1

TECHNICAL MEMORANDUM 

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

Chemicals Group 

FROM: Eastern Research Group, Inc.

DATE: April 13, 2011

SUBJECT: 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 

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

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

requirements. A previous memorandum documents the MACT floor analysis for the production 

facilities1

. 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 

control. 

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 

systems. 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 memorandum2. 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 $761,000, 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 website4. 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 HMIWI5. 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 Category1; 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)—

Methodology and Assumptions Memorandum for HMIWI6. It was assumed that the cost to 

comply with the “Fabric Filter Bag Leak Detection Guidance11” 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 

HMIWI6. 

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.
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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 

($/yr) TCI ($) 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 1,295,725 383,748 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 69,036 

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 -

Pedricktown - - - - - - - - - - - -

PolyOne - Henry - - - - - - - - - 173,930 - 173,930 

PolyOne -

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

Shintech - Freeport - - - - - - - - - - - - 

Shintech -

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

Shintech - 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.
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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 ($) TAC ($/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

Formosa-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

OxyVinyls-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-Freeport - - - - 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.
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2.4 Emission Reduction Methodology and Results

The average HAP concentration values used to calculate baseline annual emissions2for 

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 3.12except 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. 
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Table 2-2. Percent Improvement Needed for Facilities to Meet Process Vent Limits 

Company/Facility

VC

Limit: 3.2E-01 ppmvd @ 3% 

O2

HCl

Limit: 150 ppmvd @ 3% 

O2

CDD/CDF (TEQ)

Limit: 0.2.3E-02 ng/dscm 

@ 3% O2

Total Organic HAP

Limit: 12 ppmvd @ 3% 

O2

Facility 

Baseline 

(ppmvd)

Percent 

Improvement 

Needed

Facility 

Baseline 

(ppmvd)

Percent 

Improvement 

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 1.14 -

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 30.1 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
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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 - Delaware 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 -

TOTAL* 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 emissions2

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. 
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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 

Company/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

Limit: 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 5.91E-01 18.8 40.0 0

Formosa – Point Comfort 1.51E-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 1.99E-01 0 11.9 0

OxyVinyls - Pasadena 2.83 83.0 77.1 1.53

OxyVinyls - Pedricktown 2.52 80.9 39.4 0

Shintech - Addis 5.79E-01 17.1 69.3 0

Shintech - Freeport 7.72E-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 Additional 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 - Baton 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 43,612a

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 3.22, 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

Percent Reduction Needed to 

Meet Limits

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 4.64 13.3

Formosa - Baton Rouge 20.4 0 2.38E-01 2.38E-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 1.53 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 1.75E-01 1.75E-01

Shintech – Freeport 39.0 0 2.41E-01 2.41E-01

Shintech - Plaquemine 12.8 0 5.69E-02 5.69E-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

(Tons per Year)

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 - Pedricktown 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 4.64 13.3

Formosa - Baton Rouge 2.38E-01 2.38E-01

Shintech – Addis 1.75E-01 1.75E-01

Shintech – Freeport 2.41E-01 2.41E-01

Shintech - Plaquemine 5.69E-02 5.69E-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 memoranda1, constitute 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 towers12. 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. For 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

($/yrtower)($/eventtower) (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 – Aberdeen 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 – Pedricktown 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 memorandum2, 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 - Midland 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 5.77E-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 calculated10. 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 

Charles

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 28,451 188,913 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

OxyVinyls –

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 26,897 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 

Estimates8(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 study9, 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

Westlake - 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 

generation2 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 – Pedricktown 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 HON7. 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

Company/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 - Plaquemine 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 - Geismar 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

OxyVinyls - 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 3.72

, 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 8.90E-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 for 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 

Recordkeeping

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 

Formosa - 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 –

Aberdeen

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 – Addis - 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 Emission 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-08tons 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 - Plaquemine 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 - Pedricktown 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-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 
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 Quality Management District. May 15th, 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 Algorithm 
Refrigerated Condenser Package for PVC and Copolymer Process Vents

Certain Teed Georgia Gulf OxyVinyls

Lake Charles Aberdeen Pasadena

-- Inlet stream flowrate (DSCMM): 5.7 0.1 15.1-- Inlet stream flowrate (scfm): (Qin) =DSCMM/35.31 200 4 535 -- Inlet stream temperature (oC): 65 16 18

-- Inlet stream temperature (oF): (Tin) =oC*1.8+32 148 61 65-- VOC to be condensed: Vinyl chloride Vinyl chloride Vinyl chloride

-- VOC inlet volume fraction:(Yvoc,in) =ppm/1E6 0.096 0.485 0.188

-- Required VOC removal (fraction): (n) 0.937 0.835 0.660

-- Antoine equation constants for VOC: [4]

A: 6.497 6.497 6.497

B: 783.400 783.400 783.400

C: 230.010 230.010 230.010

-- VOC heat of condensation (BTU/lb-mole): (∆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,cool 0.650 0.650 0.650-- VOC boiling point (oF): (Tboil) 7 7 7

-- VOC critical temperature (oR): (Tc) 773 773 773

-- VOC molecular weight (lb/lb-mole): (MWvoc) 63 63 63-- VOC condensate density (lb/gal): 8.15 8.15 8.15

-- Air heat capacity (BTU/lb-mole-oF): (Cp,air) 6.95 6.95 6.95

DESIGN PARAMETERS:-- Outlet VOC partial pressure (mm Hg): (Pvoc) =760*(Yvoc,in*(1-n)/(1-Yvoc,in*n)) 5.0 102.2 55.4

-- Condensation temperature, Tc (oF): (Tcon) =(B/(A-log10(Pvoc))-C)*1.8+32 -138.7 -67.8 -85.4

(oR): =Tcon+460 321.3 392.2 374.6

-- VOC flowrate in (lb-moles/hr): (Mvoc,in) =Qin*Yvoc,in*60/392 2.93 0.29 15.39-- VOC flowrate out (lb-moles/hr): (Mvoc,out) =Mvoc,in*(1-n) 0.185 0.048 5.232

-- VOC condensed (lb-moles/hr): (Mvoc,con) =Mvoc,in-Mvoc,out 2.745 0.245 10.156 (lb/hr): (Lb/hrvoc,con) =Mwvoc*Mvoc,con 171.6 15.3 634.7-- VOC heat of condensation @ Tc (BTU/lb-mole): (∆Hvoc) =(∆Hvoc,r)*[(1-Tcon/Tc)/(1-Tboil/Tc)]^0.38 11679 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) 618 73 9186-- Enthalpy change, air (BTU/hr): (∆Hnoncon) =Cp,air*(Tin-Tcon)*(Qin*60/392-Mvoc,in) 55128 280 69622

-- Condenser heat load (BTU/hr): (Hload) =∆Hcon+∆huncon+∆Hnoncon 96990 3405 209726

-- Heat transfer coefficient, U (BTU/hr-ft2-oF): Estimate from OAQPS Manual 20 20 20-- Log-mean temperature difference (oF): Tlm =(Tin-Tcon-25)/ln((Tin-Tcon-10)/15) 89.9 50.2 56.1-- Condenser surface area (ft2): (Acon) =Hload/U*Tlm 54.0 3.4 186.8

-- Coolant flowrate (lb/hr): =Hload/(Cp,cool*(Tcon-15+25)-(Tcon-15)) 5969 210 12906-- Refrigeration capacity (tons): (R) =Hload/1200 8.08 0.28 17.48-- Electricity requirement (kW/ton) [6]: (kW) =-9E-06(Tcon)^3 - 0.0004(Tcon)2 - 0.0331(Tcon) + 3.560 24.45 6.77 9.07

CAPITAL COSTSEquipment Costs ($):

-- Refrigeration unit/single-stage (< 10 tons): (Rss<10) =exp(9.83-0.014Tcon+0.340lnR) 263,481 31,283 0

