pressure relief devices was also calculated. Further descriptions of these cost

estimations are listed in Section 6.2 and 6.3

.

6.2 Compliance Cost Methodology and Results

The MACT floor level of control for equipment leaks consists of a more stringent LDAR

program along with additional pressure relief valve monitoring devices. It was assumed that no

additional emissions control equipment would be necessary to achieve MACT floor level of

control. The cost estimation for a more stringent LDAR program and pressure relief device

monitoring systems is described in Section 6. 3, Testing, Monitoring, and Recordkeeping Costs

for Equipment Leaks.

## 20

6.3 Testing, Monitoring, and Recordkeeping Costs

The cost of all facilities complying with the control level 2 LDAR requirements of the

National Emissions Standards for Equipment Leaks

– Control Level 2, subpart UU of 40 CFR

part 63 was estimated. Facilities submitted estimates of the costs for conducting their LDAR

program. Using information submitted by facilities, the average cost of complying with subpart

UU of 40 CFR part 63 and subpart V of 40 CFR part 61 was calculated on a per ton of resin

capacity basis. This was done in order to standardize LDAR program costs on a production rate

basis. The average cost per ton factor was then multiplied by facility capacity to obtain a

calculated cost of compliance for subparts UU and V for each facility. The calculated cost of

subpart V was subtracted from the calculated cost of subpart UU to determine the incremental

cost of complying with subpart UU for each facility currently complying with subpart V. The

TAC of compliance was estimated at approximately $192,000. It was assumed that the cost of

using Method 21 for equipment leaks was covered by the additional TAC to comply with UU.

The TCI and TAC of installing a pressure relief device monitoring system at each facility were

also calculated 10



## . The TCI was estimated at approximately $3.1 million and the TAC was estimated at approximately $ 446,000

. Total capital investment for complying with the

equipment leaks MACT floor is $3.1 million, and TAC is $638,000 per year. Attachment K

presents the cost algorithm used to estimate the TAC of subpart UU compliance and the TCI and

TAC of the pressure relief monitoring device. Table 6 -1 summarizes the TCI and TAC required

to comply with the emission limits for equipment leaks. Source specific cost data are

documented in Attachment K.

## 21

Table 6 -1 . Summary of Testing and Monitoring Costs for Equipment Leaks

Company/Facility Cost of PRV Reduction

Monitoring System Additional

Annual Cost as a

Result of

Complying with

40 CFR Part 63

Subpart UU Total Costs

for Equipment Leaks Limits

TCI

($) TAC

($/yr) TCI

($) TAC

($/yr)

Certain Teed

- Lake

Charle s 113,116 16,105 8,736 113,116 24,841

Dow

– Midland 188

, 913 26

, 897 393 188 ,913 27,290

Formosa

- Baton

Rouge 188

, 913 26

, 897 16,670 188 ,913 43,567

Formosa

- Delaware

City 188

, 913 26

, 897 0 188 ,913 26,897

Formosa

- Point

Comfort 188

, 913 26

, 897 28,451 188 ,9 13 55,348

Georgia Gulf

– Aberdeen 188

, 913 26

, 897 18,193 188 ,913 45,090

Georgia Gulf

– Plaquemine 188

, 913 26

, 897 0 188 ,913 26,897

OxyVinyls

- Deer

Park 188

, 913 26

, 897 10,018 188 ,913 36,915

OxyVinyls

– Pasadena 188

, 913 26

, 897 38,189 188 ,913 65,086

OxyVi nyls

– Pedricktown 188

, 913 26

, 897 6,371 188 ,913 33,268

PolyOne

– Henry 188

, 913 26

, 897 2,284 188 ,913 29,181

PolyOne

– Pedricktown 188

, 913 26

, 897 2,364 188 ,913 29,261

Shintech

– Addis 188

, 913 26

, 897 11,340 188 ,913 38,237

Shintech

– Freeport 188

, 913 26

, 89 7 0 188 ,913 26,897

Shintech

– Plaquemine 188

, 913 26

, 897 23,642 188 ,913 50,539

Westlake

- Calvert

City 188

, 913 26

, 897 14,546 188 ,913 41,443

Westlake

– Geismar 188

, 913 26

, 897 10,419 188 ,913 37,316

TOTAL * 3,135,724 446,457 191,616 3,135,724 638,073

TCI – Total capital investment

TAC – Total annual cost

$/yr – Dollars per year

*Totals may not add exactly due to rounding



## 6.4 Emission Reduction Methodology and Results

Equipment leak baseline emissions of VOC, which for this analysis were considered be

total organic HAP, were estimated using EPA developed emissions factors, equipment counts,

and the control effectiveness of LDAR programs used by each facility. First, uncontrolled

## 22

emissions were calculated by multiplying the average emission factors for each piece of

equipment (in lbs/component/hour), equipment counts at each facility, and the hours of operation

(assumed 8400 for this analysis, which allows for 2 weeks downtime). The uncontrolled

emission factors were obtained from EPA’s 1995 Protocol for Equipment Leak Emission

Estimates 8 

## (i.e., Protocol). Information on actual equipment counts were not collected in the

CAA section 114 survey questionnaires sent to the industry. Model equipment counts for an

average complexity facility, from another EPA study 9



## , were used. Baseline emissions were then

calculated by applying the control effectiveness of the facilities LDAR program for each

component. The control effectiveness depends on the monitoring frequency and the leak

definition of the LDAR program, which are prescribed in the equipment leaks regulations the

facilities are complying with. The control effectiveness of different monitoring frequencies and

leak definitions for different components are provided in the Protocol document.

Table 6 -2 summarizes the LDAR program the facility is currently using and the baseline

emissions estimated for the facility. It is likely that emissions and emission reductions are

overestimated for equipment leaks because they are based on EPA average emission factors and

do not take into account the actual leaking equipment, and their leak levels. Table 6 -3 presents

emissions reduction from equipment leaks on a facility basis.

Table 6-2. LDAR Analysis Model Components

Company/Facility LDAR Program Baseline Emissions

(Tons per Year)

Certain Teed

- Lake Charles 40CFR61 V 16.5

Dow

– Midland 40CFR61 V 59.3

Formosa

- Baton Rouge 40CFR61 V 59.3

Formosa

- Delaware City 40CFR63 UU 8.1

Formosa

- Point Comfort 40CFR61 V 59.3

Georgia Gulf

– Aberdeen 40CFR61 V 59.3

Georgia Gulf

– Plaquemine 40CFR63 UU 8.1

OxyVinyls

- Deer Park 40CFR61 V 59.3

OxyVinyls

– Pasadena 40CFR61 V 59.3

OxyVinyls

– Pedricktown 40CFR61 V 59.3

PolyOne

– Henry 40CFR61 V 59.3

PolyOne

– Pedricktown 40CFR61 V 59.3

Shintech

– Addis 40CFR61 V 59.3

Shintech

– Freeport 40CFR63 UU 8.1

Shintech

– Plaquemine 40CFR61 V 59.3

Westlake

- Calvert City 40CFR61 V 59.3

Westlake

– Geismar 40CFR61 V 59.3

TOTAL * 811

LDAR – Leak detection and repair

*Totals may not add exactly due to rounding

## 23 Table 6 -3 . Estimated Emission Reductions from Equipment Leaks

Company/Facility Emission Reduction

( Tons per Year)

Total HAP

Certain Teed

- Lake Charles 14.4

Dow

– Midland 51.2

Formosa

- Baton Rouge 51.2

Formosa

- Delaware City 0

Formosa

- Point Comfort 51.2

Georgia Gulf

- Aberdeen 51.2

Georgia Gulf

- Plaquemine 0

OxyVinyls

- Deer Park 51.2

OxyVinyls

- Pasadena 51.2

OxyVinyls

- Pedricktown 51.2

PolyOne

- Henry 51.2

PolyOne

- Pedricktown 51.2

Shintech

- Addis 51.2

Shintech

- Freeport 0

Shintech

- Plaquemine 51.2

We stlake

- Calvert City 51.2

Westlake

- Geismar 51.2

TOTAL * 680

HAP – Hazardous air pollutant

*Totals may not add exactly due to rounding



## 7.0 Other Emission Sources

7.1 Selection of Controls Needed to Meet MACT Floor Limits

The MACT floor level of control for other emission sources consists of numeric emission

limits for reactor opening losses and component openings as required by 40 CFR Part 61, subpart

F.

7.2 Testing, Monitoring, and Recordkeeping Costs

All facilities currently meet the numeric emission limits required by 40 CFR Part 61,

subpart F; therefore, no additional compliance, testing, monitoring, or record keeping costs were

calculated.

7.3 Emission Reduction Methodology and Results

The MACT floor for other emissions sources consists of numeric emission limits for

reactor opening losses and component openings, as well as work practices to reduce emission

from other emission sources. It was assumed that emission reductions as a result of the MACT

floor would be negligible.

## 24

8.0 Wastewater

8.1 Selection of Controls Needed to Meet MACT Floor Limits

Average VC concentration values used to calculate baseline annual wastewater

generation 2 

## were compared to the MACT floor limit for VC in the wastewater stripper outlet.

The percent improvement needed for a facility to meet the limit was then calculated. Table 8 -1

contains the baseline VC concentration values used for each facility and the percentage

improvement required to meet the emission limits.

Table 8 -1

. Percent Reduction Needed for Facilities to Meet Wastewater Limits and

Estimated Generation Reductions

Company/Facility VC

Limit: 0.11 ppmw

Facility Baseline

(ppmw) Percent

Improvement

Needed

Certain Teed

– Lake Charles 0.40 73%

Dow

– Midland 0.54 80%

Formosa

– Baton Rouge 0.14 21%

Formosa

– Delaware City 0.54 80%

Formosa

– Point Comfort 0.54 80%

Georgia Gulf

– Aberdeen 0.70 84%

Georgia Gulf

– Plaquemine 1.00 89%

OxyVinyls

– Deer Park 0.07

- OxyVinyls

– Pasadena 0.04

- OxyVinyls

– Pedricktown 0.54 80%

PolyOne

– Henry 1.40 92%

PolyOne

– Pedrickt own 1.46 92%

Shintech

– Addis 0.01

-

Shintech

– Freeport 0.01

-

Shintech

– Plaquemine 0.01

-

Westlake

– Calvert City 0.05

-

Westlake

– Geismar 1.72 94%



## To estimate the cost for industry to meet the wastewater MACT floor limit, the cost of

additional steam in existing stripping units was estimated.

8.2 Compliance Cost Methodology and Results

## 25

The cost of using additional steam to reduce VC in the wastewater stripper outlet was

estimated. The cost algorithm for calculating the additional required steam is presented in

Attachment M and is based on the cost algorithm for wastewater stripper steam requirements

used for the development of the HON 7



## . For facilities that do not currently meet the MACT floor,

the TAC for additional steam range from $ 13 per year to $182,409 per year. Source specific cost

data are noted in Attachment M. Table 8 -2 presents a summary of the TAC for resins as a result

of complying with the emission limits.

Table 8 -2. Summary of Control Equipment Costs for Wastewater Limits

Compan y /Facility Annual Cost for

Additional Steam

($/yr)

Certain Teed

- Lake Charles 13

Dow

- Midland 2,518

Formosa

- Baton Rouge 50,944

Formosa

- Delaware City 16,702

Formosa

- Point Comfort 182,409

Georgia Gulf

- Aberdeen 39,348

Georgia Gulf

- Plaquemi ne 139,731

OxyVinyls

- Deer Park

-

OxyVinyls

- Pasadena

-

OxyVinyls

- Pedricktown 40,856

PolyOne

- Henry 18,408

PolyOne

- Pedricktown 928

Shintech

- Addis

-

Shintech

- Freeport

-

Shintech

- Plaquemine

-

Westlake

- Calvert City

-

Westlake

- Geisma r 49,127

TOTAL * 540, 984

$/yr – Dollars per year

*Totals may not add exactly due to rounding



## 8.3 Testing, Monitoring, and Recordkeeping Costs

The industry wide wastewater testing cost was estimated at approximately $250 ,000 per

year. As previously stated, an average test cost of $301 was assumed for US EPA Method

8260B. It was assumed that the cost of Method 107 was included with the cost of Method

8260B. The cost algorithm and facility specific costs are presented in Attachment N where

source specific cost data are also documented. Table 8 -3 presents the wastewater annual testing

and monitoring costs on a facility basis.

Table 8 -3 . Summary of Testing and Monitoring Costs for Wastewater

## 26 Company /Facility Testing and Monitoring

Annual Cost for Wastewater

( $/yr)

Certain Teed

- Lake Charles 14,736

Dow

- Midland 14,736

Formosa

- Baton Rouge 14,736

Formosa

- Delaware City 14,736

Formosa

- Point Comfort 14,736

Georgia Gulf

- Aberdeen 14,736

Georgia Gulf

- Plaquemine 14,736

OxyVinyls

- Deer Park 14,736

O xyVinyls

- Pasadena 14,736

OxyVinyls

- Pedricktown 14,736

PolyOne

- Henry 14,736

PolyOne

- Pedricktown 14,736

Shintech

- Addis 14,736

Shintech

- Freeport 14,736

Shintech

- Plaquemine 14,736

Westlake

- Calvert City 14,736

Westlake

- Geismar 14,736

TOTAL * 250,512

$/yr – Dollars per year

*Totals may not add exactly due to rounding



## 8.4 Generation Reduction Methodology and Results

Annual emissions reductions of VC and total HAP were calculated as a result of meeting

the MACT floor limit for VC in the wastewater stripper outlet stream. VC reductions were

estimated at approximately 0.4 tons per year and total HAP reductions were estimated at

approximately 0.4 tons per year. Total HAP reductions were a result of VC reductions only. VC

and total HAP MACT floor generation rates were estimated using the procedure described in the

memorandum titled Estimation of Baseline Emissions from Existing Polyvinyl Chloride and

Copolymer Manufacturing Units Section 3.7 2 

## , except that the VC concentration was replaced

with the MACT floor limit concentration value. Generation reductions were then calculated by

subtracting the MACT floor generation rate from the baseline generation rate. Reductions by

facility for VC and total HAP are presented in Table 8 -4

.

Table 8 -4. Summary of Testing VC and Total HAP Reductions

– Wastewater

## 27 Company/Facility VC Generation

Reduction

(Tons Per Year) Total HAP

Generation

Reduction

(Tons Per Year)

Certain Teed

– Lake Charles 4.36E

- 06 4.36E

- 06

Dow

– Midland 1.21E

- 03 1.21E

- 03

Formosa

– Baton Rouge 1.72E

- 03 1.72E

- 03

Formosa

– Delaware City 8.04E

- 03 8.04E

- 03

Formosa

– Point Comfort 8.78E

- 02 8.78E

- 02

Georgia Gulf

– Aberdeen 2.61E

- 02 2.61E

- 02

Georgia Gulf

– Plaquemine 1.40E

- 01 1.40E

- 01

OxyVinyls

– Deer Park

- - OxyVinyls

– Pasadena

- - OxyVinyls

– Pedricktown 1.97E

- 02 1.97E

- 02

PolyOne

– Henry 2.67E

- 02 2.67E

- 02

PolyOne

– Pedricktown 1.40E

- 03 1.40E

- 03

Shintech

– Addis

- -

Shintech

– Freeport

- -

Shintech

– Plaquemine

- -

Westlake

– Calvert City

- -

Westlake

– Geismar 8.90E

- 02 8.9 0E

- 02

TOTAL 4.01E

- 01 4.01E

- 01

*Totals may not add exactly due to rounding



## 9.0 Summary and Results for the Industry

9.1 Costs

The TCI for all existing PVC production facilities to meet the MACT floor emission limits is

estimated at approximately $15.7 million. The TAC for controls for all units is about $17

million. The TCI for testing and monitoring was estimated at approximately $3.2 million and the

TAC was estimated at approximately $2. 7 million. Table 9-1 summarizes the TCI and TAC of

the emission limits fo r each facility. Table 9-2 summarizes the same costs on an emission point

basis.