-- Refrigeration unit/single-stage (> 10 tons): (Rss>10) =exp(9.26-0.007Tcon+0.627lnR) 0 0 114,840-- Multistage refrigeration unit: (Mru) exp(9.73-0.012Tcon+0.584lnR) 300,831 18,176 248,966

Total equipment cost ($)--base: (ECp) =1.25*MAX(Rss<10,Rss>10,Mru) 376,039 39,103 311,208

Cost Indexa. 2010 CE Equip (Feb Final) CE Equipment index (Feb 2010 Final) 641.1 641.1 641.1

b. 1990 CE Equip (Oct Final) CE Equipment index (Oct 1990 Final) 394 394 394 ' ' ' ' --escalated: (ECpe) =(ECp)*(FebFinal/OctFinal) 612,341 63,676 506,770

Purchased Equipment Cost ($): (PECp) =ECpe*1.08 661,328 68,770 547,312Total Capital Investment ($): (TCI) =PECp*1.15 760,527 79,085 629,409 INPUT PARAMETERS: Equation

Attachment A - Condenser Cost Algorithm
Refrigerated Condenser Package for PVC and Copolymer Process Vents

Certain Teed Georgia Gulf OxyVinyls

Lake Charles Aberdeen Pasadena

 INPUT PARAMETERS: Equation

ANNUAL COST INPUTS:Operating factor (hr/yr): (OF) 8400 8400 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 shift 0.50 0.50 0.50

Maintenance labor factor (hr/sh): (MLF) 1/2 hour per 8 hour shift 0.50 0.50 0.50

Electricity price ($/kWhr): (EP) 0.0700 0.0700 0.0700

Recovered VOC value ($/lb)[5]: (Rvoc) 0.31 0.31 0.31

Annual interest rate (fraction): (Int) 0.07 0.07 0.07

Control system life (years): (EL) 20 20 20Capital recovery factor: (CRF) =Int*(1+Int)^EL/((1+Int)^EL-1) 0.0944 0.0944 0.0944

Taxes, insurance, admin. factor: (TaxF) 0.04 0.04 0.04

 ANNUAL COSTS: Item Cost ($/yr) Cost ($/yr) Cost ($/yr)Operating labor =OF/8*OLF*LR 18,165 18,165 18,165

Supervisory labor =.15*Operating Labor 2,725 2,725 2,725

Maintenance labor =OF/8*MLF*MR 19,982 19,982 19,982

Maintenance materials 100% of maintenance labor 19,982 19,982 19,982Electricity =EP*OF*kW*R/0.85 136,724 1,329 109,649Overhead =.60*(Operating Labor+Supervisory Labor+Maint Labor+Maint Materials) 36,512 36,512 36,512

Taxes, insurance, administrative =TaxF*TCI 30,421 3,163 25,176

Capital recovery =CRF*TCI 71,788 7,465 59,412Total Annual Cost (without credits) (TACwoc) =sum of all annual costs 336,298 109,322 291,601Recovery 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 1990

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. 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 A - Condenser Cost Algorithm
Attachment B 

Refrigerated Condenser Input Calculations 
Attachment B

Parameter Units EquationCompany Certain Teed Georgia Gulf OFacility Lake Charles Aberdeen P

Pollutant to be Reduced VC VC VMW of Pollutant (MW) lb/lb-mol 62.5 62.5 T.O. Outlet Conc.(C) ppmvd@3%O2 5.2 2.0 T.O. Outlet %O2 % 16.9 7.8 

T.O. Outlet Flow Rate DSCMM 33.0 10.7 Pollutant Limit (L) ppmvd@3%O2 0.320 0.320 Reduction Needed % =(C-L)/(C)*100 93.9 84.0 

T.O. Inlet VC Conc (TOVC) ppmvd@3%O2 95862.4 484981.0 T.O. Inlet VC Conc % 0.096 0.485 

T.O. Redux Eff. (TORE) % =(TOVC-C)/TOVC*100 99.9945 99.9996 

T.O Inlet VC Conc After Condenser (VCAC) ppmvd@3%O2 =L/(1-TORE/100) 5854.2 77512.5 T.O. Inlet VC Reduction % =(TOVC-VCAC)/TOVC*100 93.9 84.0 

T.O. Inlet Flow (TOIF) DSCMM 5.7 0.1 T.O. Inlet O2 Concentrations (TOO) % 0.03 2.1 T.O. Inlet Temperature C 64.7 16.3 HCl ReductionHCl Outlet Concentration ppmvd@3%O2 104.12 156.78 

HCl 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 VC 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 Inlet lbs VC before reduction (MVCBR) lbs/hr =TOVC*1E(-6)*(20.9-O)/(20.9-3)*1/0.028*1/385.3*MW*R*60 219.6 19.8 Inlet lbs VC after reduction (MVCAR) lbs/hr =VCAC*1E(-6)*(20.9-O)/(20.9-3)*1/0.028*1/385.3*MW*R*60 13.4 3.2 

Inlets VC Reduced (MVCR) lbs/hr =MVCBR-MVCAR 206.2 16.6 

Outlet HCl/Inlet VC (before redux) ratio `=(HClOFR)/(VCBR) 0.000706088 0.012504766 0

New HCl Outlet lbs/hr `=ratio*VCAR 0.009470009 0.039568587 0

New HCl Outlet Conc ppmvd@3%O2 1.351716259 5.32675826 2

HCl Reduced tons/yr 0.6115 0.8736 

MW of HCl (MWHCl) lb/lbmols 36.5 36.5 

Calculations 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 TO Inlet Flow Rate (DSCFM) 500 500

Stream Temperature (K) 293 293

Program Outputs

Min % O2 Required 19.8 19.8

Op. Temp (F) 2200 2200

Auxiliary Air Req (CFM) 2045.45 499.99

Min Fuel Req (CFM) 1 1

Auxiliary Fuel Req (CFM) 45 18

Auxiliary Fuel Cost ($/yr) $68,548 $26,930

Equipment Cost [1] $225,860 $178,813 

Auxiliary Equipment Cost 0 0

Total Equipment Cost $225,860 $178,831 

Instrumentation Cost $0 $0 

Sales Tax $6,776 $5,364 

Freight Cost $11,293 $8,941 

Purchased Equipment Cost $243,929 $193,118 

Foundation Cost $19,514 $15,449 

Equipment Erection Cost $34,150 $27,037 

Electrical Cost $9,757 $7,725 

Piping Cost $4,879 $3,862 

Insulation Cost $2,439 $1,931 

Painting Cost $2,439 $1,931 

Direct Installation Cost $73,179 $57,935 

Total Direct Capital Cost $317,108 $251,053 

Engineering Cost $24,393 $19,312 

Field Cost $12,197 $9,656 

Contractor Cost $24,393 $19,312 

Start Up Cost $4,879 $3,862 

Performance Test Cost $2,439 $1,931 

Contingencies Cost $7,318 $5,794 

Total Indirect Capital Cost $75,618 $59,867 

Total Capital Investment, $2008 (TCI2008) $392,726 $310,919 

2008 - CE Equip - Oct Final [4] 720.00 720.00 

2010 - CE Equip - Feb Final [4] 641.10 641.10 

Total Capital Investment, $2010 (TCI2010) `=TCI2008*641.1/720 $349,690 $276,847

Operating Labor $18,152 $18,152 

Supervisory Labor $2,723 $2,723 

Maintenance Labor $19,968 $19,968 

Maintenance Materials $19,968 $19,968 

Replacement Parts $0 $0 

Utilities $69,640 $28,022 

Electricity [2] $1,092 $1,092 

Total Direct Annual Cost $130,450 $88,832 

Overhead $36,486 $36,486 

Administrative Charges $7,855 $6,218 

Property Taxes - -

Insurance - -

Capital Recovery Factor - -

Capital Recovery - -

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

Recovery Credit $0 $0 

PolyOne Parameters Equation

Attachment C - Air Compliance Advisor Input Outputs for VGA to TO 

 

C-1
Henry Pedricktown

PolyOne Parameters Equation

Total Annualized Cost (2008 Dollars) `=Indirect Annual Cost + Direct Annual 

Cost $174,791 $131,537 

- -

2010 Cost Calculations - -

Overhead (2010 Dollars) [3] `=.6*(Op. Labor + Maint. Labor + Maint. 

Materials + Super. Labor) $36,486.1 $36,486.1

Administrative Charges (2010 Dollars) [3] `=0.02*TCI2010 $6,993.80 $5,536.95

Property Taxes (2010 Dollars) - -

Insurance (2010 Dollars) - -

Capital Recovery Factor - -

Capital Recovery (2010 Dollars) - -

Total Indirect Annual Cost (2010 Dollars) `=Overhead+Admin Charges $43,480 $42,023

Recovery Credit - -

Total Annualized Cost (2010 Dollars) `=Total Direct Annual Costs + Total 

Indirect Annual Costs (2010 Dollars) $173,930 $130,855

1. Does not include auxiliary equipment

2. Represented as subpart of Utilities

3. US EPA OAQPS Air Pollution Control Cost Manual - 

6th Edition (EPA 452/B-02-001) Section 3 - VOC 

Controls, Section 3.2 VOC Destruction Controls, 

Chapter 2 - Incinerators, Table 2.10

4. Chemical Engineering Equipment Cost Index

Attachment C - Air Compliance Advisor Input Outputs for VGA to TO C-2
Attachment D 

Activated Carbon Injection Cost Algorithm 
Attachment D

Activated Carbon Injection Model Costs

Parameters/Costs Equation Certain Teed Lake CharlesFormosa Baton Rouge Formosa Point Comfort Georgia Gulf Plaqu

A. Parameters

1. Annual operating hours, hr/yr (H) 8400 8400 8400 

2. Exhaust gas flow rate, dscfm (Q) 1213 4150 2646 

3. Operating labor rate, $/hr (LR) $34.60 $34.60 $34.60 4. Activated carbon cost, $/lb (ACC) $1.38 $1.38 $1.38 5. Dust disposal cost, $/ton (DDC) $34.29 $34.29 $34.29 6. Capital recovery factor, 20-yr equipment life, 7% interest (CRF)

= [i x (1 + i)a] / [(1 + i)a - 1], where i = interest rate, a = equipment life

0.09439 0.09439 0.09439 

7. Cost index a. 2010 CE Equip (Feb Final) 641.1 641.1 641.1  b. 1990 CE Equip (Oct Final) 393.7 393.7 393.7 8. ACI Adjustment Factor (AF) =% Reduction required / 98 0.27 0.31 0.99 

B. Total Capital Investment

1. $ = 4,500 x (Q/1,976)0.6 x (1.2 retrofit factor) x 

(575.4/361.3)

$7,797 $16,310 $12,451 

2. $/dscfm = $ / Q $6.43 $3.93 $4.71 

C. Direct Annual Costs, $/yr

1. Operating labor = (0.25 hr/8-hr shift) x H x LR $9,083 $9,083 $9,083 

2. Supervisory labor = 0.15 x (operating labor) $1,362 $1,362 $1,362 3. Maintenance = 0.2 x TCI $1,559 $3,262 $2,490 4. Activated carbon = 0.00127 x Q x H x ACC x AF $4,755 $18,702 $38,754 5. Dust disposal = 0.00127 x Q x (1 ton/2,000 lb) x H x DDC x AF $59 $232 $481 

D. Indirect Annual Costs, $/yr

1. Overhead = 0.6 x (labor + maintenance materials) $7,203 $8,224 $7,761 

2. Property taxes, insurance, and administration

= 0.04 x TCI $312 $652 $498 

3. Capital recovery = CRF x TCI $736 $1,540 $1,175 

E. Total Annual Cost

1. $/yr = Direct Annual Costs + Indirect Annual Costs $25,069 $43,057 $61,604 

2. ($/yr) / dscfm = ($/yr) / Q $20.67 $10.38 $23.28 

Note:

Factor of 1.27 x 10-3 for activated carbon is based on injecting carbon at a rate to achieve a carbon concentration of 338

mg/dscm (achieving reductions of 90% for Hg, 98% for CDD/CDF).Sources:

1. Cost equations: Hospital/Medical/Infectious Waste Incinerators (HMIWI) [EPA-HQ-OAR-2006-0534] Model Plant Description and Cost Report (II-A-112).2. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2007 National Industry-Specific 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 Algorithm 
Attachment E1 - Fabric Filter

Fabric Filter Cost Algorithm

Parameters/Costs Equation Certain Teed Lake Charles Formosa Baton Rouge Formosa Point Comfort Georgia Gulf Plaquemine Westlake Geism

A. Parameters

1. Annual operating hours, hr/yr (H) 8400 8400 8400 8400 

2. Exhaust gas flow rate, dscfm (Q) 1213 4150 2646 11869 

3. PM concentration, gr/dscf (PM) assumed from original costing alg. 1.58E-02 1.58E-02 1.58E-02 1.58E-02 

4. Water vapor in gas from incinerator (10% by weight) a. lb/min = Q / (385 ft3/lb-mol) x (29 lb/lb-mol) x 

moisture content (0.10)

9.1 31.3 19.9 89.4 

 b. scfm = (lb/min) / (18 lb/lb-mol) x (385 ft3/lbmol) 195 669 426 1,912 

5. Enthalpy change in quench (1800°F to 

300°F) a. Dry gas from incinerator, Btu/lb air = [7.010 x (300°F - 77°F) - 7.554 x 

(1800°F - 77°F)] / (29 lb/lb-mol)

395 395 395 395 

 b. Water vapor from incinerator, Btu/lb water vapor

= [8.154 x (300°F - 77°F) - 9.215 x (1800°F - 77°F)] / (18 lb/lb-mol)

781 781 781 781 

 c. Total gas stream, Btu/yr = [(Btu/lb air) x Q / (385 ft3/lb-mol) x (29 

lb/lb-mol) x (60 min/hr) x H] + [(Btu/lb water vapor) x Q x (0.00753 lb water vapor/ft3) x (60 min/hr) x H]

2.18E+10 7.45E+10 4.75E+10 2.13E+11 

 d. Cooling water i. Heat of vaporization at 77°F, Btu/lb 1,050 1,050 1,050 1,050 

 ii. Sensible heat for vapor, Btu/lb 85 85 85 85 

 iii. Total, Btu/lb water 1,135 1,135 1,135 1,135 

6. Cooling water evaporated, lb/yr a. lb/yr = [enthalpy change (total gas stream, 

Btu/yr)] / [enthalpy change (cooling water, Btu/lb)]

1.92E+07 6.57E+07 4.19E+07 1.88E+08 

 b. scfm = [cooling water evaporated (lb/yr)] / (18 

lb/lb-mol) x (385 ft3/lb-mol) / (H * 60 min/hr)

814 2,786 1,776 7,969 

7. Actual gas flow into fabric filter, acfm (AQ) = [Q + (water vapor in gas from 

incinerator, scfm) + (water vapor added in quench, i.e., cooling water evaporated, scfm)] x [(300°F + 460°F)/528°R]

3,199 10,946 6,979 31,308 

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

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

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

11. Compressed air cost, $/1,000 ft3 (CAC) $0.24 $0.24 $0.24 $0.24 

12. Dust disposal cost, $/ton (DDC) $34.29 $34.29 $34.29 $34.29 13. Capital recovery factors = [i x (1 + i)a] / [(1 + i)a - 1], where i = 

interest rate, a = equipment life

 a. Bag CRF, 2-yr life, 7% interest 0.55309 0.55309 0.55309 0.55309  b. Cage CRF, 4-yr life, 7% interest 0.29523 0.29523 0.29523 0.29523 

 c. Equipment CRF, 20-yr life, 7% interest 0.09439 0.09439 0.09439 0.09439 

14. Cost index a. 2010 CE Equip (Feb Final) 641.1 641.1 641.1 641.1 

 b. 1989 CE Equip (Oct Final) 392.6 392.6 392.6 392.6 

B. Total Capital Investment

1. $ = (47.0 x Q + 306,720) x (1.4 retrofit 

cost factor) x (525.4/357.5)