## 28

Table 9-1. Summary of Control Equipment and Testing and Monitoring Costs by Facility

Company /Facility MACT Floor Costs

Control Equipment Costs Testing, Monitoring, and

R ecordkeeping Total Emission Limits

Costs

TCI

($) TAC

($/yr) TCI

($) TAC

($/yr) TCI

($) TAC

($/yr)

Certain Teed

- Lake

Charles 1,643,288 177,556 133,416 154,795 1,776,704 332,351



### Dow

– Midland

- 617,925 188,913 142,044 188,913 759,969



### Formo sa

- Baton Rouge 1,312,035 2,240,712 209,213 161,621 1,521,248 2,402,333



### Formosa

- Delaware

City - 420,029 188,913 153,551 188,913 573,580



### Formosa

- Point

Comfort 1,092,721 568,117 209,213 173,402 1,301,934 741,519



### Georgia Gulf

– Aberd een 79,085 700,287 188,913 195,544 267,998 895,831



### Georgia Gulf

– Plaquemine 3,585,978 4,095,916 232,213 162,150 3,818,191 4,258,066



### OxyVinyls

- Deer Park

- - 188,913 175,469 188,913 175,469



### OxyVinyls

- Pasadena 629,409 1,423,349 188 ,913 191,740 818,322 1,615,089



### OxyVinyls

– Pedricktown - 594,664 188,913 99,991 188,913 694,655



### PolyOne

– Henry

- 192,338 188,913 165,741 188,913 358,079



### PolyOne

- Pedricktown

- 131,783 188,913 144,015 188,913 275,798



### Shintech

– A ddis

- 1,438,860 188,913 152,991 188,913 1,591,851



### Shintech

– Freeport

- 711,840 188,913 141,651 188,913 853,490



### Shintech

- Plaquemine

- 730,691 188,913 165,293 188,913 895,984



### Westlake

- Calvert City

- 689,404 188,913 156,197 188, 913 845,601



### Westlake

– Geismar 4,037,296 2,240,302 209,213 155,370 4,246,509 2,395,672



### TOTAL * 12,379,812 16,973,774 3,260,224 2,691,560 15,640,036 19,665,335



### TCI – Total capital investment

TAC – Total annual cost

$ - Dollars

$/yr – Dollars per year

*Totals may not add exactly due to rounding

## 29

Table 9 -2 . Summary of Emission Limits Control Equipment and Testing and Monitoring

Costs by Emission Point

Emission

Point Costs

Control Costs Testing, Monitoring, and

Recordkeeping Costs Total Emis sion Limits Costs

TCI

($) TAC

($/yr) TCI

($) TAC

($/yr) TCI

($) TAC

($/yr)

Process

Vents 12,379,812 2,322,423 124,500 1,101,064 12,504,312 3,423,487

Resin

- 14,110,366

- 392,511

- 14,502,877

Wastewater

- 540,986

- 250,512

- 791,498

Equipment

Leaks - - 3,135,724 638,073 3,135,724 638,073

Storage

- - - - - -

Heat

Exchange

Systems - - - 309,400

- 309,400

Other

Emission

Sources - - - - - -

TOTAL * 12,379,812 16,973,774 3,260,224 2,691,560 15,640,036 19,665,335



### TCI – Total capital investment

TAC – Total annual cost

$ - Dollars

$/yr – Dollars per year

*Totals may not add exactly due to rounding

## 30

9.2 Emission Reductions

Industry wide VC reductions were estimated at 135 tons per year, HCl at 33 tons per

year, CDD/CDF at 2.45E-08 tons per year, and total HAP at 1,570 tons per year. Tables 9 -3 and

9 -4 summarize the reductions by facility and by emission point, respectively.

Table 9 -3 . Summary of Industry Emission Reductions by Facility

Emission Reduction ( Tons per Year )

Company/ Facility VC HCl CDD/CDF Total HAP

Certain Teed

- Lake Charles 2.57E

- 01 6.12E

- 01 3.44E

- 11 16.61

Dow

– Midland 4.71

- - 64.93

Formosa

- Delaware 3.64

- - 32.54

Formosa

- Baton Rouge 2.69E

- 01

- 4.06E

- 10 51.62

Formosa

- Point Comfort 2.20

- 2.04E

- 08 65.20

Georgia Gulf

- Plaqu emine 69.2 29.2 2.52E

- 09 544.00

Georgia Gulf

- Aberdeen 12.4 8.74E

- 01

- 160.25

OxyVinyls

- Deer Park 3.20E

- 01

- - 53.30

OxyVinyls

- Pedricktown 1.47

- - 53.65

OxyVinyls

– Pasadena 7.72 2.29

- 60.52

Poly One

– Henry 5.46E

- 01

- - 55.55

Poly One

- Ped ricktown 2.75E

- 03

- - 51.55

Shintech

- Addis 1.81E

- 01

- - 51.40

Shintech

– Freeport 2.46E

- 01

- - 0.27

Shintech

– Plaquemine 6.26E

- 02

- - 51.28

Westlake

- Calvert City 23.1

- - 196.80

Westlake

- Geismar 8.64

- 1.18E

- 09 60.92

TOTAL * 135 33.0 2.45E

- 0 8 1

, 570

VC – Vinyl Chloride

HCl – Hydrogen chloride

CDD/CDF – Chlorinated dibenzodioxin and chlorinated dibenzofurans

HAP - Hazardous air pollutant

*Totals may not add exactly due to rounding

## 31

Table 9 -4 . Summary of Industry Emission Reductions by Emission Point

Emission Point Emission Reduction (tons per year)

VC HCl CDD/CDF Total HAP

Process Vents 0.0850 33.0 2.45E

- 08 2.26

Resin 129 0 0 853

Wastewater 0.401 0 0 0.401

Equipment Leaks 0 0 0 680

Storage 0 0 0 0

Heat Exchange Systems 5.26 0 0 34.6

Other Emission Sources 0 0 0 0

TOTAL * 135 33.0 2.45E

- 08 1

, 570

VC – Vinyl Chloride

HCl – Hydrogen chloride

CDD/CDF – Chlorinated dibenzodioxin and chlorinated dibenzofurans

HAP - Hazardous air pollutant

*Totals may not add exactly due to rounding

## 32

10.0 References

1. “MACT Floor Analysis for the Polyvinyl Chloride and Copolymers (PVC) Production

Source Category.” Memorandum from Eastern Research Group, Inc. to Jodi Howard,

U.S. Environmental Protection Agency. April 2011.

2. “Baseline Emission Estimates for the Polyvinyl Chloride and Copolymers (PVC)

Production Source Category.” Memorandum from Eastern Research Group, Inc. to Jodi

Howard, U.S. Environmental Protection Agency. April 2011.

3. U.S. Environmental Protection Agency. December 1995. OAQPS Control Cost

Manual. Section 3.1: VOC Recapture Controls Chapter 2: Refrigerated Condensers.

Publication Number EPA/452/B-02 -001.

4. http://www.epa.gov/ttncatc1/products.html

5. U.S. Environmental Protection Agency. July 1994. Medical Waste Incinerators

-- Background Information for Proposed Standards and Guidelines: Model Plant

Description and Cost Report for New and Existing Facilities. Publication Number EPA453/R-94 -045a. (Docket item no. II-A-112).

6. Memorandum from Thomas Holloway, RTI, to Rick Copland, EPA. March 17,

1997. Revised Testing and Monitoring Options and Costs for Medical Waste Incinerators

(MWI’s)—

Methodology and Assumptions. (Docket item no. IV-B-66)

7. U.S. Environmental Protection Agency. November 1992. Hazardous Air Pollutant

Emissions from Process Units in the Synthetic Organic Chemical Manufacturing

Industry

—

Background Information for Proposed Standards. Publication Number EPA453/D -92 -016c.

8. 1995 Protocol for Equipment Leak Emission Estimates. U.S. Environmental Protection

Agency. November 1995. EPA-453/R-95 -017

.

9. “Data and Assumptions used in the Equipment Leaks Cost Analysis for the SOCMI.”

Memorandum from Kristin Parrish and David Randall, RTI International, to Karen

Rackley, U.S. Environmental Protection Agency. October 31, 2006. (Docket item no.

EPA- HQ

- OAR -2006-0699-0035).

10. “Proposed Amended Rule 1173 – Control of Volatile Organic Compound Leaks and

Releases from Components at Petroleum Facilities and Chemical Plants.” South Coast

Air Qu ality Management District. May 15 th 

## , 2007.

11. U.S. Environmental Protection Agency. September 1997. “Fabric Filter Bag Leak

Detection Guidance.” EPA-454/R-98 -015.

12. “Air Stripping Method (Modified El Paso Method) for Determination of Volatile Organic

Compound Emissions from Water Sources,” Revision Number One, dated January 2003,

## 33

Sampling Procedures Manual, Appendix P: Cooling Tower Monitoring, prepared by

Texas Commission on Environmental Quality, January 31, 2003.

## Attachments

Attachment A. Refrigerated Condenser Cost Algorithm

Attachment B. Refrigerated Condenser Input Calculations

Attachment C. Air Compliance Advisor Program Inputs and Outputs for VGA Routed to

Thermal Oxidizer

Attachment D. Activated Carbon Injection Cost Algorithm

Attachment E. Fabric Filter Cost Algorithm

Attachment F. Process Vent Emissions Testing and Monitoring Cost Algorithm

Attachment G. Recordkeeping and Reporting Cost Algorithm

Attachment H. Cost Algorithm For Additional Resin Stripping Steam

Attachment I. Resin Testing and Monitoring Cost Algorithm

Attachment J. Heat Exchange System Cost Analysis

Attachment K. Equipment Leak Testing and Monitoring Cost Algorithm

Attachment L. Wastewater Compliance Cost Algorithm

Attachment M. Wastewater Testing and Monitoring Cost Algorithm

Attachment N. THC Concentration Analysis

Attachment O. HCl Packed Bed Scrubber Cost Algorithm

## Attachment A

Refrigerated Condenser Cost AlgorithmRefrigerated Condenser Package for PVC and Copolymer Process VentsCertain Teed Georgia Gulf OxyVinylsLake Charles Aberdeen Pasadena-- Inlet stream flowrate (DSCMM):5.70.115.1-- Inlet stream flowrate (scfm): (Qin)=DSCMM/35.312004535-- Inlet stream temperature (oC):651618-- Inlet stream temperature (oF): (Tin)=oC*1.8+321486165-- VOC to be condensed:Vinyl chloride Vinyl chloride Vinyl chloride-- VOC inlet volume fraction:(Yvoc,in)=ppm/1E60.096 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 6.497B:783.400 783.400 783.400C:230.010 230.010 230.010-- VOC heat of condensation (BTU/lb-mole): (**∆**Hvoc,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,cool0.650 0.650 0.650-- VOC boiling point (oF): (Tboil)777-- VOC critical temperature (oR): (Tc)773773773-- VOC molecular weight (lb/lb-mole): (MWvoc)636363-- VOC condensate density (lb/gal):8.158.158.15-- Air heat capacity (BTU/lb-mole-oF): (Cp,air)6.956.956.95DESIGN PARAMETERS:-- Outlet VOC partial pressure (mm Hg): (Pvoc)=760*(Yvoc,in*(1-n)/(1-Yvoc,in*n))5.0 102.255.4-- Condensation temperature, Tc (oF): (Tcon)=(B/(A-log10(Pvoc))-C)*1.8+32-138.7 -67.8 -85.4(oR): =Tcon+460321.3 392.2 374.6-- VOC flowrate in (lb-moles/hr): (Mvoc,in)=Qin*Yvoc,in*60/3922.930.29 15.39-- VOC flowrate out (lb-moles/hr): (Mvoc,out)=Mvoc,in*(1-n)0.1850.048 5.232-- VOC condensed (lb-moles/hr): (Mvoc,con)=Mvoc,in-Mvoc,out2.7450.245 10.156(lb/hr): (Lb/hrvoc,con)=Mwvoc*Mvoc,con171.615.3 634.7-- VOC heat of condensation @ Tc (BTU/lb-mole): (**∆**Hvoc)=(**∆**Hvoc,r)*[(1-Tcon/Tc)/(1-Tboil/Tc)]^0.3811679 10946 11135-- Enthalpy change, condensed VOC (BTU/hr): (**∆**Hcon)=Mvoc,con[**∆**Hvoc+Cp,voc(Tin-Tcon)41244 3052 130918-- Enthalpy change, uncondensed VOC (BTU/hr):(**∆**Huncon)=Mvoc,out*Cp,voc*(Tin-Tcon)61873 9186-- Enthalpy change, air (BTU/hr): (**∆**Hnoncon)=Cp,air*(Tin-Tcon)*(Qin*60/392-Mvoc,in)55128280 69622-- Condenser heat load (BTU/hr): (Hload)=**∆**Hcon+**∆**huncon+**∆**Hnoncon96990 3405 209726-- Heat transfer coefficient, U (BTU/hr-ft2-oF):Estimate from OAQPS Manual202020-- Log-mean temperature difference (oF): Tlm=(Tin-Tcon-25)/ln((Tin-Tcon-10)/15)89.950.256.1-- Condenser surface area (ft2): (Acon)=Hload/U*Tlm54.03.4 186.8-- Coolant flowrate (lb/hr):=Hload/(Cp,cool*(Tcon-15+25)-(Tcon-15))5969210 12906-- Refrigeration capacity (tons): (R)=Hload/12008.080.28 17.48-- Electricity requirement (kW/ton) [6]: (kW)=-9E-06(Tcon)^3 - 0.0004(Tcon)2 - 0.0331(Tcon) + 3.56024.456.779.07CAPITAL COSTSEquipment Costs ($):-- Refrigeration unit/single-stage (< 10 tons): (Rss<10)=exp(9.83-0.014Tcon+0.340lnR)263,481 31,2830-- Refrigeration unit/single-stage (> 10 tons): (Rss>10)=exp(9.26-0.007Tcon+0.627lnR)00 114,840-- Multistage refrigeration unit: (Mru)exp(9.73-0.012Tcon+0.584lnR)300,83118,176248,966Total equipment cost ($)--base: (ECp)=1.25*MAX(Rss<10,Rss>10,Mru)376,039 39,103 311,208Cost Indexa. 2010 CE Equip (Feb Final)CE Equipment index (Feb 2010 Final)641.1641.1 641.1b. 1990 CE Equip (Oct Final)CE Equipment index (Oct 1990 Final)394394394' ' ' ' --escalated: (ECpe)=(ECp)*(FebFinal/OctFinal)612,341 63,676 506,770Purchased Equipment Cost ($): (PECp)=ECpe*1.08661,328 68,770 547,312Total Capital Investment ($): (TCI)=PECp*1.15760,527 79,085 629,409INPUT PARAMETERS:EquationRefrigerated Condenser Package for PVC and Copolymer Process VentsCertain Teed Georgia Gulf OxyVinylsLake Charles Aberdeen PasadenaINPUT PARAMETERS:EquationANNUAL COST INPUTS:Operating factor (hr/yr): (OF)8400 8400 8400Operating labor rate ($/hr): (LR)34.60 34.60 34.60Maintenance labor rate ($/hr): (MR)38.06 38.06 38.06Operating labor factor (hr/sh): (OLF)1/2 hour per 8 hour shift0.500.500.50Maintenance labor factor (hr/sh): (MLF)1/2 hour per 8 hour shift0.500.500.50Electricity price ($/kWhr): (EP)0.0700 0.0700 0.0700Recovered VOC value ($/lb)[5]: (Rvoc)0.310.310.31Annual interest rate (fraction): (Int)0.070.070.07Control system life (years): (EL)202020Capital recovery factor: (CRF)=Int*(1+Int)^EL/((1+Int)^EL-1)0.0944 0.0944 0.0944Taxes, insurance, admin. factor: (TaxF)0.040.040.04ANNUAL COSTS:ItemCost ($/yr) Cost ($/yr) Cost ($/yr)Operating labor=OF/8*OLF*LR18,165 18,165 18,165Supervisory labor=.15*Operating Labor2,725 2,725 2,725Maintenance labor=OF/8*MLF*MR19,982 19,982 19,982Maintenance materials100% of maintenance labor19,982 19,982 19,982Electricity=EP*OF*kW*R/0.85136,724 1,329 109,649Overhead=.60*(Operating Labor+Supervisory Labor+Maint Labor+Maint Materials)36,512 36,512 36,512Taxes, insurance, administrative=TaxF*TCI30,421 3,163 25,176Capital recovery=CRF*TCI71,788 7,465 59,412Total Annual Cost (without credits) (TACwoc)=sum of all annual costs336,298 109,322 291,601Recovery 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 19902.Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2008 National Industry-Specific Occupational Employment and Wage Estimates3. Electricity cost: Energy Information Administration. Average Industrial Retail Price of Electricity: October 2009.4. Antoine constants listed in OAQPS Manual5. 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 B