$874,964 $1,295,725 $1,080,270 $2,401,684 $

2. $/dscfm = $ / Q $721.42 $312.24 $408.28 $202.34 
Fabric Filter Cost Algorithm

Parameters/Costs Equation Certain Teed Lake Charles Formosa Baton Rouge Formosa Point Comfort Georgia Gulf Plaquemine Westlake Geism

C. Direct Annual Operating Costs, $/yr

1. Electricity = (0.746 kW/hp) x hp (0.0072 x Q + 

3.20) x H x EC

$4,995 $13,846 $9,314 $37,113 

3. Evaporative cooler water = (0.1007 x Q + 23.1506) gal/min x (60 

min/hr) x H x WC

$14,645 $44,456 $29,191 $122,815 

4. Operating labor = (1 hr/shift) x (1 shift/8 hr) x H x LR $36,330 $36,330 $36,330 $36,330 

5. Supervisory labor = 0.15 x (operating labor) $5,450 $5,450 $5,450 $5,450 

6. Maintenance labor = (0.5 hr/shift) x (1 shift/8 hr) x H x (LR 

x 1.1)

$19,982 $19,982 $19,982 $19,982 

7. Maintenance materials = 0.02 x TCI $17,499 $25,914 $21,605 $48,034 

8. Compressed air = AQ x (2 ft3 air/1,000 ft3 filtered) x (60 

min/hr) x H x CAC

$774 $2,648 $1,688 $7,574 

9. Dust disposal = (PM gr/dscf x Q x 60 min/hr x 1 

lb/7,000 gr) x (1 ton/2,000 lb) x H x DDC

$24 $81 $52 $231 

10. Bag replacement a. Bag cost = AQ x ($2.5/ft2) x (525.4/317.4) x (1.08 

taxes and freight ratio)/(3.5 ft/min G/C 

ratio)

$4,085 $13,978 $8,912 $39,979 

 b. Bag replacement labor cost = AQ x (0.15 hr/bag)/(18 ft2 bag 

area)/(3.5 ft/min G/C ratio) x LR

$264 $902 $575 $2,579 

 c. Bag replacement cost = Bag CRF x [(total bag cost) + (bag 

replacement labor cost)]

$2,405 $8,230 $5,247 $23,539 

11. Cage replacement a. Number of bags = AQ/(3.5 ft/min G/C ratio)/(18 ft2 bag 

area)

$51 $174 $111 $497 

 b. Cage replacement labor cost = bag replacement labor cost $264 $902 $575 $2,579 

 c. Cage replacement cost = Cage CRF x [single-cage cost 

(4.941+ 0.163 x 18 ft2 bag area) x (number of bags) x (525.4/317.4) + 

(cage replacement labor cost)]

$273 $935 $596 $2,674 

D. Indirect Annual Costs, $/yr

1. Overhead = 0.6 x (labor + maintenance materials) $47,556 $52,605 $50,020 $65,877 

2. Property taxes, insurance, and administration

= 0.04 x TCI $34,999 $51,829 $43,211 $96,067 

3. Capital recovery = Equipment CRF x (TCI - bag 

replacement cost - cage replacement cost)

$82,338 $121,442 $101,418 $224,228 

E. Total Annual Cost

1. $/yr

= Direct Annual Costs + Indirect Annual Costs

$267,268 $383,748 $324,103 $689,912 $

2. ($/yr) / dscfm = ($/yr) / Q $220.37 $92.47 $122.49 $58.13 

Sources:

1. Cost equations: Hospital/Medical/Infectious Waste Incinerators (HMIWI) [EPA-HQ-OAR-2006-0534] Model Plant Description and Cost Report (II-A-112); and Dry Injection Fabric Filter Cost Memorandum (IV-B-32).2. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2008 National Industry-Specific Occupational Employment and Wage 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 lime/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 Capital 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. Maintenance 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 E2. Fabric Filter Monitoring Costs
Attachment F 

Process Vent Emissions Testing and Monitoring Cost Algorithm 
Attachment F - Process Vents Testing and Monitoring Cost Algorithm

Process Vents Emission Testing Costs

Parameters/Costs Equation Values Testing Freq.* Annual Cost of Test Annual Cost of Initial A. Parameters

1. CE Plant Cost index  a. 2010 (Feb 10 Final CE Index) 539.1

b. 2009 (Annual CE Index) 521.9

 c. 1992 (Annual CE Index) 358.2

B. Testing Costs, $

1. Method 1 or 1A Included as part of M 23 $ - 1 $ - $ 

2. Method 26 (HCl) = $5,000 x (539.1/358.2) $8,000 1 $ 3. Method 23 (CDD/CDF) = $21,000 x (539.1/358.2) - $5,000 $27,000 1 $ 27,000 $ 4. Method 25A (THC) =$6,000x(539.1/521.9) $6,198 1 $ 6,198 $ 5. Method 18 (Assumed cost equal to 0031) $10,000 1 $ 10,000 $ 

C. CRF (20 yr, 7%): (0.07*(1+0.07)^20)/((1+0.07)^20-1) 0.09439D. Facility Totals

1. HCl, TOH, &VC 

2. CDD/CDF 

3. Facility Total $ 51,197.74 

* Number of Years Between Tests

Note:

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 Cost Questions.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 also adjusted based on additional information from EPA.Sources:
Attachment G 

Recordkeeping and Reporting Cost Algorithm 
Attachment G1 - Recordkeeping and Reporting Annual Cost Summary

Year 1 $ 2,740,467

Year 2 $ 2,774,693

Year 3 $ 2,774,693

Total $ 8,289,852

Year 1 $ 2,434,720

Year 2 $ 2,461,400

Year 3 $ 2,461,400

Total $ 7,357,520

Total Cost $ 8,289,852

Performance Testing $ 7,357,520

Difference $ 932,332

Annual Difference (difference divided by 3) $ 310,777

Annual Difference $ 310,777

Number of Facilities 17Cost per Facility $ 18,281

Per Facility Record Keeping and Reporting Cost Less Performance Testing and Monitoring

Table 1.D Calculation of Annual Recordkeeping and Reporting Costs

on a Per Facility Basis

Caclulation of Annual Recordkeeping and Reporting Cost on a Per Facility Basis

Total Recordkeeping, Monitoring, and Reporting CostInitial / Yearly Performance Testing and Monitoring CostRecord Keeping and Reporting Cost less Performance Testing and Monitoring 
Attachment G2 



(A) (B) (C) (D) (E) (F) (G)

Respondent Non-Labor Number of Hours Number of Technical Management Clerical Total Total Total 

Hours per Costs Occurrences Per Respondents Hours Hours Hours Labor Costs Non-Labor Responses

Occurrence Per Per Respondent Per Year Per Year Per Year Per Year Per Year Costs Per Year

(Technical Occurrence Respondent Per Year Per Year

Burden Item hours) Per Year (C=A x B) (CXD) (E x 0.05) (E x 0.1)

1. Applications N/A2. Surveys and Studies N/A3. Reporting Requirements

A. Read and Understand Rule Requirements 25 $100 1 25 17 425 21 43 $46,229 $1,700 0 a,b

B. Required Activities

1) Initial performance test, sampling, and report 40 $53,139 1 40 17 680 34 68 $73,966 $903,355 0 a2) Periodic performance test, sampling, and report 15 $54,042 1 15 17 255 13 26 $27,737 $918,716 0 f

3) Establish operating parameters and monitoring plan 20 $0 1 20 17 340 17 34 $36,983 $0 0 a