Refrigerated Condenser Input CalculationsAttachment BParameterUnitsEquationCompanyCertain TeedGeorgia GulfOxyVinylsFacilityLake CharlesAberdeenPasadenaPollutant to be ReducedVC VCVCMW of Pollutant (MW)lb/lb-mol62.5 62.5 62.5T.O. Outlet Conc.(C)ppmvd@3%O25.22.01.0T.O. Outlet %O2%16.97.87.7T.O. Outlet Flow RateDSCMM33.0 10.7 15.1Pollutant Limit (L)ppmvd@3%O20.320 0.320 0.320Reduction Needed%=(C-L)/(C)*10093.9 84.0 67.1T.O. Inlet VC Conc (TOVC)ppmvd@3%O295862.4 484981.0 187913.9T.O. Inlet VC Conc%0.096 0.485 0.188T.O. Redux Eff. (TORE)%=(TOVC-C)/TOVC*10099.994599.999699.9995T.O Inlet VC Conc After Condenser (VCAC) ppmvd@3%O2 =L/(1-TORE/100)5854.2 77512.5 61906.6T.O. Inlet VC Reduction%=(TOVC-VCAC)/TOVC*10093.9 84.0 67.1T.O. Inlet Flow (TOIF)DSCMM5.70.115.1T.O. Inlet O2 Concentrations (TOO)%0.032.14.9T.O. Inlet TemperatureC64.716.318.5HCl ReductionHCl Outlet Concentrationppmvd@3%O2104.12156.78359.74HCl Outlet flow rate (HClOFR)lbs/hr =HClOC*1E(-6)*(20.9-O)/(20.9-3)*1/0.028*1/385.3*MW*R*60 0.1551 0.2476 0.8139VC Outlet flow rate (VCOFR)lbs/hr =HClOC*1E(-6)*(20.9-O)/(20.9-3)*1/0.028*1/385.3*MW*R*60 0.0134 0.0054 0.0038Inlet lbs VC before reduction (MVCBR) lbs/hr =TOVC*1E(-6)*(20.9-O)/(20.9-3)*1/0.028*1/385.3*MW*R*60219.6 19.8 882.5Inlet lbs VC after reduction (MVCAR) lbs/hr =VCAC*1E(-6)*(20.9-O)/(20.9-3)*1/0.028*1/385.3*MW*R*6013.43.2 290.7Inlets VC Reduced (MVCR)lbs/hr=MVCBR-MVCAR206.216.6591.8Outlet HCl/Inlet VC (before redux)ratio`=(HClOFR)/(VCBR)0.000706088 0.012504766 0.000922327New HCl Outletlbs/hr `=ratio*VCAR0.009470009 0.039568587 0.268142401New HCl Outlet Concppmvd@3%O21.3517162595.3267582625.19413699HCl Reducedtons/yr0.6115 0.8736 2.2923MW of HCl (MWHCl)lb/lbmols36.536.536.5Calculations and Inputs for Vinyl Chloride Reduction Refrigerated Condenser

## Attachment C

Air Compliance Advisor Program Inputs and Outputs for VGA Routed to Thermal

Oxidizer

### 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 T O Inlet Flow

Rate (DSCFM) 500 500

Stream Temperature (K) 293 293

Program Outputs



### Min % O2 Required 19.8 19.8

Op. Tem p (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 Equipm ent 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 Recov ery

- -

Total Indirect Annual Cost `=Overhead+Admin Charges $44,341 $42,704



### Recovery Credit $0 $0 

### PolyOne Equation Parameters

### Henry Pedricktown 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 equipm ent

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. Chem ical Engineering Equipm ent Cost Index

## Attachment D

Activated Carbon Injection Cost AlgorithmAttachment DActivated Carbon Injection Model CostsParameters/CostsEquationCertain Teed Lake CharlesFormosa Baton Rouge Formosa Point Comfort Georgia Gulf Plaquemine Westlake Geismar Industry TotalA. Parameters1. Annual operating hours, hr/yr (H)840084008400840084002. Exhaust gas flow rate, dscfm (Q)12134150264611869229683. Operating labor rate, $/hr (LR)$34.60$34.60$34.60$34.60$34.604. Activated carbon cost, $/lb (ACC)$1.38$1.38$1.38$1.38$1.385. Dust disposal cost, $/ton (DDC)$34.29$34.29$34.29$34.29$34.296. Capital recovery factor, 20-yrequipment life, 7% interest (CRF)= [i x (1 + i)a] / [(1 + i)a- 1], where i = interest rate,a = equipment life0.094390.094390.094390.094390.094397. Cost indexa. 2010 CE Equip (Feb Final)641.1641.1641.1641.1641.1b. 1990 CE Equip (Oct Final)393.7393.7393.7393.7393.78. ACI Adjustment Factor (AF)=% Reduction required / 980.270.310.990.520.22B. Total Capital Investment1. $= 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$112,7322. $/dscfm= $ / Q$6.43$3.93$4.71$2.58$1.98C. Direct Annual Costs, $/yr1. Operating labor= (0.25 hr/8-hr shift) x H x LR$9,083$9,083$9,083$9,083$9,0832. Supervisory labor= 0.15 x (operating labor)$1,362$1,362$1,362$1,362$1,3623. Maintenance= 0.2 x TCI$1,559$3,262$2,490$6,128$9,1074. Activated carbon= 0.00127 x Q x H x ACC x AF$4,755$18,702$38,754$90,936$72,8035. Dust disposal= 0.00127 x Q x (1 ton/2,000 lb) x H x DDC x AF$59$232$481$1,130$904D. Indirect Annual Costs, $/yr1. Overhead= 0.6 x (labor + maintenance materials)$7,203$8,224$7,761$9,944$11,7312. Property taxes, insurance, andadministration= 0.04 x TCI$312$652$498$1,226$1,8213. Capital recovery= CRF x TCI$736$1,540$1,175$2,892$4,298E. Total Annual Cost1. $/yr= Direct Annual Costs + Indirect Annual Costs$25,069$43,057$61,604$122,701$111,109$363,5402. ($/yr) / dscfm= ($/yr) / Q$20.67$10.38$23.28$10.34$4.84Note:Factor of 1.27 x 10-3for activated carbon is based on injecting carbon at a rate to achieve a carbon concentration of 338mg/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 OccupationalEmployment and Wage Estimates.3. Activated carbon cost: The Innovation Group. Chemical Profiles: Carbon, Activated. 2002. Assumed 20% price increase based on onlineinformation from Norit, an activated carbon vendor.4. Dust disposal cost: NSWMA’s 2005 Tip Fee Survey.

## Attachment E

Fabric Filter Cost AlgorithmAttachment E1 - Fabric FilterFabric Filter Cost AlgorithmParameters/CostsEquationCertain Teed Lake Charles Formosa Baton Rouge Formosa Point Comfort Georgia Gulf Plaquemine Westlake Geismar Industry TotalA. Parameters1. Annual operating hours, hr/yr (H)840084008400840084002. Exhaust gas flow rate, dscfm (Q)12134150264611869229683. PM concentration, gr/dscf (PM)assumed from original costing alg.1.58E-021.58E-021.58E-021.58E-021.58E-024. Water vapor in gas from incinerator (10%by weight)a. lb/min= Q / (385 ft3/lb-mol) x (29 lb/lb-mol) xmoisture content (0.10)9.131.319.989.4173.0b. scfm= (lb/min) / (18 lb/lb-mol) x (385 ft3/lbmol)1956694261,9123,7005.Enthalpy change in quench (1800°F to300°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)395395395395395b. Water vapor from incinerator, Btu/lbwater vapor= [8.154 x (300°F - 77°F) - 9.215 x(1800°F - 77°F)] / (18 lb/lb-mol)781781781781781c. Total gas stream, Btu/yr= [(Btu/lb air) x Q / (385 ft3/lb-mol) x (29lb/lb-mol) x (60 min/hr) x H] + [(Btu/lbwater vapor) x Q x (0.00753 lb watervapor/ft3) x (60 min/hr) x H]2.18E+107.45E+104.75E+102.13E+114.12E+11d. Cooling wateri. Heat of vaporization at 77°F, Btu/lb1,0501,0501,0501,0501,050ii. Sensible heat for vapor, Btu/lb8585858585iii. Total, Btu/lb water1,1351,1351,1351,1351,1356. Cooling water evaporated, lb/yra. lb/yr= [enthalpy change (total gas stream,Btu/yr)] / [enthalpy change (coolingwater, Btu/lb)]1.92E+076.57E+074.19E+071.88E+083.63E+08b. scfm= [cooling water evaporated (lb/yr)] / (18lb/lb-mol) x (385 ft3/lb-mol) / (H * 60min/hr)8142,7861,7767,96915,4217. Actual gas flow into fabric filter, acfm (AQ) = [Q + (water vapor in gas fromincinerator, scfm) + (water vapor addedin quench, i.e., cooling waterevaporated, scfm)] x [(300°F +460°F)/528°R]3,19910,9466,97931,30860,5848. Operating labor rate, $/hr (LR)$34.60$34.60$34.60$34.60$34.609. Electricity cost, $/kWh (EC)$0.07$0.07$0.07$0.07$0.0710. Water cost, $/1,000 gal (WC)$0.20$0.20$0.20$0.20$0.2011. Compressed air cost, $/1,000 ft3(CAC)$0.24$0.24$0.24$0.24$0.2412. Dust disposal cost, $/ton (DDC)$34.29$34.29$34.29$34.29$34.2913. Capital recovery factors= [i x (1 + i)a] / [(1 + i)a- 1], where i =interest rate, a = equipment lifea. Bag CRF, 2-yr life, 7% interest0.55309 0.55309 0.553090.553090.55309b. Cage CRF, 4-yr life, 7% interest0.295230.295230.295230.295230.29523c. Equipment CRF, 20-yr life, 7% interest0.094390.094390.094390.094390.0943914. Cost indexa. 2010 CE Equip (Feb Final)641.1641.1641.1641.1641.1b. 1989 CE Equip (Oct Final)392.6392.6392.6392.6392.6B. Total Capital Investment1. $= (47.0 x Q + 306,720) x (1.4 retrofitcost factor) x (525.4/357.5)$874,964$1,295,725$1,080,270$2,401,684$3,991,764$9,644,4072. $/dscfm= $ / Q$721.42$312.24$408.28$202.34$173.79Fabric Filter Cost AlgorithmParameters/CostsEquationCertain Teed Lake Charles Formosa Baton Rouge Formosa Point Comfort Georgia Gulf Plaquemine Westlake Geismar Industry TotalC. Direct Annual Operating Costs, $/yr1. 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$70,5633. Evaporative cooler water= (0.1007 x Q + 23.1506) gal/min x (60min/hr) x H x WC$14,645$44,456$29,191$122,815$235,4754. Operating labor= (1 hr/shift) x (1 shift/8 hr) x H x LR$36,330$36,330$36,330$36,330$36,3305. Supervisory labor= 0.15 x (operating labor)$5,450$5,450$5,450$5,450$5,4506. Maintenance labor= (0.5 hr/shift) x (1 shift/8 hr) x H x (LRx 1.1)$19,982$19,982$19,982$19,982$19,9827. Maintenance materials= 0.02 x TCI$17,499$25,914$21,605$48,034$79,8358. Compressed air= AQ x (2 ft3air/1,000 ft3filtered) x (60min/hr) x H x CAC$774$2,648$1,688$7,574$14,6569. Dust disposal= (PM gr/dscf x Q x 60 min/hr x 1lb/7,000 gr) x (1 ton/2,000 lb) x H xDDC$24$81$52$231$44710. Bag replacementa. Bag cost= AQ x ($2.5/ft2) x (525.4/317.4) x (1.08taxes and freight ratio)/(3.5 ft/min G/Cratio)$4,085$13,978$8,912$39,979$77,363b. Bag replacement labor cost= AQ x (0.15 hr/bag)/(18 ft2bagarea)/(3.5 ft/min G/C ratio) x LR$264$902$575$2,579$4,991c. Bag replacement cost= Bag CRF x [(total bag cost) + (bagreplacement labor cost)]$2,405$8,230$5,247$23,539$45,54911. Cage replacementa. Number of bags= AQ/(3.5 ft/min G/C ratio)/(18 ft2bagarea)$51$174$111$497$962b. Cage replacement labor cost= bag replacement labor cost$264$902$575$2,579$4,991c. 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$5,174D. Indirect Annual Costs, $/yr1. Overhead= 0.6 x (labor + maintenance materials)$47,556$52,605$50,020$65,877$84,9582. Property taxes, insurance, andadministration= 0.04 x TCI$34,999$51,829$43,211$96,067$159,6713. Capital recovery= Equipment CRF x (TCI - bagreplacement cost - cage replacementcost)$82,338$121,442$101,418$224,228$372,006E. Total Annual Cost1. $/yr= Direct Annual Costs + Indirect AnnualCosts$267,268$383,748$324,103$689,912$1,130,097$2,795,1292. ($/yr) / dscfm= ($/yr) / Q$220.37$92.47$122.49$58.13$49.20Sources: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 Estimates3. 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 Survey7. Assumed a PM concentration of 1.58E-2 gr/dscf as a result of the ACI.Parameters/Costs Equation Certain Teed Lake Charles Formosa Baton Rouge Formosa Point Comfort Georgia Gulf Plaquemine West Lake Geismar Industry Total

A. Parameters

1. Recording l i me/carbon flow, min/4-

hr period

2. Annual operating hours, hr/yr (H) 8,400 8,400 8,400 8,400 8,400

3. Cost index

a. 2010 (CE Feb Final) 641.1 641.1 641.1 641.1 641.1

b. 1997 386.5 386.5 386.5 386.5 386.5

c. 1993 359.2 359.2 359.2 359.2 359.2

4. Operating labor wage rate, $/hr

(LR) $98.20 $98.20 $98.20 $98.20 $98.20

5. 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

B. Total Capi tal Investment, $ (TCI)

1. Planning $800 $800 $800 $800 $800

2. Select type of equipment $500 $500 $500 $500 $500

3. Provide support facilities $1,700 $1,700 $1,700 $1,700 $1,700

4. Purchased equipment cost (PEC) $14,500 $14,500 $14,500 $14,500 $14,500

5. Install and check equipment $1,200 $1,200 $1,200 $1,200 $1,200

6. Perf. spec. tests (certif.) $800 $800 $800 $800 $800

7. Prepare QA/QC plan $800 $800 $800 $800 $800

8. Total capital cost = Planning + selecting equipment + support

facilities + PEC + installation + perf. spec. tests +

QA/QC plan $ 20,300.00 $ 20,300.00 $ 20,300.00 $ 20,300.00 $ 20,300.00 $ 101,500.00

C. Annual Costs, $/yr

1. Operating labor = (5 min to record lime/carbon flow/4-hr period) x (1

hr/60 min) x H x LR

2. Main ten ance materials = 0.02 x TCI $400 $400 $400 $400 $400

3. Operation & maintenance = Day-to-day activities + annual RATA + CGA +

annual QA + O&M review and update

4. Overhead = 0.6 x (labor + maintenance materials) $200 $200 $200 $200 $200

5. Property taxes, insurance, and

administration = 0.04 x TCI $800 $800 $800 $800 $800

6. Capital recovery = CRF x TCI $1,900 $1,900 $1,900 $1,900 $1,900

7. Total annual cost = Operating labor + maintenance materials +

overhead + property taxes, insurance, and

administration + capital recovery $3,300 $3,300 $3,300 $3,300 $3,300

$16,500

Notes:

1. Monitoring costs have been rounded to the nearest $100 to be consistent with level of rounding in original costs.

Sources:

1. Hospital/Medical/Infectious Waste Incinerators (HMIWI) [EPA-HQ-OAR-2006-0534] Testing and Monitoring Options and Costs Memo (IV-B-66).

## Attachment F

Process Vent Emissions Testing and Monitoring Cost AlgorithmAttachment F - Process Vents Testing and Monitoring Cost AlgorithmProcess Vents Emission Testing CostsParameters/CostsEquationValues Testing Freq.* Annual Cost of Test Annual Cost of Initial Test TAC of TestingA. Parameters1. CE Plant Cost indexa. 2010 (Feb 10 Final CE Index)539.1b. 2009 (Annual CE Index)521.9c. 1992 (Annual CE Index)358.2B. Testing Costs, $1. Method 1 or 1AIncluded as part of M 23-$1-$-$-$2. Method 26 (HCl)= $5,000 x (539.1/358.2)$8,0001755$755$3. Method 23 (CDD/CDF)= $21,000 x (539.1/358.2) - $5,000$27,000127,000$2,549$29,549$4. Method 25A (THC)=$6,000x(539.1/521.9)$6,19816,198$585$6,783$5. Method 18 (Assumed cost equal to 0031)$10,000110,000$944$10,944$C. CRF (20 yr, 7%):(0.07*(1+0.07)^20)/((1+0.07)^20-1)0.09439D. Facility Totals1. HCl, TOH, &VC18,482$2. CDD/CDF29,549$3. Facility Total$ 51,197.7448,030$* Number of Years Between TestsNote:4. Conversation with Ray Merrill, ERG - 11/5/2010.5. Email from Peter Westlin, EPA 4/8/2011 to ERG: Method 18 Costs1. Memorandum from R. Segall, EPA/EMB, to R. Copland, EPA/SDB. October 14, 1992. Medical Waste Incinerator Study:Emission Measurement and Continuous Monitoring. (II-B-89)2. E-mail from Jason Dewees, EPA, to Peter Westlin, EPA. August 20, 2008. Monitoring Options for SNCR & Test Cost Questions.3. E-mail from Jason Dewees, EPA, to Mary Johnson, EPA. August 20, 2008. Re: Monitoring Options for SNCR & Test CostQuestions.1. Initial testing costs to be annualized over 20 years at 7% interest.2. Testing costs have been rounded to the nearest $1,000 to be consistent with level of rounding in original costs; costs alsoadjusted based on additional information from EPA.Sources:

## Attachment G

Recordkeeping and Reporting Cost AlgorithmAttachment G1 - Recordkeeping and Reporting Annual Cost SummaryYear 12,740,467$Year 22,774,693$Year 32,774,693$Total8,289,852$Year 12,434,720$Year 22,461,400$Year 32,461,400$Total7,357,520$Total Cost8,289,852$Performance Testing7,357,520$Difference932,332$Annual Difference (difference divided by 3)310,777$Annual Difference310,777$Number of Facilities17Cost per Facility18,281$Per Facility Record Keeping and Reporting Cost Less Performance Testing and MonitoringTable 1.D Calculation of Annual Recordkeeping and Reporting Costson a Per Facility BasisCaclulation of Annual Recordkeeping and Reporting Cost on a Per Facility BasisTotal Recordkeeping, Monitoring, and Reporting CostInitial / Yearly Performance Testing and Monitoring CostRecord Keeping and Reporting Cost less Performance Testing and MonitoringAttachment G2(A)(B)(C)(D) (E) (F) (G)Respondent Non-Labor Number of Hours Number of Technical Management Clerical Total Total TotalHours per Costs Occurrences Per Respondents Hours Hours Hours Labor Costs Non-Labor ResponsesOccurrence Per Per Respondent Per Year Per Year Per Year Per Year Per Year Costs Per Year(Technical Occurrence Respondent Per YearPer YearBurden Itemhours)Per Year (C=A x B)(CXD) (E x 0.05) (E x 0.1)1. ApplicationsN/A2. Surveys and StudiesN/A3. Reporting RequirementsA. Read and Understand Rule Requirements25 $10012517 425 21 43 $46,229 $1,700 0 a,bB. Required Activities1) Initial performance test, sampling, and report40 $53,139 14017 680 34 68 $73,966 $903,355 0 a2) Periodic performance test, sampling, and report15 $54,042 11517 255 13 26 $27,737 $918,716 0 f3) Establish operating parameters and monitoring plan20$012017 340 17 34 $36,983 $00 a4) Continuous parameter monitoringa) Initial capital costs (Fabric Filters)0 $17,100 105 0 0 0 $0 $85,500 0 a,db) Annualized capital and O&M costs (Fabric Filters & ACI)11 $31,700 1115 55 3 6 $5,983 $158,500 0 c,ec) Initial capital costs (PRD Electronic Monitor)0 $188,913 1017 0 0 0 $0 $3,211,521 0 a,dd) Annualized capital and O&M costs (PRD Electronic Monitor) 11 $26,897 11117 187 9 19 $20,341 $457,249 0 c,ee) Initial capital costs (PB Scrubber Monitor)0 $23,000 101 0 0 0 $0 $23,000 0 a,df) Annualized capital and O&M costs (PB Scrubber Monitor11 $5,300 1111 11 1 1 $1,197 $5,300 0 c,eC. Create InformationIncl. in 3.BD. Gather InformationIncl. in 3.EE. Report Preparation1) Initial Notification5$01517 85 4 9 $9,246 $0172) Batch precompliance report5$01517 85 4 9 $9,246 $0173) Notification of performance test with test plan10$011017 170 9 17 $18,492 $0174) Notification of compliance status20$012017 340 17 34 $36,983 $017 b5) Compliance report25$01250 0 0 0 $0$006) Notice of inspection5$01517 85 4 9 $9,246 $0177) Affirmative defense18$01180 18 12 0 $0$00 gReportingSubtotal2,718 136 272 $295,647 $2,444,820 854. Recordkeeping RequirementsA. Read InstructionsIncl. in 3.AB. Implement ActivitiesN/AC. Develop Record SystemN/AD. Record Information1) Records of process vent requirements10$01100 0 0 0 $0$002) Records of resin stripper and wastewater requirements15$01150 0 0 0 $0$003) Records of storage vessel requirements10$01100 0 0 0 $0$004) Records of equipment leak requirements25$01250 0 0 0 $0$005) Records of heat exchanger requirements10$01100 0 0 0 $0$00E. Personnel TrainingIncl. in 3.BF. Time for AuditsN/ARecordkeeping Subtotal0 0 0$0$00TOTAL:2,718 136 272 $295,647 $2,444,820 85Total Hours Labor Non-Labor TotalSummary of Respondent Burden 3,126 $295,647 $2,444,820 $2,740,467Initial Capital and Startup$3,298,721$2,444,820FOOTNOTESa One-time only costs.b Cost incurred by a facility regardless of the number of affected units at the plant.c Annual cost. Annual costs are not incurred until the second year of operation.d Based on the sum of the total capital costs for each monitoring system required for PVC facilities.e Based on the sum of the annualized capital costs for each monitoring system required for PVC facilities.fIncludes 11 months testing for wastewater and resin to cover rest of the year after the initial test.g Hours for affirmative defense are shown only for illustration and are not included in the total burden estimateAnnualized Capital/Start-up and O & Mfor Existing Sources: Polyvinyl Chloride and CopolymerManufacturing Units - Year 1Table 1 - Annual Respondent Burden and Cost of Recordkeeping and Reporting Requirements of the MACT Floor FootnotesAttachment G3(A)(B)(C)(D) (E) (F) (G)Respondent Non-Labor Number of Hours Number of Technical Management Clerical Total Total TotalHours per Costs Occurrences Per Respondents Hours Hours Hours Labor Costs Non-Labor ResponsesOccurrence PerPer Respondent Per Year Per Year Per Year Per Year Per Year Costs Per Year(Technical Occurrence Respondent Per YearPer YearBurden Itemhours)Per Year (C=A x B)(CXD) (E x 0.05) (E x 0.1)1. ApplicationsN/A2. Surveys and StudiesN/A3. Reporting RequirementsA. Read and Understand Rule Requirements25 $1001250000 $0$00 a,bB. Required Activities1) Initial performance test, sampling, and report40 $53,139 1400000 $0$00 a2) Periodic performance test, sampling, and report50 $108,750 15017 850 43 85 $92,458 $1,848,751 03) Establish operating parameters and monitoring plan20$01200000 $0$00 a4) Continuous parameter monitoringa) Initial capital costs (Fabric Filters)0$0100000 $0$00 a,db) Annualized capital and O&M costs (Fabric Filters & ACI)11 $31,700 111555 36 $5,983 $158,500 0 c,ec) Initial capital costs (PRD Electronic Monitor)0$0100000 $0$00 a,dd) Annualized capital and O&M costs (PRD Electronic Monitor) 11 $26,897 11117 187 9 19 $20,341 $457,249 0 c,ee) Initial capital costs (PB Scrubber Monitor)0$0100000 $0$00 a,df) Annualized capital and O&M costs (PB Scrubber Monitor11 $5,300111111 11 $1,197 $5,300 0 c,eC. Create InformationIncl. in 3.BD. Gather InformationIncl. in 3.EE. Report Preparation1) Initial Notification5$0150000 $0$002) Batch precompliance report5$0150000 $0$003) Notification of performance test with test plan10$01100000 $0$004) Notification of compliance status20$01200000 $0$00 b5) Compliance report25$012517 425 21 43 $46,229 $0176) Notice of inspection5$01517 85 49 $9,246 $0177) Affirmative defense18$0118018 12 0 $0$00 fReportingSubtotal1,613 81 161 $175,452 $2,469,800 344. Recordkeeping RequirementsA. Read InstructionsIncl. in 3.AB. Implement ActivitiesN/AC. Develop Record SystemN/AD. Record Information1) Records of process vent requirements10$011017 170 9 17 $18,492 $002) Records of resin stripper and wastewater requirements15$011517 255 13 26 $27,737 $003) Records of storage vessel requirements10$011017 170 9 17 $18,492 $004) Records of equipment leak requirements25$012517 425 21 43 $46,229 $005) Records of heat exchanger requirements10$011017 170 9 17 $18,492 $00E. Personnel TrainingIncl. in 3.BF. Time for AuditsN/ARecordkeeping Subtotal1190 59.5 119$129,441$0 0TOTAL:2,803 140 280 $304,893 $2,469,800 34Total Hours Labor Non-Labor TotalSummary of Respondent Burden3,223 $304,893 $2,469,800 $2,774,693Initial Capital and Startup$0$2,469,800FOOTNOTESa One-time only costs.b Cost incurred by a facility regardless of the number of affected units at the plant.c Annual cost. Annual costs are not incurred until the second year of operation.d Based on the sum of the total capital costs for each monitoring system required for PVC facilities.e Based on the sum of the annualized capital costs for each monitoring system required for PVC facilities.f Hours for affirmative defense are shown only for illustration and are not included in the total burden estimateAnnualized Capital/Start-up and O & Mfor Existing Sources: Polyvinyl Chloride and CopolymerManufacturing Units - Year 2Table 2 - Annual Respondent Burden and Cost of Recordkeeping and Reporting Requirements of the MACT Floor FootnotesAttachment G4(A)(B) (C)(D) (E) (F) (G)Respondent Non-Labor Number of Hours Number of Technical Management Clerical Total Total TotalHours per Costs Occurrences Per Respondents Hours Hours Hours Labor Costs Non-Labor ResponsesOccurrence PerPer Respondent Per Year Per Year Per Year Per Year Per Year Costs Per Year(Technical Occurrence Respondent Per YearPer YearBurden Itemhours)Per Year (C=A x B)(CXD) (E x 0.05) (E x 0.1)1. ApplicationsN/A2. Surveys and StudiesN/A3. Reporting RequirementsA. Read and Understand Rule Requirements25 $1001250 0 0 0 $0 $0 0 a,bB. Required Activities1) Initial performance test, sampling, and report40 $53,139 1400 0 0 0 $0 $0 0 a2) Periodic performance test, sampling, and report50 $108,750 15017 850 43 85 $92,458 $1,848,751 03) Establish operating parameters and monitoring plan20$01200 0 0 0 $0 $0 0 a4) Continuous parameter monitoringa) Initial capital costs (Fabric Filters)0$0100 0 0 0 $0 $0 0 a,db) Annualized capital and O&M costs (Fabric Filters & ACI) 11 $31,700 1115 55 3 6 $5,983 $158,500 0 c,ec) Initial capital costs (PRD Electronic Monitor)0$0100 0 0 0 $0 $0 0 a,dd) Annualized capital and O&M costs (PRD Electronic Monitor) 11 $26,897 11117 187 9 19 $20,341 $457,249 0 c,ee) Initial capital costs (PB Scrubber Monitor)0$0100 0 0 0 $0 $0 0 a,df) Annualized capital and O&M costs (PB Scrubber Monitor 11 $5,300 1111 11 1 1 $1,197 $5,300 0 c,eC. Create InformationIncl. in 3.BD. Gather InformationIncl. in 3.EE. Report Preparation1) Initial Notification5$0150 0 0 0 $0 $0 02) Batch precompliance report5$0150 0 0 0 $0 $0 03) Notification of performance test with test plan10$01100 0 0 0 $0 $0 04) Notification of compliance status20$01200 0 0 0 $0 $0 0 b5) Compliance report25$012517 425 21 43 $46,229 $0 176) Notice of inspection5$01517 85 4 9 $9,246 $0 177) Affirmative defense18$01180 18 12 0 $0 $0 0 fReportingSubtotal1,613 81 161 $175,452 $2,469,800 344. Recordkeeping RequirementsA. Read InstructionsIncl. in 3.AB. Implement ActivitiesN/AC. Develop Record SystemN/AD. Record Information1) Records of process vent requirements10$011017 170 9 17 $18,492 $0 02) Records of resin stripper and wastewater requirements15$011517 255 13 26 $27,737 $0 03) Records of storage vessel requirements10$011017 170 9 17 $18,492 $0 04) Records of equipment leak requirements25$012517 425 21 43 $46,229 $0 05) Records of heat exchanger requirements10$011017 170 9 17 $18,492 $0 0E. Personnel TrainingIncl. in 3.BF. Time for AuditsN/ARecordkeeping Subtotal1190 59.5 119$129,441$0 0TOTAL:2,803 140 280 $304,893 $2,469,800 34Total Hours Labor Non-Labor TotalSummary of Respondent Burden 3,223 $304,893 $2,469,800 $2,774,693Initial Capital and Startup$0$2,469,800FOOTNOTESa One-time only costs.b Cost incurred by a facility regardless of the number of affected units at the plant.c Annual cost. Annual costs are not incurred until the second year of operation.d Based on the sum of the total capital costs for each monitoring system required for PVC facilities.e Based on the sum of the annualized capital costs for each monitoring system required for PVC facilities.f Hours for affirmative defense are shown only for illustration and are not included in the total burden estimateAnnualized Capital/Start-up and O & Mfor Existing Sources: Polyvinyl Chloride and CopolymerManufacturing Units - Year 3Table 3 - Annual Respondent Burden and Cost of Recordkeeping and Reporting Requirements of the MACT Floor Footnotes