4) Continuous parameter monitoring

a) Initial capital costs (Fabric Filters) 0 $17,100 1 0 5 0 0 0 $0 $85,500 0 a,d

b) Annualized capital and O&M costs (Fabric Filters & ACI) 11 $31,700 1 11 5 55 3 6 $5,983 $158,500 0 c,e

c) Initial capital costs (PRD Electronic Monitor) 0 $188,913 1 0 17 0 0 0 $0 $3,211,521 0 a,dd) Annualized capital and O&M costs (PRD Electronic Monitor) 11 $26,897 1 11 17 187 9 19 $20,341 $457,249 0 c,e

e) Initial capital costs (PB Scrubber Monitor) 0 $23,000 1 0 1 0 0 0 $0 $23,000 0 a,d

f) Annualized capital and O&M costs (PB Scrubber Monitor 11 $5,300 1 11 1 11 1 1 $1,197 $5,300 0 c,e

C. Create Information Incl. in 3.BD. Gather Information Incl. in 3.EE. Report Preparation

1) Initial Notification 5 $0 1 5 17 85 4 9 $9,246 $0 172) Batch precompliance report 5 $0 1 5 17 85 4 9 $9,246 $0 173) Notification of performance test with test plan 10 $0 1 10 17 170 9 17 $18,492 $0 174) Notification of compliance status 20 $0 1 20 17 340 17 34 $36,983 $0 17 b5) Compliance report 25 $0 1 25 0 0 0 0 $0 $0 06) Notice of inspection 5 $0 1 5 17 85 4 9 $9,246 $0 177) Affirmative defense 18 $0 1 18 0 18 12 0 $0 $0 0 g

ReportingSubtotal 2,718 136 272 $295,647 $2,444,820 854. Recordkeeping Requirements

A. Read Instructions Incl. in 3.A 

B. Implement Activities N/AC. Develop Record System N/AD. Record Information

1) Records of process vent requirements 10 $0 1 10 0 0 0 0 $0 $0 0

2) Records of resin stripper and wastewater requirements 15 $0 1 15 0 0 0 0 $0 $0 0

3) Records of storage vessel requirements 10 $0 1 10 0 0 0 0 $0 $0 04) Records of equipment leak requirements 25 $0 1 25 0 0 0 0 $0 $0 05) Records of heat exchanger requirements 10 $0 1 10 0 0 0 0 $0 $0 0

E. Personnel Training Incl. in 3.B 

F. Time for Audits N/A

Recordkeeping Subtotal 0 0 0 $0 $0 0TOTAL: 2,718 136 272 $295,647 $2,444,820 85

Total Hours Labor Non-Labor Total

Summary of Respondent Burden 3,126 $295,647 $2,444,820 $2,740,467Initial Capital and Startup $3,298,721

 $2,444,820

FOOTNOTES

a 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 Includes 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 estimate

Annualized Capital/Start-up and O & M

for Existing Sources: Polyvinyl Chloride and Copolymer Manufacturing Units - Year 1

Table 1 - Annual Respondent Burden and Cost of Recordkeeping and Reporting Requirements of the MACT Floor

Footnotes
Attachment G3

(A) (B) (C) (D) (E) (F) (G)

Respondent Non-Labor Number of Hours Number of Technical Management Clerical Total Total Total 

Hours per Costs Occurrences Per Respondents Hours Hours Hours Labor Costs Non-Labor Responses

Occurrence Per Per Respondent Per Year Per Year Per Year Per Year Per Year Costs Per Year

(Technical Occurrence Respondent Per Year Per Year

Burden Item hours) Per Year (C=A x B) (CXD) (E x 0.05) (E x 0.1)

1. Applications N/A2. Surveys and Studies N/A3. Reporting Requirements

A. Read and Understand Rule Requirements 25 $100 1 25 0 0 0 0 $0 $0 0 a,b

B. Required Activities

1) Initial performance test, sampling, and report 40 $53,139 1 40 0 0 0 0 $0 $0 0 a

2) Periodic performance test, sampling, and report 50 $108,750 1 50 17 850 43 85 $92,458 $1,848,751 0

3) Establish operating parameters and monitoring plan 20 $0 1 20 0 0 0 0 $0 $0 0 a

4) Continuous parameter monitoring

a) Initial capital costs (Fabric Filters) 0 $0 1 0 0 0 0 0 $0 $0 0 a,d

b) Annualized capital and O&M costs (Fabric Filters & ACI) 11 $31,700 1 11 5 55 3 6 $5,983 $158,500 0 c,ec) Initial capital costs (PRD Electronic Monitor) 0 $0 1 0 0 0 0 0 $0 $0 0 a,d

d) Annualized capital and O&M costs (PRD Electronic Monitor) 11 $26,897 1 11 17 187 9 19 $20,341 $457,249 0 c,e

e) Initial capital costs (PB Scrubber Monitor) 0 $0 1 0 0 0 0 0 $0 $0 0 a,d

f) Annualized capital and O&M costs (PB Scrubber Monitor 11 $5,300 1 11 1 11 1 1 $1,197 $5,300 0 c,e

C. Create Information Incl. in 3.BD. Gather Information Incl. in 3.E

E. Report Preparation

1) Initial Notification 5 $0 1 5 0 0 0 0 $0 $0 02) Batch precompliance report 5 $0 1 5 0 0 0 0 $0 $0 03) Notification of performance test with test plan 10 $0 1 10 0 0 0 0 $0 $0 0

4) Notification of compliance status 20 $0 1 20 0 0 0 0 $0 $0 0 b

5) Compliance report 25 $0 1 25 17 425 21 43 $46,229 $0 176) Notice of inspection 5 $0 1 5 17 85 4 9 $9,246 $0 17

7) Affirmative defense 18 $0 1 18 0 18 12 0 $0 $0 0 f

ReportingSubtotal 1,613 81 161 $175,452 $2,469,800 344. Recordkeeping Requirements

A. Read Instructions Incl. in 3.A 

B. Implement Activities N/AC. Develop Record System N/AD. Record Information

1) Records of process vent requirements 10 $0 1 10 17 170 9 17 $18,492 $0 0

2) Records of resin stripper and wastewater requirements 15 $0 1 15 17 255 13 26 $27,737 $0 0

3) Records of storage vessel requirements 10 $0 1 10 17 170 9 17 $18,492 $0 0

4) Records of equipment leak requirements 25 $0 1 25 17 425 21 43 $46,229 $0 0

5) Records of heat exchanger requirements 10 $0 1 10 17 170 9 17 $18,492 $0 0

E. Personnel Training Incl. in 3.B 

F. Time for Audits N/A

Recordkeeping Subtotal 1190 59.5 119 $129,441 $0 0TOTAL: 2,803 140 280 $304,893 $2,469,800 34

Total Hours Labor Non-Labor Total

Summary of Respondent Burden 3,223 $304,893 $2,469,800 $2,774,693Initial Capital and Startup $0

 $2,469,800

FOOTNOTES

a 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 estimate

Annualized Capital/Start-up and O & M

for Existing Sources: Polyvinyl Chloride and Copolymer Manufacturing Units - Year 2

Table 2 - Annual Respondent Burden and Cost of Recordkeeping and Reporting Requirements of the MACT Floor

Footnotes
Attachment G4



(A) (B) (C) (D) (E) (F) (G)

Respondent Non-Labor Number of Hours Number of Technical Management Clerical Total Total Total 

Hours per Costs Occurrences Per Respondents Hours Hours Hours Labor Costs Non-Labor Responses

Occurrence Per Per Respondent Per Year Per Year Per Year Per Year Per Year Costs Per Year

(Technical Occurrence Respondent Per Year Per Year

Burden Item hours) Per Year (C=A x B) (CXD) (E x 0.05) (E x 0.1)

1. Applications N/A2. Surveys and Studies N/A3. Reporting Requirements

A. Read and Understand Rule Requirements 25 $100 1 25 0 0 0 0 $0 $0 0 a,b

B. Required Activities

1) Initial performance test, sampling, and report 40 $53,139 1 40 0 0 0 0 $0 $0 0 a

2) Periodic performance test, sampling, and report 50 $108,750 1 50 17 850 43 85 $92,458 $1,848,751 0

3) Establish operating parameters and monitoring plan 20 $0 1 20 0 0 0 0 $0 $0 0 a4) Continuous parameter monitoring

a) Initial capital costs (Fabric Filters) 0 $0 1 0 0 0 0 0 $0 $0 0 a,db) Annualized capital and O&M costs (Fabric Filters & ACI) 11 $31,700 1 11 5 55 3 6 $5,983 $158,500 0 c,e

c) Initial capital costs (PRD Electronic Monitor) 0 $0 1 0 0 0 0 0 $0 $0 0 a,dd) Annualized capital and O&M costs (PRD Electronic Monitor) 11 $26,897 1 11 17 187 9 19 $20,341 $457,249 0 c,ee) Initial capital costs (PB Scrubber Monitor) 0 $0 1 0 0 0 0 0 $0 $0 0 a,df) Annualized capital and O&M costs (PB Scrubber Monitor 11 $5,300 1 11 1 11 1 1 $1,197 $5,300 0 c,e

C. Create Information Incl. in 3.BD. Gather Information Incl. in 3.EE. Report Preparation

1) Initial Notification 5 $0 1 5 0 0 0 0 $0 $0 0

2) Batch precompliance report 5 $0 1 5 0 0 0 0 $0 $0 0

3) Notification of performance test with test plan 10 $0 1 10 0 0 0 0 $0 $0 04) Notification of compliance status 20 $0 1 20 0 0 0 0 $0 $0 0 b5) Compliance report 25 $0 1 25 17 425 21 43 $46,229 $0 176) Notice of inspection 5 $0 1 5 17 85 4 9 $9,246 $0 177) Affirmative defense 18 $0 1 18 0 18 12 0 $0 $0 0 f

ReportingSubtotal 1,613 81 161 $175,452 $2,469,800 344. Recordkeeping Requirements

A. Read Instructions Incl. in 3.A B. Implement Activities N/AC. Develop Record System N/AD. Record Information

1) Records of process vent requirements 10 $0 1 10 17 170 9 17 $18,492 $0 0

2) Records of resin stripper and wastewater requirements 15 $0 1 15 17 255 13 26 $27,737 $0 03) Records of storage vessel requirements 10 $0 1 10 17 170 9 17 $18,492 $0 04) Records of equipment leak requirements 25 $0 1 25 17 425 21 43 $46,229 $0 05) Records of heat exchanger requirements 10 $0 1 10 17 170 9 17 $18,492 $0 0

E. Personnel Training Incl. in 3.B 

F. Time for Audits N/A

Recordkeeping Subtotal 1190 59.5 119 $129,441 $0 0TOTAL: 2,803 140 280 $304,893 $2,469,800 34

Total Hours Labor Non-Labor Total

Summary of Respondent Burden 3,223 $304,893 $2,469,800 $2,774,693Initial Capital and Startup $0

 $2,469,800

FOOTNOTES

a 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 estimate

Annualized Capital/Start-up and O & M

for Existing Sources: Polyvinyl Chloride and Copolymer Manufacturing Units - Year 3

Table 3 - Annual Respondent Burden and Cost of Recordkeeping and Reporting Requirements of the MACT Floor

Footnotes
Attachment H 

Cost Algorithm for Additional Resin Stripping Steam 
Steam Stripper - PVC Resin - Cost Analysis - VC and TOH

Company CertainTeed Corporation CertainTeed Corporation The Dow Chemical Company Formosa Plastics Corporation USA Formosa Plastics Corporation USA Formosa Plastics Corporation USA For

PlaCor

US

Facility

Lake Charles Polymer Plant

Lake Charles Polymer Plant

Dow Midland - 

SARAN Resins

Formosa Plastics Corporation 

Baton Rouge

Delaware City

Delaware City Poi

Process Type Bulk Bulk Suspension (A) Suspension Dispersion Dispersion Sus

Process Type Std Bulk Bulk Suspension Suspension Dispersion Dispersion SusProcess Unit ID P-1 P-2 Vinyl Train P-1 P-1 P-2 P-1 Stripped Resin Stream ID S-6 S-15 S-1 (Reactor) S-4 S-2, S-7 S-2 U-5 Stripping Type Batch Batch Batch Continuous Batch Batch ConInlet Stream Flow, liters/min 292 161 1249 3562 411 411 

A. Parameters (Inputs and Example 

Calculation)

1. Stripper inlet flow rate, lpm (Q) 500 292 161 1249 3562 411 411 2. Annual operating hours, hr/yr (H) 8400 8400 8400 8400 8400 8400 8400 3. Steam to Feed Ratio, kg / l (S) 0.096 0.096 0.096 0.096 0.096 0.096 0.096 4. Electricity use, kWhr/day (EU) 260 260 260 260 260 260 260 5. Operating labor rate, $/hr (LR) [2] $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 6. Electricity cost, $/kWh (EC) [3] $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 7. Water cost, $/1,000 gal (WC) [4] $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 8. Steam cost, $/1,000 lb (SC) [4] $4.65 $4.65 $4.65 $4.65 $4.65 $4.65 $4.65 

9. Capital recovery factor = [i x (1 + i)a] / [(1 + i)a - 1], where i = interest rate, a = equipment life a. Equipment CRF, 20-yr life, 7% 

interest

0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 

10. Cost index a. 2010 641.1 641.1 641.1 641.1 641.1 641.1 641.1  b. 1989 356.0 356.0 356.0 356.0 356.0 356.0 356.0 11. VCM Concnetration, ppm [C] 7.10 7.10 7.16 0.59 67.4 67.4 12. VCM limit, ppm [L] 20.0 7.10 7.10 0.47 0.47 55.00 55.00 13. VCM recovery percentage, % 99.0 0.0 0.0 93.4 20.5 18.4 18.4 14. VOC recovery value, $/lb [RV] $0.313 $0.313 $0.313 $0.313 $0.313 $0.313 $0.313 

B. Total Capital Investment

1. $ = 0.3731 x Q^0.267 x 10^6 $0 $0 $0 $0 $0 $0 $0 2. $ / lpm = $ / Q $0 $0 $0 $0 $0 $0 $0 

C. Direct Annual Operating Costs, $/yr

1. Electricity = EU / (24 hr/day) x H x EC $6,079 $0 $0 $0 $0 $0 $0 2. 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 $

3. Water = Q x (5220 liters water-min / liters feed-day) x (1 day / 24 hr) x H x (0.264 

gal/liter) x WC / 1000

$0 $0 $0 $0 $0 $0 $0 

Parameters/Costs Equation

gal/liter) x WC / 1000

4. Operating labor = (1 hr/shift) x (1 shift/8 hr) x H x LR $36,330 $0 $0 $0 $0 $0 $0 5. Supervisory labor = 0.15 x (operating labor) $5,450 $0 $0 $0 $0 $0 $0 6. 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 7. Maintenance materials = 0.02 x TCI $0 $0 $0 $0 $0 $0 $0 

D. Indirect Annual Costs, $/yr

1. Overhead = 0.6 x (labor + maintenance materials) $37,057 $0 $0 $0 $0 $0 $0 

2. Property taxes, insurance, and 

administration

= 0.04 x TCI $0 $0 $0 $0 $0 $0 $0 

3. Capital recovery = Equipment CRF x TCI $0 $0 $0 $0 $0 $0 $0 

E. Recovery Credit, $/yr

a. Recovered vinyl chloride, kg/yr [VCR] = C x 10^-6 x Q x (1 kg/l) x (60 min/hr) x H x RP 0.00 0.00 0.00 4211.96 217.23 2568.59 2568.59 b. Value of recovered vinyl chloride, $/yr = VCR x (2.2 lb/kg) x RV $0 $0 $0 $2,900 $150 $1,769 $1,769 

F. Include in Annual Cost? No No Yes Yes Yes Yes No F. Total Annual Cost

1. $/yr = Direct Annual Costs + Indirect Annual Costs - Recovery Credit $352,381 0 0 $615,407 $1,762,963 $201,663 $201,663 0 2. ($/yr) / lpm = ($/yr) / Q $705 $493 $495 $491 $491 