## Attachment H

Cost Algorithm for Additional Resin Stripping SteamSteam Stripper - PVC Resin - Cost Analysis - VC and TOHCompanyCertainTeedCorporationCertainTeedCorporationThe DowChemicalCompanyFormosaPlasticsCorporationUSAFormosaPlasticsCorporationUSAFormosaPlasticsCorporationUSAFormosaPlasticsCorporationUSAFormosaPlasticsCorporationUSAGeorgia GulfCorporationFacilityLake CharlesPolymerPlantLake CharlesPolymerPlantDow Midland -SARANResinsFormosaPlasticsCorporationBaton RougeDelawareCityDelawareCityPoint Comfort Point ComfortGeorgia GulfChemicalsAberdeenFacilityProcess TypeBulk BulkSuspension(A)Suspension Dispersion Dispersion SuspensionSuspension(A)Process Type StdBulkBulkSuspensionSuspensionDispersionDispersionSuspensionSuspensionSuspensionProcess Unit IDP-1P-2Vinyl TrainP-1P-1P-2P-1P-11Stripped Resin Stream IDS-6S-15S-1 (Reactor)S-4S-2, S-7S-2U-5U-6S-7Stripping TypeBatchBatchBatchContinuousBatchBatchContinuousContinuousContinuousInlet Stream Flow, liters/min29216112493562411411257225721211A. Parameters(Inputs and ExampleCalculation)1. Stripper inlet flow rate,lpm (Q)500292161124935624114112572257212112. Annual operating hours, hr/yr (H)84008400840084008400840084008400840084003. Steam to Feed Ratio, kg /l(S)0.0960.0960.0960.0960.0960.0960.0960.0960.0960.0964. Electricity use, kWhr/day (EU)2602602602602602602602602602605. Operating labor rate, $/hr (LR) [2]$34.60$34.60$34.60$34.60$34.60$34.60$34.60$34.60$34.60$34.606. Electricity cost, $/kWh (EC) [3]$0.07$0.07$0.07$0.07$0.07$0.07$0.07$0.07$0.07$0.077. Water cost, $/1,000 gal (WC) [4]$0.20$0.20$0.20$0.20$0.20$0.20$0.20$0.20$0.20$0.208. Steam cost, $/1,000 lb (SC) [4]$4.65$4.65$4.65$4.65$4.65$4.65$4.65$4.65$4.65$4.659. Capital recovery factor= [i x (1 + i)a] / [(1 + i)a- 1], where i = interest rate, a = equipment lifea. Equipment CRF, 20-yr life, 7%interest0.094390.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.0943910. Cost indexa. 2010641.1641.1641.1641.1641.1641.1641.1641.1641.1641.1b. 1989356.0356.0356.0356.0356.0356.0356.0356.0356.0356.011. VCM Concnetration, ppm [C]7.107.107.160.5967.467.40.1510.15118.7112. VCM limit, ppm [L]20.07.107.100.470.4755.0055.000.470.470.4713. VCM recovery percentage, %99.00.00.093.420.518.418.4-211.3-211.397.514. VOC recovery value, $/lb [RV]$0.313$0.313$0.313$0.313$0.313$0.313$0.313$0.313$0.313$0.313B. Total Capital Investment1. $= 0.3731 x Q^0.267 x 10^6$0$0$0$0$0$0$0$0$0$02. $ /lpm= $ / Q$0$0$0$0$0$0$0$0$0$0C. Direct Annual Operating Costs, $/yr1. Electricity= EU / (24 hr/day) x H x EC$6,079$0$0$0$0$0$0$0$0$02. Steam= Q x S x (2.2 lb/kg) x (60 min/hr) x H x SC / 1000$247,484$144,714$79,615$618,307$1,763,113$203,432$203,432$1,273,059$1,273,059$599,5713. Water= Q x (5220 liters water-min / liters feed-day) x (1 day / 24 hr) x H x (0.264gal/liter) x WC / 1000$0$0$0$0$0$0$0$0$0$0EquationParameters/Costsgal/liter) x WC / 10004. Operating labor= (1 hr/shift) x (1 shift/8 hr) x H x LR$36,330$0$0$0$0$0$0$0$0$05. Supervisory labor= 0.15 x (operating labor)$5,450$0$0$0$0$0$0$0$0$06. Maintenance labor= (0.5 hr/shift) x (1 shift/8 hr) x H x (LR x 1.1)$19,982$0$0$0$0$0$0$0$0$07. Maintenance materials= 0.02 x TCI$0$0$0$0$0$0$0$0$0$0D. Indirect Annual Costs, $/yr1. Overhead= 0.6 x (labor + maintenance materials)$37,057$0$0$0$0$0$0$0$0$02. Property taxes, insurance, andadministration= 0.04 x TCI$0$0$0$0$0$0$0$0$0$03. Capital recovery= Equipment CRF x TCI$0$0$0$0$0$0$0$0$0$0E. Recovery Credit, $/yra. Recovered vinyl chloride, kg/yr [VCR]= C x 10^-6 x Q x (1 kg/l) x (60 min/hr) x H x RP0.000.000.004211.96217.232568.592568.59(413.52)(413.52)11135.72b. Value of recovered vinyl chloride, $/yr= VCR x (2.2 lb/kg) x RV$0$0$0$2,900$150$1,769$1,769($285)($285)$7,668F. Include in Annual Cost?NoNoYesYesYesYesNoNoYesF. Total Annual Cost1. $/yr= Direct Annual Costs + Indirect Annual Costs - Recovery Credit$352,38100$615,407$1,762,963$201,663$201,66300$591,9032. ($/yr) /lpm= ($/yr) / Q$705$493$495$491$491$489Sources:1. Cost equations: HON BID, Vol 1-b and 1-c, Nov 1992 (EPA-453/D-92-016c)2. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2008 National Industry-Specific Occupational Employment and Wage Estimates3. Electricity cost: Energy Information Administration. Average Industrial Retail Price of Electricity: October 2009.4. Water cost and steam cost: Air Compliance Advisor,version 7.5.5. ICIS, http://www.icis.com/v2/chemicals/9076567/vinyl-chloride/pricing.html, October 20, 2010. (Avg. $690/tonne = $0.313/lb)Steam Stripper - PVC Resin - Cost Analysis - VC and TOHCompanyFacilityProcess TypeProcess Type StdProcess Unit IDStripped Resin Stream IDStripping TypeInlet Stream Flow, liters/minA. Parameters(Inputs and ExampleCalculation)1. Stripper inlet flow rate,lpm (Q)5002. Annual operating hours, hr/yr (H)84003. Steam to Feed Ratio, kg /l(S)0.0964. Electricity use, kWhr/day (EU)2605. Operating labor rate, $/hr (LR) [2]$34.606. Electricity cost, $/kWh (EC) [3]$0.077. Water cost, $/1,000 gal (WC) [4]$0.208. Steam cost, $/1,000 lb (SC) [4]$4.659. Capital recovery factor= [i x (1 + i)a] / [(1 + i)a- 1], where i = interest rate, a = equipment lifea. Equipment CRF, 20-yr life, 7%interest0.0943910. Cost indexa. 2010641.1b. 1989356.011. VCM Concnetration, ppm [C]12. VCM limit, ppm [L]20.013. VCM recovery percentage, %99.014. VOC recovery value, $/lb [RV]$0.313B. Total Capital Investment1. $= 0.3731 x Q^0.267 x 10^6$02. $ /lpm= $ / Q$0C. Direct Annual Operating Costs, $/yr1. Electricity= EU / (24 hr/day) x H x EC$6,0792. Steam= Q x S x (2.2 lb/kg) x (60 min/hr) x H x SC / 1000$247,4843. Water= Q x (5220 liters water-min / liters feed-day) x (1 day / 24 hr) x H x (0.264gal/liter) x WC / 1000$0EquationParameters/CostsGeorgia GulfCorporationOxyVinyls, LP OxyVinyls, LP OxyVinyls, LP OxyVinyls, LP OxyVinyls, LP OxyVinyls, LP OxyVinyls, LP OxyVinyls, LPGeorgia GulfChemicalsPlaquemineFacilityOxyVinylsDeer ParkOxyVinylsDeer ParkOxyVinylsDeer ParkOxyVinylsPasadenaOxyVinylsPasadenaOxyVinylsPasadenaOxyVinylsPasadenaOxyVinylsPasadenaSuspension(A)Suspension Suspension Suspension Suspension Suspension Suspension Suspension SuspensionSuspensionSuspensionSuspensionSuspensionSuspensionSuspensionSuspensionSuspensionSuspensionP-1P-1P-1P-2P-3P-4P-5P-6P-7S-1S-146S-149S-245S-308S-408S-508S-508S-508ContinuousContinuousContinuousContinuous58676445301003891978661991996586764453010038919786619919968400840084008400840084008400840084000.0960.0960.0960.0960.0960.0960.0960.0960.096260260260260260260260260260$34.60$34.60$34.60$34.60$34.60$34.60$34.60$34.60$34.60$0.07$0.07$0.07$0.07$0.07$0.07$0.07$0.07$0.07$0.20$0.20$0.20$0.20$0.20$0.20$0.20$0.20$0.20$4.65$4.65$4.65$4.65$4.65$4.65$4.65$4.65$4.650.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439641.1641.1641.1641.1641.1641.1641.1641.1641.1356.0356.0356.0356.0356.0356.0356.0356.0356.021.390.200.200.202.832.832.832.832.830.470.470.470.470.470.470.470.470.4797.8-136.2-136.2-136.283.483.483.483.483.4$0.313$0.313$0.313$0.313$0.313$0.313$0.313$0.313$0.313$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$2,904,171$318,522$262,312$496,520$441,119$484,249$326,962$490,480$492,888$0$0$0$0$0$0$0$0$0gal/liter) x WC / 10004. Operating labor= (1 hr/shift) x (1 shift/8 hr) x H x LR$36,3305. Supervisory labor= 0.15 x (operating labor)$5,4506. Maintenance labor= (0.5 hr/shift) x (1 shift/8 hr) x H x (LR x 1.1)$19,9827. Maintenance materials= 0.02 x TCI$0D. Indirect Annual Costs, $/yr1. Overhead= 0.6 x (labor + maintenance materials)$37,0572. Property taxes, insurance, andadministration= 0.04 x TCI$03. Capital recovery= Equipment CRF x TCI$0E. Recovery Credit, $/yra. Recovered vinyl chloride, kg/yr [VCR]= C x 10^-6 x Q x (1 kg/l) x (60 min/hr) x H x RP0.00b. Value of recovered vinyl chloride, $/yr= VCR x (2.2 lb/kg) x RV$0F. Include in Annual Cost?F. Total Annual Cost1. $/yr= Direct Annual Costs + Indirect Annual Costs - Recovery Credit$352,3812. ($/yr) /lpm= ($/yr) / Q$705Sources:1. Cost equations: HON BID, Vol 1-b and 1-c, Nov 1992 (EPA-453/D-92-016c)2. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2008 National Industry-Specific Occupational Employment and Wage Estimates3. Electricity cost: Energy Information Administration. Average Industrial Retail Price of Electricity: October 2009.4. Water cost and steam cost: Air Compliance Advisor,version 7.5.5. ICIS, http://www.icis.com/v2/chemicals/9076567/vinyl-chloride/pricing.html, October 20, 2010. (Avg. $690/tonne = $0.313/lb)$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$061863.86(87.89)(72.38)(137.01)1060.481164.18786.041179.151184.94$42,599($61)($50)($94)$730$802$541$812$816YesNoNoNoYesYesYesYesYes$2,861,572000$440,388$483,448$326,420$489,668$492,072$488$494$494$494$494$494Steam Stripper - PVC Resin - Cost Analysis - VC and TOHCompanyFacilityProcess TypeProcess Type StdProcess Unit IDStripped Resin Stream IDStripping TypeInlet Stream Flow, liters/minA. Parameters(Inputs and ExampleCalculation)1. Stripper inlet flow rate,lpm (Q)5002. Annual operating hours, hr/yr (H)84003. Steam to Feed Ratio, kg /l(S)0.0964. Electricity use, kWhr/day (EU)2605. Operating labor rate, $/hr (LR) [2]$34.606. Electricity cost, $/kWh (EC) [3]$0.077. Water cost, $/1,000 gal (WC) [4]$0.208. Steam cost, $/1,000 lb (SC) [4]$4.659. Capital recovery factor= [i x (1 + i)a] / [(1 + i)a- 1], where i = interest rate, a = equipment lifea. Equipment CRF, 20-yr life, 7%interest0.0943910. Cost indexa. 2010641.1b. 1989356.011. VCM Concnetration, ppm [C]12. VCM limit, ppm [L]20.013. VCM recovery percentage, %99.014. VOC recovery value, $/lb [RV]$0.313B. Total Capital Investment1. $= 0.3731 x Q^0.267 x 10^6$02. $ /lpm= $ / Q$0C. Direct Annual Operating Costs, $/yr1. Electricity= EU / (24 hr/day) x H x EC$6,0792. Steam= Q x S x (2.2 lb/kg) x (60 min/hr) x H x SC / 1000$247,4843. Water= Q x (5220 liters water-min / liters feed-day) x (1 day / 24 hr) x H x (0.264gal/liter) x WC / 1000$0EquationParameters/CostsOxyVinyls, LP OxyVinyls, LP OxyVinyls, LPPolyOneCorporationPolyOneCorporationPolyOneCorporationPolyOneCorporationPolyOneCorporationPolyOneCorporationOxyVinylsPasadenaOxyVinylsPedricktownOxyVinylsPedricktownPolyOneHenryPolyOneHenryPolyOneHenryPolyOneHenryPolyOneHenryPolyOnePedricktownSuspension Suspension Suspension Dispersion Dispersion Dispersion Suspension Suspension DispersionSuspensionSuspensionSuspensionDispersionDispersionDispersionDispersionDispersionDispersionP-8P-1P-2P-1P-2P-3P-4P-5P-1S-508S-109S-209S-1S-2S-1S-3S-4S-1ContinuousContinuousBatchBatchBatchContinuousContinuousContinuous115156056055118251068132211515605605511825106813228400840084008400840084008400840084000.0960.0960.0960.0960.0960.0960.0960.0960.096260260260260260260260260260$34.60$34.60$34.60$34.60$34.60$34.60$34.60$34.60$34.60$0.07$0.07$0.07$0.07$0.07$0.07$0.07$0.07$0.07$0.20$0.20$0.20$0.20$0.20$0.20$0.20$0.20$0.20$4.65$4.65$4.65$4.65$4.65$4.65$4.65$4.65$4.650.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439641.1641.1641.1641.1641.1641.1641.1641.1641.1356.0356.0356.0356.0356.0356.0356.0356.0356.02.832.522.5242.8042.8042.8042.8042.8028.500.470.470.4755.0055.0055.0055.0055.0055.0083.481.381.3-28.5-28.5-28.5-28.5-28.5-93.0$0.313$0.313$0.313$0.313$0.313$0.313$0.313$0.313$0.313$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$569,568$277,302$277,302$27,009$58,174$12,466$52,462$40,097$159,261$0$0$0$0$0$0$0$0$0gal/liter) x WC / 10004. Operating labor= (1 hr/shift) x (1 shift/8 hr) x H x LR$36,3305. Supervisory labor= 0.15 x (operating labor)$5,4506. Maintenance labor= (0.5 hr/shift) x (1 shift/8 hr) x H x (LR x 1.1)$19,9827. Maintenance materials= 0.02 x TCI$0D. Indirect Annual Costs, $/yr1. Overhead= 0.6 x (labor + maintenance materials)$37,0572. Property taxes, insurance, andadministration= 0.04 x TCI$03. Capital recovery= Equipment CRF x TCI$0E. Recovery Credit, $/yra. Recovered vinyl chloride, kg/yr [VCR]= C x 10^-6 x Q x (1 kg/l) x (60 min/hr) x H x RP0.00b. Value of recovered vinyl chloride, $/yr= VCR x (2.2 lb/kg) x RV$0F. Include in Annual Cost?F. Total Annual Cost1. $/yr= Direct Annual Costs + Indirect Annual Costs - Recovery Credit$352,3812. ($/yr) /lpm= ($/yr) / Q$705Sources:1. Cost equations: HON BID, Vol 1-b and 1-c, Nov 1992 (EPA-453/D-92-016c)2. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2008 National Industry-Specific Occupational Employment and Wage Estimates3. Electricity cost: Energy Information Administration. Average Industrial Retail Price of Electricity: October 2009.4. Water cost and steam cost: Air Compliance Advisor,version 7.5.5. ICIS, http://www.icis.com/v2/chemicals/9076567/vinyl-chloride/pricing.html, October 20, 2010. (Avg. $690/tonne = $0.313/lb)$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$01369.29577.71577.71(335.53)(722.67)(154.86)(651.72)(498.11)(4297.43)$943$398$398($231)($498)($107)($449)($343)($2,959)YesYesYesNoNoNoNoNoNo$568,625$276,904$276,904000000$494$494$494Steam Stripper - PVC Resin - Cost Analysis - VC and TOHCompanyFacilityProcess TypeProcess Type StdProcess Unit IDStripped Resin Stream IDStripping TypeInlet Stream Flow, liters/minA. Parameters(Inputs and ExampleCalculation)1. Stripper inlet flow rate,lpm (Q)5002. Annual operating hours, hr/yr (H)84003. Steam to Feed Ratio, kg /l(S)0.0964. Electricity use, kWhr/day (EU)2605. Operating labor rate, $/hr (LR) [2]$34.606. Electricity cost, $/kWh (EC) [3]$0.077. Water cost, $/1,000 gal (WC) [4]$0.208. Steam cost, $/1,000 lb (SC) [4]$4.659. Capital recovery factor= [i x (1 + i)a] / [(1 + i)a- 1], where i = interest rate, a = equipment lifea. Equipment CRF, 20-yr life, 7%interest0.0943910. Cost indexa. 2010641.1b. 1989356.011. VCM Concnetration, ppm [C]12. VCM limit, ppm [L]20.013. VCM recovery percentage, %99.014. VOC recovery value, $/lb [RV]$0.313B. Total Capital Investment1. $= 0.3731 x Q^0.267 x 10^6$02. $ /lpm= $ / Q$0C. Direct Annual Operating Costs, $/yr1. Electricity= EU / (24 hr/day) x H x EC$6,0792. Steam= Q x S x (2.2 lb/kg) x (60 min/hr) x H x SC / 1000$247,4843. Water= Q x (5220 liters water-min / liters feed-day) x (1 day / 24 hr) x H x (0.264gal/liter) x WC / 1000$0EquationParameters/CostsPolyOneCorporationShintech, Inc.CorporateOfficeShintech, Inc.CorporateOfficeShintech, Inc.CorporateOfficeShintech, Inc.CorporateOfficeShintech, Inc.CorporateOfficeWestlakeChemicalCorporationWestlakeChemicalCorporationWestlakeChemicalCorporationPolyOnePedricktownShintechAddisShintechAddisShintechFreeportShintechFreeportShintechPlaquemineWestlakeCalvert CityWestlakeCalvert CityWestlakeGeismarDispersionSuspension(A)Suspension(A)Suspension(A)Suspension(A)Suspension(A)Suspension Suspension SuspensionDispersionSuspensionSuspensionSuspensionSuspensionSuspensionSuspensionSuspensionSuspensionP-1P-1P-1P-1P-1P-1P-1P-1P-1S-2S-1AS-1BS-1aS-1bS-1S-1S-2S-1ContinuousContinuousContinuousContinuousContinuousContinuousContinuous303145414546447951476646775193030314541454644795147664677519308400840084008400840084008400840084000.0960.0960.0960.0960.0960.0960.0960.0960.096260260260260260260260260260$34.60$34.60$34.60$34.60$34.60$34.60$34.60$34.60$34.60$0.07$0.07$0.07$0.07$0.07$0.07$0.07$0.07$0.07$0.20$0.20$0.20$0.20$0.20$0.20$0.20$0.20$0.20$4.65$4.65$4.65$4.65$4.65$4.65$4.65$4.65$4.650.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439641.1641.1641.1641.1641.1641.1641.1641.1641.1356.0356.0356.0356.0356.0356.0356.0356.0356.028.500.580.580.770.770.5429.3829.388.2655.000.470.470.470.470.470.470.470.47-93.018.818.839.139.113.098.498.494.3$0.313$0.313$0.313$0.313$0.313$0.313$0.313$0.313$0.313$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$149,893$719,485$719,485$318,522$393,468$730,727$319,848$383,819$955,190$0$0$0$0$0$0$0$0$0gal/liter) x WC / 10004. Operating labor= (1 hr/shift) x (1 shift/8 hr) x H x LR$36,3305. Supervisory labor= 0.15 x (operating labor)$5,4506. Maintenance labor= (0.5 hr/shift) x (1 shift/8 hr) x H x (LR x 1.1)$19,9827. Maintenance materials= 0.02 x TCI$0D. Indirect Annual Costs, $/yr1. Overhead= 0.6 x (labor + maintenance materials)$37,0572. Property taxes, insurance, andadministration= 0.04 x TCI$03. Capital recovery= Equipment CRF x TCI$0E. Recovery Credit, $/yra. Recovered vinyl chloride, kg/yr [VCR]= C x 10^-6 x Q x (1 kg/l) x (60 min/hr) x H x RP0.00b. Value of recovered vinyl chloride, $/yr= VCR x (2.2 lb/kg) x RV$0F. Include in Annual Cost?F. Total Annual Cost1. $/yr= Direct Annual Costs + Indirect Annual Costs - Recovery Credit$352,3812. ($/yr) /lpm= ($/yr) / Q$705Sources:1. Cost equations: HON BID, Vol 1-b and 1-c, Nov 1992 (EPA-453/D-92-016c)2. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2008 National Industry-Specific Occupational Employment and Wage Estimates3. Electricity cost: Energy Information Administration. Average Industrial Retail Price of Electricity: October 2009.4. Water cost and steam cost: Air Compliance Advisor,version 7.5.5. ICIS, http://www.icis.com/v2/chemicals/9076567/vinyl-chloride/pricing.html, October 20, 2010. (Avg. $690/tonne = $0.313/lb)$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0(4044.64)79.8579.8597.95121.0052.089414.5411297.517580.60($2,785)$55$55$67$83$36$6,483$7,779$5,220NoYesYesYesYesYesYesYesYes0$719,430$719,430$318,455$393,385$730,691$313,365$376,040$949,970$495$495$495$495$495$485$485$492

## Attachment I

Resin Testing and Monitoring Cost Algorithm

### Resin Sampling and Monitoring



### Low High Average

Cost of US EPA Method 8260B [1] 

### $201 $400 $301

Initial Compliance



### 3 inlet tests $9 0 1.50

3 outlet tests $901.50

Total Compliance Cost 

### $1,803.00

CR F (20 yr, 7%): (0.07*(1+ 0.07)^20)/((1+0.07)^20-1) 0.09439



### Annual Cost of Initial Compliance `= (3 inlet tests*Avg Cost + 3 outlet test*Avg Cost)*CRF $170.19

Monitoring



### 1 test per month for each type of resin $3 0 0.50

Certain Teed Lake Charles B 1 $3,776.19

Formosa Baton Rouge S 1 $3,776.19

Formosa Delaware D 1 $3,776.19

Formosa Point Comfort S 1 $3,776.19

Georgia Gulf Aberdeen S 1 $3,776.19

Georgia Gulf Plaquemine S 1 $3,776.19

OxyVinyls Deer Park S 1 $3,776.19

OxyVinyls Pasadena S 1 $3,776.19

OxyVinyls Pedricktown S 1 $3,776.19

PolyOne Henry S/D 2 $7,382.19

PolyOne Pedricktown D 1 $3,776.19

Shintech Addis S 1 $3,776.19

Shintech Freeport S 1 $3,776.19

Shintech Plaquemine S 1 $3,776.19

Dow Midland S 1 $3,776.19

Westlake Calvert City S 1 $3,776.19

Westlake Geismar S 1 $3,776.19 

### TAC of

Re s in

Testing 

### Company Lo c ation Resin Type Number of

Resin Types

1. National Environmental Methods Index Website

https://www.nemi.gov/apex/f?p=237:38:951365369293524::::P38_METHOD_ID:7041

## Attachment J

Heat Exchange System Cost AnalysisSummary of Testing and Monitoring Costs for Heat Exchange SystemsCompanyName FacilityNameNumof CTsCT IDSampling andAnalysis, $/yrtowerCosts toRepair,$/event-towerRepairs,event/yrSampling andAnalysis, $/yrCosts toRepair, $/yearTotal AnnualCosts, $/yrCertainTeedLake Charles1U-13$7,600$4,3001$7,600$4,300$11,900CertainTeedLake Charles1U-19$7,600$4,3001$7,600$4,300$11,900FormosaBaton Rouge1U-10$7,600$4,3001$7,600$4,300$11,900FormosaDelaware City1U-14$7,600$4,3001$7,600$4,300$11,900FormosaDelaware City1U-73$7,600$4,3001$7,600$4,300$11,900FormosaPoint Comfort - PVC1U-24$7,600$4,3001$7,600$4,300$11,900Georgia GulfAberdeen1U-66$7,600$4,3001$7,600$4,300$11,900Georgia GulfAberdeen1U-67$7,600$4,3001$7,600$4,300$11,900Georgia GulfAberdeen1U-68$7,600$4,3001$7,600$4,300$11,900Georgia GulfAberdeen1U-69$7,600$4,3001$7,600$4,300$11,900Georgia GulfPlaquemine1unknown - assume 2 CTs$7,600$4,3001$7,600$4,300$11,900Georgia GulfPlaquemine1unknown - assume 2 CTs$7,600$4,3001$7,600$4,300$11,900OxyVinylsDeer Park1unknown - assume 3 CTs$7,600$4,3001$7,600$4,300$11,900OxyVinylsDeer Park1unknown - assume 3 CTs$7,600$4,3001$7,600$4,300$11,900OxyVinylsDeer Park1unknown - assume 3 CTs$7,600$4,3001$7,600$4,300$11,900OxyVinylsPasadena1U-1103$7,600$4,3001$7,600$4,300$11,900OxyVinylsPasadena1U-1104$7,600$4,3001$7,600$4,300$11,900OxyVinylsPedricktown1U-600$7,600$4,3001$7,600$4,300$11,900PolyOneHenry1U-1$7,600$4,3001$7,600$4,300$11,900PolyOnePedricktwon1U-18$7,600$4,3001$7,600$4,300$11,900ShintechAddis1U-62$7,600$4,3001$7,600$4,300$11,900ShintechFreeport1U-45$7,600$4,3001$7,600$4,300$11,900ShintechPlaquemine1U-58$7,600$4,3001$7,600$4,300$11,900DowMidland1CTW-1$7,600$4,3001$7,600$4,300$11,900Midland$11,900WestlakeCalvert City1U-89$7,600$4,3001$7,600$4,300$11,900WestlakeGeismar1U-40$7,600$4,3001$7,600$4,300$11,900Bulk$0-$-$Dispersion$30,40017,200.00$47,600.00$Other159,600.00$90,300.00$249,900.00$TOTAL$190,000$107,500$297,500* PolyOne - Henry included in "Dispersion" category