Sources: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)

H-1
Steam Stripper - PVC Resin - Cost Analysis - VC and TOH

CompanyFacilityProcess Type

Process Type StdProcess Unit IDStripped Resin Stream IDStripping TypeInlet Stream Flow, liters/min

A. Parameters (Inputs and Example 

Calculation)

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] $4.65

9. Capital recovery factor = [i x (1 + i)a] / [(1 + i)a - 1], where i = interest rate, a = equipment life a. Equipment CRF, 20-yr life, 7% 

interest

0.09439

10. Cost index a. 2010 641.1 b. 1989 356.011. VCM Concnetration, ppm [C]12. VCM limit, ppm [L] 20.013. VCM recovery percentage, % 99.014. VOC recovery value, $/lb [RV] $0.313

B. Total Capital Investment

1. $ = 0.3731 x Q^0.267 x 10^6 $0 2. $ / lpm = $ / Q $0 

C. Direct Annual Operating Costs, $/yr

1. Electricity = EU / (24 hr/day) x H x EC $6,079 2. Steam = Q x S x (2.2 lb/kg) x (60 min/hr) x H x SC / 1000 $247,484 

3. Water = Q x (5220 liters water-min / liters feed-day) x (1 day / 24 hr) x H x (0.264 

gal/liter) x WC / 1000

$0 

Parameters/Costs Equation

Georgia Gulf Corporation OxyVinyls, LP OxyVinyls, LP OxyVinyls, LP OxyVinyls, LP OxyVinyls, LP OxyGeorgia Gulf Chemicals Plaquemine 

Facility

OxyVinyls Deer Park

OxyVinyls Deer Park

OxyVinyls Deer Park

OxyVinyls Pasadena

OxyVinyls Pasadena

OxyPas

Suspension 

(A) Suspension Suspension Suspension Suspension Suspension SusSuspension Suspension Suspension Suspension Suspension Suspension SusP-1 P-1 P-1 P-2 P-3 P-4 P-5 S-1 S-146 S-149 S-245 S-308 S-408 S-5Continuous Continuous Continuous Continuous

5867 644 530 1003 891 978 

5867 644 530 1003 891 978 8400 8400 8400 8400 8400 8400 

0.096 0.096 0.096 0.096 0.096 0.096 

260 260 260 260 260 260 

$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 $4.65 

0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 

641.1 641.1 641.1 641.1 641.1 641.1 356.0 356.0 356.0 356.0 356.0 356.0 21.39 0.20 0.20 0.20 2.83 2.83 

0.47 0.47 0.47 0.47 0.47 0.47 97.8 -136.2 -136.2 -136.2 83.4 83.4 

$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 

$2,904,171 $318,522 $262,312 $496,520 $441,119 $484,249 

$0 $0 $0 $0 $0 $0 

gal/liter) x WC / 1000

4. Operating labor = (1 hr/shift) x (1 shift/8 hr) x H x LR $36,330 5. Supervisory labor = 0.15 x (operating labor) $5,450 6. Maintenance labor = (0.5 hr/shift) x (1 shift/8 hr) x H x (LR x 1.1) $19,982 7. Maintenance materials = 0.02 x TCI $0 

D. Indirect Annual Costs, $/yr

1. Overhead = 0.6 x (labor + maintenance materials) $37,057 

2. Property taxes, insurance, and 

administration

= 0.04 x TCI $0 

3. Capital recovery = Equipment CRF x TCI $0 

E. Recovery Credit, $/yr

a. Recovered vinyl chloride, kg/yr [VCR] = C x 10^-6 x Q x (1 kg/l) x (60 min/hr) x H x RP 0.00b. Value of recovered vinyl chloride, $/yr = VCR x (2.2 lb/kg) x RV $0 

F. Include in Annual Cost?F. Total Annual Cost

1. $/yr = Direct Annual Costs + Indirect Annual Costs - Recovery Credit $352,381 2. ($/yr) / lpm = ($/yr) / Q $705

Sources: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 

61863.86 (87.89) (72.38) (137.01) 1060.48 1164.18 

$42,599 ($61) ($50) ($94) $730 $802 

Yes No No No Yes Yes Yes 

$2,861,572 0 0 0 $440,388 $483,448 

$488 $494 $494 

H-2
Steam Stripper - PVC Resin - Cost Analysis - VC and TOH

CompanyFacilityProcess Type

Process Type StdProcess Unit IDStripped Resin Stream IDStripping TypeInlet Stream Flow, liters/min

A. Parameters (Inputs and Example 

Calculation)

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] $4.65

9. Capital recovery factor = [i x (1 + i)a] / [(1 + i)a - 1], where i = interest rate, a = equipment life a. Equipment CRF, 20-yr life, 7% 

interest

0.09439

10. Cost index a. 2010 641.1 b. 1989 356.011. VCM Concnetration, ppm [C]12. VCM limit, ppm [L] 20.013. VCM recovery percentage, % 99.014. VOC recovery value, $/lb [RV] $0.313

B. Total Capital Investment

1. $ = 0.3731 x Q^0.267 x 10^6 $0 2. $ / lpm = $ / Q $0 

C. Direct Annual Operating Costs, $/yr

1. Electricity = EU / (24 hr/day) x H x EC $6,079 2. Steam = Q x S x (2.2 lb/kg) x (60 min/hr) x H x SC / 1000 $247,484 

3. Water = Q x (5220 liters water-min / liters feed-day) x (1 day / 24 hr) x H x (0.264 

gal/liter) x WC / 1000

$0 

Parameters/Costs Equation

OxyVinyls, LP OxyVinyls, LP OxyVinyls, LP PolyOne Corporation PolyOne Corporation PolyOne Corporation Pol

Cor

OxyVinyls Pasadena

OxyVinyls Pedricktown

OxyVinyls Pedricktown

PolyOne Henry

PolyOne Henry

PolyOne Henry

PolHen

Suspension Suspension Suspension Dispersion Dispersion Dispersion Sus

Suspension Suspension Suspension Dispersion Dispersion Dispersion DisP-8 P-1 P-2 P-1 P-2 P-3 P-4 S-508 S-109 S-209 S-1 S-2 S-1 S-3 

Continuous Continuous Batch Batch Batch Con

1151 560 560 55 118 25 

1151 560 560 55 118 25 8400 8400 8400 8400 8400 8400 

0.096 0.096 0.096 0.096 0.096 0.096 

260 260 260 260 260 260 

$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 $4.65 

0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 

641.1 641.1 641.1 641.1 641.1 641.1 356.0 356.0 356.0 356.0 356.0 356.0 

2.83 2.52 2.52 42.80 42.80 42.80 0.47 0.47 0.47 55.00 55.00 55.00 83.4 81.3 81.3 -28.5 -28.5 -28.5 

$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 

$569,568 $277,302 $277,302 $27,009 $58,174 $12,466 

$0 $0 $0 $0 $0 $0 

gal/liter) x WC / 1000

4. Operating labor = (1 hr/shift) x (1 shift/8 hr) x H x LR $36,330 5. Supervisory labor = 0.15 x (operating labor) $5,450 6. Maintenance labor = (0.5 hr/shift) x (1 shift/8 hr) x H x (LR x 1.1) $19,982 7. Maintenance materials = 0.02 x TCI $0 

D. Indirect Annual Costs, $/yr

1. Overhead = 0.6 x (labor + maintenance materials) $37,057 

2. Property taxes, insurance, and 

administration

= 0.04 x TCI $0 

3. Capital recovery = Equipment CRF x TCI $0 

E. Recovery Credit, $/yr

a. Recovered vinyl chloride, kg/yr [VCR] = C x 10^-6 x Q x (1 kg/l) x (60 min/hr) x H x RP 0.00b. Value of recovered vinyl chloride, $/yr = VCR x (2.2 lb/kg) x RV $0 

F. Include in Annual Cost?F. Total Annual Cost

1. $/yr = Direct Annual Costs + Indirect Annual Costs - Recovery Credit $352,381 2. ($/yr) / lpm = ($/yr) / Q $705