## Attachment K

Equipment Leak Testing and Monitoring Cost AlgorithmAttachment K - Equipment LeaksCompany FacilityLDARProgramType (bySurvey)FacilityReported LDARCost ($)2006Capacity1,000 USTonsFacility LDARCost$/1,000TonFacility LDARCost by UsingAverage Cost of40CFR61V x 2006Facility LDAR Costby Using AverageCost of40CFR63UU x 2006Increase inLDAR Costfrom V to UUPRV CostReduction TAC[1]PRV CostReduction TCI[1]TCI perFacility ($)TAC perFacility($/year)Certain TeedLake Charles40CFR61 V$26,000 240.3 108$$55,860$64,595 $8,73616,105$113,116$113,116$$24,841Formosa Baton Rouge40CFR61 V- 458.6-$106,595$123,265 $16,67026,897$188,913$188,913$$43,567FormosaDelaware City40CFR63 UU$20,000 71.7 279$$16,655$19,260$026,897$188,913$188,913$$26,897FormosaPoint Comfort40CFR61 V$43,675 782.6 56$ $181,929$210,380 $28,45126,897$188,913$188,913$$55,348Georgia Gulf Aberdeen40CFR61 V- 500.4-$116,332$134,524 $18,19326,897$188,913$188,913$$45,090Georgia Gulf Plaquemine40CFR63 UU$155,000 599.7258$$139,393$161,192$026,897$188,913$188,913$$26,897OxyVinyls Deer Park40CFR61 V$29,094 275.6106$$64,059$74,077 $10,01826,897$188,913$188,913$$36,915OxyVinyls Pasadena40CFR61 V$85,277 1050.581$$244,194$282,383 $38,18926,897$188,913$188,913$$65,086OxyVinyls Pedricktown40CFR61 V$16,000 175.391$$40,742$47,113 $6,37126,897$188,913$188,913$$33,268PolyOne Henry40CFR61 V$2,160 62.834$$14,606$16,890 $2,28426,897$188,913$188,913$$29,181PolyOne Pedricktown40CFR61 V$20,000 65.0308$$15,118$17,482 $2,36426,897$188,913$188,913$$29,261Shintech Addis40CFR61 V$14,000 312.045$$72,515$83,856 $11,34026,897$188,913$188,913$$38,237Shintech Freeport40CFR63 UU- 1598.3-$371,544$429,649$026,897$188,913$188,913$$26,897Shintech Plaquemine40CFR61 V$17,000 650.426$$151,180$174,823 $23,64226,897$188,913$188,913$$50,539DowMidland240CFR61 V$20,000 10.8 1,852$$2,511$2,903$39326,897$188,913$188,913$$27,290Westlake Calvert City40CFR61 V$10,000 400.125$$93,014$107,560 $14,54626,897$188,913$188,913$$41,443Westlake Geismar40CFR61 V$16,525 286.658$$66,622$77,040 $10,41926,897$188,913$188,913$$37,316Total446,457$3,135,724$3,135,724$638,073$[1] EPA supplied cost factors from "PVC_PRV_Cost_reductions_110310" option 4, average facility40CFR61 V232.5[2] Non CBI production data - Capacity information not available40CFR63UU268.8Average $/KTon

## Attachment L

Wastewater Compliance Cost AlgorithmAttachment L - Process Wastewater Compliance Cost AlgorithmSteam Stripper - PVC Resin - Cost Analysis - VC and TOHCompanyCertain Teed Lake CharlesDow MidlandFormosa Baton RougeFormosa DelawareFormosa Point ComfortOxyVinyls Deer ParkProcess TypeBulkOtherOtherDispersionOtherOtherProcess Type StdBulkInlet Stream Flow, gal/yr3600677273.0019137030404493214.09149079723.1417281592.66Inlet Stream Flow, liters/min0.0270395.086859102.92073833.747615368.627789129.798517A. Parameters(Inputs and ExampleCalculation)1. Stripper inlet flow rate,lpm (Q)5000.0275.087102.92133.748368.628129.7992. Annual operating hours, hr/yr (H)84008400840084008400840084003. Steam to Feed Ratio, kg /l(S)0.0960.0960.0960.0960.0960.0960.0964. Electricity use, kWhr/day (EU)2602602602602602602605. Operating labor rate, $/hr (LR) [2]$34.60$34.60$34.60$34.60$34.60$34.60$34.606. Electricity cost, $/kWh (EC) [3]$0.07$0.07$0.07$0.07$0.07$0.07$0.077. Water cost, $/1,000 gal (WC) [4]$0.20$0.20$0.20$0.20$0.20$0.20$0.208. Steam cost, $/1,000 lb (SC) [4]$4.65$4.65$4.65$4.65$4.65$4.65$4.659. Capital recovery factor= [i x (1 + i)a] / [(1 + i)a- 1], where i =interest rate, a = equipment lifea. Equipment CRF, 20-yr life, 7%interest0.094390.09439 0.094390.094390.094390.094390.0943910. Cost indexa. 2010641.1641.1641.1641.1641.1641.1641.1b. 1989356.0356.0356.0356.0356.0356.0356.011. VCM Concnetration, ppm [C]0.400.540.140.540.540.0712. VCM limit, ppm [L]20.00.110.110.110.110.110.1113. VCM recovery percentage, %99.072.579.621.479.679.6-69.214. VOC recovery value, $/lb [RV]$0.313$0.313$0.313$0.313$0.313$0.313$0.313B. Total Capital Investment1. $= 0.3731 x Q^0.267 x 10^6$0$0$1$2$3$4$52. $ /lpm= $ / Q$0$0$0$0$0$0$0C. Direct Annual Operating Costs, $/yr1. Electricity= EU / (24 hr/day) x H x EC$6,079$0$1$2$3$4$52. Steam= Q x S x (2.2 lb/kg) x (60 min/hr) x H xSC / 1000$247,484$13 $2,518$50,943$16,704$182,459$64,2463. Water= Q x (5220 liters water-min / liters feedday) x (1 day / 24 hr) x H x (0.264gal/liter) x WC / 1000$0$0$0$0$0$0$04. Operating labor= (1 hr/shift) x (1 shift/8 hr) x H x LR$36,330$0$0$0$0$0$05. Supervisory labor= 0.15 x (operating labor)$5,450$0$0$0$0$0$06. Maintenance labor= (0.5 hr/shift) x (1 shift/8 hr) x H x (LR x$19,982$0$0$0$0$0$07. Maintenance materials= 0.02 x TCI$0$0$0$0$0$0$0D. Indirect Annual Costs, $/yr1. Overhead= 0.6 x (labor + maintenance materials)$37,057$0$0$0$0$0$02. Property taxes, insurance, and= 0.04 x TCI$0$0$0$0$0$0$0EquationParameters/Costs2. Property taxes, insurance, andadministration= 0.04 x TCI$0$0$0$0$0$0$03. Capital recovery= Equipment CRF x TCI$0$0$0$0$0$0$0E. Recovery Credit, $/yra. Recovered vinyl chloride, kg/yr [VCR]= C x 10^-6 x Q x (1 kg/l) x (60 min/hr) xH x RP0.000.001.101.567.2979.65(2.94)b. Value of recovered vinyl chloride, $/yr= VCR x (2.2 lb/kg) x RV$0$0$1$1$5$55($2)F. Include in Annual Cost?YesYesYesYesYesNoF. Total Annual Cost1. $/yr= Direct Annual Costs + Indirect AnnualCosts - Recovery Credit$352,381$13 $2,518$50,944$16,702$182,409 02.($/yr) /lpm= ($/yr) / Q$705$495$495$495$495$495Sources:1. Cost equations: HON BID, Vol 1-b and 1-c, Nov 1992 (EPA-453/D-92-016c)2. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2008National Industry-Specific Occupational Employment and Wage Estimates3. Electricity cost: Energy Information Administration. Average Industrial Retail Price ofElectricity: October 2009.4. Water cost and steam cost: Air Compliance Advisor,version 7.5.5. ICIS, http://www.icis.com/v2/chemicals/9076567/vinyl-chloride/pricing.html, October 20, 2010.(Avg. $690/tonne = $0.313/lb)Attachment L - Process Wastewater Compliance Cost AlgorithmSteam Stripper - PVC Resin - Cost Analysis - VC and TOHCompanyProcess TypeProcess Type StdInlet Stream Flow, gal/yrInlet Stream Flow, liters/minA. Parameters(Inputs and ExampleCalculation)1. Stripper inlet flow rate,lpm (Q)5002. Annual operating hours, hr/yr (H)84003. Steam to Feed Ratio, kg /l(S)0.0964. Electricity use, kWhr/day (EU)2605. Operating labor rate, $/hr (LR) [2]$34.606. Electricity cost, $/kWh (EC) [3]$0.077. Water cost, $/1,000 gal (WC) [4]$0.208. Steam cost, $/1,000 lb (SC) [4]$4.659. Capital recovery factor= [i x (1 + i)a] / [(1 + i)a- 1], where i =interest rate, a = equipment lifea. Equipment CRF, 20-yr life, 7%interest0.0943910. Cost indexa. 2010641.1b. 1989356.011. VCM Concnetration, ppm [C]12. VCM limit, ppm [L]20.013. VCM recovery percentage, %99.014. VOC recovery value, $/lb [RV]$0.313B. Total Capital Investment1. $= 0.3731 x Q^0.267 x 10^6$02. $ /lpm= $ / Q$0C. Direct Annual Operating Costs, $/yr1. Electricity= EU / (24 hr/day) x H x EC$6,0792. Steam= Q x S x (2.2 lb/kg) x (60 min/hr) x H xSC / 1000$247,4843. Water= Q x (5220 liters water-min / liters feedday) x (1 day / 24 hr) x H x (0.264gal/liter) x WC / 1000$04. Operating labor= (1 hr/shift) x (1 shift/8 hr) x H x LR$36,3305. Supervisory labor= 0.15 x (operating labor)$5,4506. Maintenance labor= (0.5 hr/shift) x (1 shift/8 hr) x H x (LR x$19,9827. Maintenance materials= 0.02 x TCI$0D. Indirect Annual Costs, $/yr1. Overhead= 0.6 x (labor + maintenance materials)$37,0572. Property taxes, insurance, and= 0.04 x TCI$0EquationParameters/CostsOxyVinyls Pasadena OxyVinyls Pedricktown PolyOne Henry PolyOne Pedricktown Shintech Addis Shintech FreeportOther OtherOther/Dispersion DispersionOtherOther6400000010991092.9349536002471011483920027000000480.69094582.55185737.2054791.855925111.454204202.791492480.69182.55237.2051.856111.454202.7918400840084008400840084000.0960.0960.0960.0960.0960.096260260260260260260$34.60$34.60$34.60$34.60$34.60$34.60$0.07$0.07$0.07$0.07$0.07$0.07$0.20$0.20$0.20$0.20$0.20$0.20$4.65$4.65$4.65$4.65$4.65$4.650.094390.094390.094390.09439 0.094390.09439641.1641.1641.1641.1641.1641.1356.0356.0356.0356.0356.0356.00.040.541.401.460.010.010.110.110.110.110.110.11-175.079.692.192.5-1733.3-1733.3$0.313$0.313$0.313$0.313$0.313$0.313$6$7$8$9$10$11$0$0$0$5$0$0$6$7$8$9$10$11$237,927$40,861 $18,416$919 $55,166$100,375$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$02. Property taxes, insurance, andadministration= 0.04 x TCI$03. Capital recovery= Equipment CRF x TCI$0E. Recovery Credit, $/yra. Recovered vinyl chloride, kg/yr [VCR]= C x 10^-6 x Q x (1 kg/l) x (60 min/hr) xH x RP0.00b. Value of recovered vinyl chloride, $/yr= VCR x (2.2 lb/kg) x RV$0F. Include in Annual Cost?F. Total Annual Cost1. $/yr= Direct Annual Costs + Indirect AnnualCosts - Recovery Credit$352,3812. ($/yr) /lpm = ($/yr) / Q$705Sources:1. Cost equations: HON BID, Vol 1-b and 1-c, Nov 1992 (EPA-453/D-92-016c)2. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2008National Industry-Specific Occupational Employment and Wage Estimates3. Electricity cost: Energy Information Administration. Average Industrial Retail Price ofElectricity: October 2009.4. Water cost and steam cost: Air Compliance Advisor,version 7.5.5. ICIS, http://www.icis.com/v2/chemicals/9076567/vinyl-chloride/pricing.html, October 20, 2010.(Avg. $690/tonne = $0.313/lb)$0$0$0$0$0$0$1$1$1$1$1$1(16.96)17.8424.191.27(5.84)(10.63)($12)$12$17$1($4)($7)NoYesYesYesNoNo0$40,856 $18,408$928 00$495$495$500Attachment L - Process Wastewater Compliance Cost AlgorithmSteam Stripper - PVC Resin - Cost Analysis - VC and TOHCompanyProcess TypeProcess Type StdInlet Stream Flow, gal/yrInlet Stream Flow, liters/minA. Parameters(Inputs and ExampleCalculation)1. Stripper inlet flow rate,lpm (Q)5002. Annual operating hours, hr/yr (H)84003. Steam to Feed Ratio, kg /l(S)0.0964. Electricity use, kWhr/day (EU)2605. Operating labor rate, $/hr (LR) [2]$34.606. Electricity cost, $/kWh (EC) [3]$0.077. Water cost, $/1,000 gal (WC) [4]$0.208. Steam cost, $/1,000 lb (SC) [4]$4.659. Capital recovery factor= [i x (1 + i)a] / [(1 + i)a- 1], where i =interest rate, a = equipment lifea. Equipment CRF, 20-yr life, 7%interest0.0943910. Cost indexa. 2010641.1b. 1989356.011. VCM Concnetration, ppm [C]12. VCM limit, ppm [L]20.013. VCM recovery percentage, %99.014. VOC recovery value, $/lb [RV]$0.313B. Total Capital Investment1. $= 0.3731 x Q^0.267 x 10^6$02. $ /lpm= $ / Q$0C. Direct Annual Operating Costs, $/yr1. Electricity= EU / (24 hr/day) x H x EC$6,0792. Steam= Q x S x (2.2 lb/kg) x (60 min/hr) x H xSC / 1000$247,4843. Water= Q x (5220 liters water-min / liters feedday) x (1 day / 24 hr) x H x (0.264gal/liter) x WC / 1000$04. Operating labor= (1 hr/shift) x (1 shift/8 hr) x H x LR$36,3305. Supervisory labor= 0.15 x (operating labor)$5,4506. Maintenance labor= (0.5 hr/shift) x (1 shift/8 hr) x H x (LR x$19,9827. Maintenance materials= 0.02 x TCI$0D. Indirect Annual Costs, $/yr1. Overhead= 0.6 x (labor + maintenance materials)$37,0572. Property taxes, insurance, and= 0.04 x TCI$0EquationParameters/CostsShintech Plaquemine Westlake Calvert City Westlake Geismar Georgia Gulf Aberdeen Georgia Gulf PlaquemineOther Other OtherOtherOther38016002890800013225138.431058400037604745.6228.553042217.12209199.33131779.494265282.44157428.553217.12299.33179.494282.442840084008400840084000.0960.0960.0960.0960.096260260260260260$34.60$34.60$34.60$34.60$34.60$0.07$0.07$0.07$0.07$0.07$0.20$0.20$0.20$0.20$0.20$4.65$4.65$4.65$4.65$4.650.094390.094390.094390.094390.09439641.1641.1641.1641.1641.1356.0356.0356.0356.0356.00.010.051.720.701.000.110.110.110.110.11-1000.0-120.093.684.389.0$0.313$0.313$0.313$0.313$0.313$12$13$14$15$16$0$0$0$0$0$12$13$14$15$16$14,133$107,469$49,166$39,347$139,800$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$0$1$1$1$12. Property taxes, insurance, andadministration= 0.04 x TCI$03. Capital recovery= Equipment CRF x TCI$0E. Recovery Credit, $/yra. Recovered vinyl chloride, kg/yr [VCR]= C x 10^-6 x Q x (1 kg/l) x (60 min/hr) xH x RP0.00b. Value of recovered vinyl chloride, $/yr= VCR x (2.2 lb/kg) x RV$0F. Include in Annual Cost?F. Total Annual Cost1. $/yr= Direct Annual Costs + Indirect AnnualCosts - Recovery Credit$352,3812. ($/yr) /lpm = ($/yr) / Q$705Sources:1. Cost equations: HON BID, Vol 1-b and 1-c, Nov 1992 (EPA-453/D-92-016c)2. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2008National Industry-Specific Occupational Employment and Wage Estimates3. Electricity cost: Energy Information Administration. Average Industrial Retail Price ofElectricity: October 2009.4. Water cost and steam cost: Air Compliance Advisor,version 7.5.5. ICIS, http://www.icis.com/v2/chemicals/9076567/vinyl-chloride/pricing.html, October 20, 2010.(Avg. $690/tonne = $0.313/lb)$0$1$1$1$1$1$1$1$1$2(1.44)(6.57)80.7523.64126.69($1)($5)$56$16$87NoNoYesYesYes00$49,127$39,348$139,731$495$495$495

## Attachment M

Wastewater Testing and Monitoring Cost Algorithm

### Attachment M - Wastewater Testing and Monitoring Cost Algorithm



### Wastewater Sampling and Monitoring

Low H i gh 

### Average

Cost of US EPA Method 8260B [1] $201 $ 4 00 $301

Initial Testing for All Streams

8 Average number of wastewater streams - Assume

M107 is insignificant compared to 8260B $2,404



### Initial Wastewater Stripper Compliance - .11 PPMW Limit

(assuming M107 cost = 8260B)

3 o utlet tests (assume cost of 8260B) $901.50



### Total initial Cost $3,305.50

C R F (20 yr, 7%): (0

. 07*(1+0.07)^20)/((1+0.07)^20-1) 0.09439



### Annual Cost of Initial Compliance `= ( 3 outlet test*Avg Cost +

8 wastewater streams* Avg Cost)*CRF $312.02



### Monthly Testing

3 average of uncontrolled streams $ 9 01.50

1 stripper outlet test (to comply with 99.9%) $300.50



### Monthly Monitoring Costs $1,202.00



### Total Annual Wastewater Sampling and Monitoring Facility Costs $14,736.02

*National Environmental Methods Index Website

h t tps://www.nemi.gov/apex/f?p=237:38:951365369293524::::P38_METHOD_ID:7041

## Attachment N

THC Concentration AnalysisAttachment N - THC Concentration Analysis

THC Monitoring Data, 30 Day-Daily Averages for Top 5 TOHAP Facilities

Daily Average THC

Average of THC_ppmvdaspropane@3%O2

Company Facility Process_Unit_ID Equip_ID Date_Std Total Ln Average TOHAP Rank

Formosa Baton Rouge PVC Unit Process Gas Incinerator/Caustic Scrubber 1/19/2010 0.03 -3.5065579 0.2389286 3

1/20/2010 0.12 -2.1202635

1/21/2010 0.03 -3.5065579

1/22/2010 0.1 -2.3025851

1/23/2010 0.04 -3.2188758

1/24/2010 0.09 -2.4079456

1/25/2010 0.23 -1.469676

1/26/2010

1/27/2010

1/28/2010 0.07 -2.65926

1/29/2010 0.06 -2.8134107

1/30/2010 0.21 -1.5606477

1/31/2010 0.25 -1.3862944

2/1/2010 0.1 -2.3025851

2/2/2010 0.05 -2.9957323

2/3/2010 0.02 -3.912023

2/4/2010 0.26 -1.3470736

2/5/2010 0.07 -2.65926

2/6/2010 0.15 -1.89712

2/7/2010 0.22 -1.5141277

2/8/2010 0.17 -1.7719568

2/9/2010 0.71 -0.3424903

2/10/2010 0.52 -0.6539265

2/11/2010 0.53 -0.6348783

2/12/2010 0.5 -0.6931472

2/13/2010 0.43 -0.8439701

2/14/2010 0.28 -1.2729657

2/15/2010 0.54 -0.6161861

2/16/2010 0.49 -0.7133499

2/17/2010 0.42 -0.8675006

Delaware City

WD710 Thermal Oxidizer Scrubber 1/12/2010 0.2307589 -1.4663819 0.0769196 2

1/13/2010 0

1/14/2010 0

OxyVinyls Deer Park C-301A LaPorte Thermal Oxidizer 12/10/2009 0.0002416 -8.3280494 2.1945908 4

12/11/2009 0

12/12/2009 0

12/13/2009 0.0039177 -5.5422425

12/14/2009 0.011974 -4.4250176

12/15/2009 0.0109589 -4.5136022

12/16/2009 0

12/17/2009 0

1/7/2010 0

1/15/2010 0

1/16/2010 0.0892092 -2.4167708

1/17/2010 0

1/20/2010 0.1891953 -1.6649755

1/22/2010 0

1/23/2010 0.0762022 -2.5743653

1/24/2010 0

1/25/2010 0

1/26/2010 0

1/27/2010 0

1/28/2010 0

1/29/2010 0

1/30/2010 0

1/31/2010 0

2/1/2010 0

2/2/2010 0

2/3/2010 0

2/4/2010 62.686686 4.13814907

2/5/2010 2.7288194 1.00386906

2/6/2010 0

2/7/2010 0.0405196 -3.2059703

(blank)

Shintech Addis P-1 C-1/C-2 1/20/2010 0.5935962 -0.5215559 0.9269967 5Attachment N - THC Concentration Analysis

THC Monitoring Data, 30 Day-Daily Averages for Top 5 TOHAP Facilities

1/21/2010 0.6044741 -0.5033964

1/22/2010 0.6923227 -0.3677031

1/23/2010 0.5657931 -0.5695268

1/24/2010 0.5774363 -0.5491572

1/25/2010 0.590861 -0.5261746

1/26/2010 0.8199277 -0.1985391

1/27/2010 0.9739714 -0.0263734

1/28/2010 1.4897408 0.39860212

1/29/2010 1.6886345 0.52392019

1/30/2010 1.7041386 0.53305977

1/31/2010 1.7337279 0.55027393

2/1/2010 0.6111226 -0.4924576

2/2/2010 0.1253508 -2.0766392

2/3/2010 1.6124649 0.47776403

2/4/2010 0.5400766 -0.6160443

2/5/2010 0.4941063 -0.7050046

2/6/2010 0.7400704 -0.30101

2/7/2010 0.7581575 -0.2768641

2/8/2010 0.8322257 -0.1836515

2/9/2010 0.8095578 -0.2112671

2/10/2010 0.934112 -0.0681589

2/11/2010 0.9179987 -0.0855593

2/12/2010 0.9358617 -0.0662876

2/13/2010 0.9537934 -0.0473082

2/14/2010 0.9865519 -0.0135393

2/15/2010 1.1079198 0.10248418

2/16/2010 1.1151699 0.10900679

2/17/2010 1.0242047 0.02391637

2/18/2010 1.1093342 0.10376001

2/19/2010 1.0941936 0.09001766

Freeport P-1 C-1/C-2 12/11/2009 5.2 1.64865863 6.0133333 1

12/12/2009 5.7 1.74046617

12/13/2009 5.8 1.75785792

12/14/2009 7.2 1.97408103

12/15/2009 7.2 1.97408103

12/16/2009 7.4 2.00148

12/17/2009 5.9 1.77495235

12/18/2009 6.1 1.80828877

12/19/2009 6 1.79175947

12/20/2009 5.9 1.77495235

12/21/2009 6.1 1.80828877

12/22/2009 6 1.79175947

12/23/2009 6.3 1.84054963

12/24/2009 6.2 1.82454929

12/25/2009 6 1.79175947

12/26/2009 6.5 1.87180218

12/27/2009 6.4 1.85629799

12/28/2009

12/29/2009

12/30/2009

12/31/2009

1/2/2010 5.4 1.68639895

1/3/2010 6 1.79175947

1/4/2010 5.3 1.66770682

1/5/2010 6.4 1.85629799

1/6/2010 5.9 1.77495235

1/7/2010 5.2 1.64865863

1/8/2010 5.5 1.70474809

1/9/2010 5 1.60943791

1/10/2010 5.7 1.74046617

1/11/2010 5.8 1.75785792

1/12/2010 6.3 1.84054963

1/13/2010 6.6 1.88706965

1/14/2010 5.4 1.68639895Attachment N - THC Concentration Analysis

THC Monitoring Data, 30 Day-Daily Averages for Top 5 TOHAP Facilities

TOHAP Rank Normal LN

Sample Size 122 100

Compliance Avg 30 30

Average 2.3106 -0.3280

Median 0.55 -0.205

Standard Deviation 6.04 2.022

Minimum 0.00 -8.328

Maximum 62.69 4.138

Skewness 8.43 -0.88

SE Skewness 0.22 0.24

Skewness Test Non-normal Normal

Kurtosis 83.68 1.55

SE Kurtosis 0.44 0.49

Kurtosis Test Non-normal Non-normal

99.0% t-statistic for UL 2.36 2.36

99.0% UL 16.55 85.936

99.0% t-statistic for UPL 2.36 2.36

99.0% UPL 5.21 1.949

99.0% UL 85.9 PPMVD as propane @ 3% O2

99.0% UPL 1.9 PPMVD as propane @ 3% O2

Normal LN

Sample Size 28 28

Compliance Avg 30 30

Average 6.0536 1.7962

Median 6.00 1.792

Standard Deviation 0.58 0.095

Minimum 5.00 1.609

Maximum 7.40 2.001

Skewness 0.56 0.28

SE Skewness 0.46 0.46

Skewness Test Normal Normal

Kurtosis 0.39 0.15

SE Kurtosis 0.93 0.93

Kurtosis Test Normal Normal

99.0% t-statistic for UL 2.47 2.47

99.0% UL 7.50 7.623

99.0% t-statistic for UPL 2.47 2.47

99.0% UPL 6.43 6.412

99.0% UL 7.5 PPMVD as propane @ 3% O2

99.0% UPL 6.4 PPMVD as propane @ 3% O2

Calculated new source limit greater than existing - new source limit will be defualt: 1.9 ***

THC Variability Analysis - Existing

THC Variability Analysis - NewAttachment N - THC Concentration Analysis

THC Monitoring Data, 30 Day-Daily Averages for Top 5 TOHAP Facilities

## Attachment O

Packed Bed Scrubber Cost AlgorithmAttachment O1 - Packed Bed Scrubber Cost Estimate

Packed Bed Scrubber Costs

Parameters/Costs Equation Georgia Gulf Plaquemine

1

A

. Parameters

2. Temperature into quench, F (T1) 68

3. Temperature out of PB to ID fan, F

(T2) 68

4. Annual operating hours, hr/yr (H) 8,400

5. Exhaust gas flow rate, dscfm (Qd) 11,871

6. Assumed moisture content in gas

entering quench, % (M) 2

7. Exhaust gas flow rate, scfm (Qw) = (Qd) / (1 - M/100) 12,142

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 -

7 7 °F)) x 0.1) x (lb-mole/385 scf) x Qw /

(1,160 Btu/lb) / (18 lb/lb-mole) x (0.7302 ft 3

-

atm/lb-mol- ° R) x 528 ° R / 1 atm 0

9

. Actual flow out of PB, acfm (Qa) = (Qw + Qh) x (460°F + T2)/(528°R) 12,141

10. HCl or SO2 concentration, (max

ppmvd) 184.26

11. Operating labor rate, $/hr (LR) $34.60

12. Electricity cost, $/kWh (EC) $0.07

13. Caustic cost, $/ton (CC) $357

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

(SDC) $3.80

15. Water cost, $/1,000 gal (WC) $0.20

16. Assumed pressure drop through

control system, inches of water ( **∆** P) 15

17. Surface area-to-volume ratio for 1"

dia. Ceramic Raschig rings, ft 2 /ft 3

(SAV) 58

1 8 . Minimum packing wetting rate,

ft 2 /hr (WR) 1

19. Water density, lb/ft 3 (Wd) 62.4

2 0 . Water circulation flow rate, lb/hr-ft 2

(Gs) = SAV x Wd x WR 4

, 705

21. Estimated column cross-sectional

area, ft 2 (A) 19.2

2 2 . Water circulation rate, gpm (GPM) = Gs x A x (1 hr/60 min) x (1 gal/8.33 lb) 181

23. Water head, ft of water (Head) 60

24. Wastewater (blowdown) flow, gpm

(B) = (HCl/1000000) x (Qd) x (lb-mole/385 ft 3 ) 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) 0.397

2 5 . 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 0.10979

2 6 . Chemical Engineering plant cost

index

a. Feb. 2010 CE 539.1

b. 1989 357.5

B. Total Capital Investment

1. $ = (27.6 x Qd + 109,603) x (525.4/357.5) x

(1.4 retrofit factor) $1,153,653

2. $/dscfm = $ / Qd $97.18

C. Direct Annual Costs, $/yr

1. Operating labor = (if Qa < 20,000, then 0, otherwise 0.5

hr/shift) x H x LR $0

2. Supervisory labor = 0.15 x (operating labor) $0

3. Maintenance labor = (0.5 hr/8-hr shift) x H x (LR x 1.1) $19,982

4. Maintenance materials = 0.02 x TCI $23,073

5. Electricity = (0.000181 x Qa x **∆** P x H x EC) +

(0.000289 x GPM x Head x H x EC) $19,843

6. Caustic = HCl x (3.117E-9) x Q x H x CC $20,418

7. Sewage disposal = B x (60 min/hr) x H x SDC $0

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 $40

D. Indirect Annual Costs, $/yr

1. Overhead = 0.6 x (labor + maintenance materials) $25,833

2. Property taxes, insurance, and

administration = 0.04 x TCI $46,146

3. Capital recovery = CRF x TCI $126,665

E. Total Annual Cost

1. $/yr = Direct Annual Costs + Indirect Annual

Costs $282,000

2. ($/yr) /dscfm = ($/yr) / Qd $23.76

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 Wet Scrubber Cost Memorandum (IV-B-30).

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.

### Attachment O2



## Monitoring Costs - Packed Bed Scrubber

A. Parameters

1. Recording liquor pH monitor, min/4-hr period

2. Annual operating hours, hr/yr (H)

3. Cost index

a. 2010 539.1

b. 2006 499.6

c. 1997 386.5

d. 1993 359.2

e. 1992 358.2

4. Operating labor wage rate, $/hr (LR) $34.60

5. 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

B. Total Capital Investment, $ (TCI)

1. Planning $700

2. Select type of equipment $400

3. Provide support facilities $1,400

4. Purchased equipment cost (PEC) $18,100

5. Install and check equipment $1,000

6. Perf. spec. tests (certif.) $700

7. Prepare QA/QC plan $700

8. Total capital cost = Planning + selecting equipment +

support facilities + PEC + installation +

perf. spec. tests + QA/QC plan $23,000

C. Annual Costs, $/yr

1. Maintenance materials = 0.02 x TCI $500

2. Recordkeeping and reporting = $1,000 x (525.4/386.5) $1,400

3. Overhead = 0.6 x (labor + maintenance materials) $300

4. Property taxes, insurance, and administration = 0.04 x TCI $900

5. Capital recovery = CRF x TCI $2,200

6. Total annual cost = Operating labor + maintenance

materials + recordkeeping and reporting

+ overhead + property taxes, insurance,

and administration + capital recovery $5,300

Notes:

1. Monitoring costs have been rounded to the nearest $100 to be consistent with level of rounding in original costs.

2. Costs to be replaced include: scrubber liquor pH monitor (wet scrubbers)

Sources:

1. Hospital/Medical/Infectious Waste Incinerators (HMIWI) [EPA-HQ-OAR-2006-0534] Testing and Monitoring Options and Costs Memo (IV-B-66). Georgia Gulf Plaquemine Parameters/Costs Equation