Sources: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 

1369.29 577.71 577.71 (335.53) (722.67) (154.86) 

$943 $398 $398 ($231) ($498) ($107) 

Yes Yes Yes No No No No 

$568,625 $276,904 $276,904 0 0 0 0 

$494 $494 $494

H-3
Steam Stripper - PVC Resin - Cost Analysis - VC and TOH

CompanyFacilityProcess Type

Process Type StdProcess Unit IDStripped Resin Stream IDStripping TypeInlet Stream Flow, liters/min

A. Parameters (Inputs and Example 

Calculation)

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] $4.65

9. Capital recovery factor = [i x (1 + i)a] / [(1 + i)a - 1], where i = interest rate, a = equipment life a. Equipment CRF, 20-yr life, 7% 

interest

0.09439

10. Cost index a. 2010 641.1 b. 1989 356.011. VCM Concnetration, ppm [C]12. VCM limit, ppm [L] 20.013. VCM recovery percentage, % 99.014. VOC recovery value, $/lb [RV] $0.313

B. Total Capital Investment

1. $ = 0.3731 x Q^0.267 x 10^6 $0 2. $ / lpm = $ / Q $0 

C. Direct Annual Operating Costs, $/yr

1. Electricity = EU / (24 hr/day) x H x EC $6,079 2. Steam = Q x S x (2.2 lb/kg) x (60 min/hr) x H x SC / 1000 $247,484 

3. Water = Q x (5220 liters water-min / liters feed-day) x (1 day / 24 hr) x H x (0.264 

gal/liter) x WC / 1000

$0 

Parameters/Costs Equation

PolyOne Corporation

Shintech, Inc. Corporate Office

Shintech, Inc. Corporate Office

Shintech, Inc. Corporate Office

Shintech, Inc. Corporate Office

Shintech, Inc. Corporate Office

WeCheCor

PolyOne Pedricktown

Shintech Addis 

Shintech Addis 

Shintech Freeport

Shintech Freeport

Shintech Plaquemine

WeCal

Dispersion Suspension (A) Suspension (A) Suspension (A) Suspension (A) Suspension (A) Sus

Dispersion Suspension Suspension Suspension Suspension Suspension SusP-1 P-1 P-1 P-1 P-1 P-1 P-1 S-2 S-1A S-1B S-1a S-1b S-1 S-1 Continuous Continuous Continuous Continuous Continuous Continuous 

303 1454 1454 644 795 1476 

303 1454 1454 644 795 1476 

8400 8400 8400 8400 8400 8400 

0.096 0.096 0.096 0.096 0.096 0.096 

260 260 260 260 260 260 

$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 $4.65 

0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 

641.1 641.1 641.1 641.1 641.1 641.1 356.0 356.0 356.0 356.0 356.0 356.0 28.50 0.58 0.58 0.77 0.77 0.54 55.00 0.47 0.47 0.47 0.47 0.47 

-93.0 18.8 18.8 39.1 39.1 13.0 

$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 

$149,893 $719,485 $719,485 $318,522 $393,468 $730,727 

$0 $0 $0 $0 $0 $0 

gal/liter) x WC / 1000

4. Operating labor = (1 hr/shift) x (1 shift/8 hr) x H x LR $36,330 5. Supervisory labor = 0.15 x (operating labor) $5,450 6. Maintenance labor = (0.5 hr/shift) x (1 shift/8 hr) x H x (LR x 1.1) $19,982 7. Maintenance materials = 0.02 x TCI $0 

D. Indirect Annual Costs, $/yr

1. Overhead = 0.6 x (labor + maintenance materials) $37,057 

2. Property taxes, insurance, and 

administration

= 0.04 x TCI $0 

3. Capital recovery = Equipment CRF x TCI $0 

E. Recovery Credit, $/yr

a. Recovered vinyl chloride, kg/yr [VCR] = C x 10^-6 x Q x (1 kg/l) x (60 min/hr) x H x RP 0.00b. Value of recovered vinyl chloride, $/yr = VCR x (2.2 lb/kg) x RV $0 

F. Include in Annual Cost?F. Total Annual Cost

1. $/yr = Direct Annual Costs + Indirect Annual Costs - Recovery Credit $352,381 2. ($/yr) / lpm = ($/yr) / Q $705

Sources: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 

(4044.64) 79.85 79.85 97.95 121.00 52.08 

($2,785) $55 $55 $67 $83 $36 

No Yes Yes Yes Yes Yes Yes 0 $719,430 $719,430 $318,455 $393,385 $730,691 

$495 $495 $495 $495 $495 

H-4
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 $901.50

3 outlet tests $901.50

Total Compliance Cost $1,803.00

CRF (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 $300.50

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 

Resin 

Testing

Company Location 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 I -Resin Testing and Monitoring Cost Algorithm I-1
Attachment J 

Heat Exchange System Cost Analysis 
Summary of Testing and Monitoring Costs for Heat Exchange Systems

CompanyName FacilityName Num of CTs CT ID Sampling and Analysis, $/yrtower Costs to Repair, $/event-tower Repairs, event/yr Sampling and Analysis, $/yr Co

Repa

CertainTeed Lake Charles 1 U-13 $7,600 $4,300 1 $7,600 CertainTeed Lake Charles 1 U-19 $7,600 $4,300 1 $7,600 Formosa Baton Rouge 1 U-10 $7,600 $4,300 1 $7,600 Formosa Delaware City 1 U-14 $7,600 $4,300 1 $7,600 Formosa Delaware City 1 U-73 $7,600 $4,300 1 $7,600 Formosa Point Comfort - PVC 1 U-24 $7,600 $4,300 1 $7,600 Georgia Gulf Aberdeen 1 U-66 $7,600 $4,300 1 $7,600 Georgia Gulf Aberdeen 1 U-67 $7,600 $4,300 1 $7,600 Georgia Gulf Aberdeen 1 U-68 $7,600 $4,300 1 $7,600 Georgia Gulf Aberdeen 1 U-69 $7,600 $4,300 1 $7,600 Georgia Gulf Plaquemine 1 unknown - assume 2 CTs $7,600 $4,300 1 $7,600 Georgia Gulf Plaquemine 1 unknown - assume 2 CTs $7,600 $4,300 1 $7,600 OxyVinyls Deer Park 1 unknown - assume 3 CTs $7,600 $4,300 1 $7,600 OxyVinyls Deer Park 1 unknown - assume 3 CTs $7,600 $4,300 1 $7,600 OxyVinyls Deer Park 1 unknown - assume 3 CTs $7,600 $4,300 1 $7,600 OxyVinyls Pasadena 1 U-1103 $7,600 $4,300 1 $7,600 OxyVinyls Pasadena 1 U-1104 $7,600 $4,300 1 $7,600 OxyVinyls Pedricktown 1 U-600 $7,600 $4,300 1 $7,600 PolyOne Henry 1 U-1 $7,600 $4,300 1 $7,600 PolyOne Pedricktwon 1 U-18 $7,600 $4,300 1 $7,600 Shintech Addis 1 U-62 $7,600 $4,300 1 $7,600 Shintech Freeport 1 U-45 $7,600 $4,300 1 $7,600 Shintech Plaquemine 1 U-58 $7,600 $4,300 1 $7,600 Dow Midland Midland 1 CTW-1 $7,600 $4,300 1 $7,600 Westlake Calvert City 1 U-89 $7,600 $4,300 1 $7,600 Westlake Geismar 1 U-40 $7,600 $4,300 1 $7,600 

Bulk $0 $ Dispersion $30,400 $ Other $ 159,600.00 $ 9TOTAL $190,000 * PolyOne - Henry included in "Dispersi

J-1
Attachment K 

Equipment Leak Testing and Monitoring Cost Algorithm 
Attachment K - Equipment Leaks

Company Facility

LDAR 

Program 

Type (by 

Survey)

Facility 

Reported LDAR 

Cost ($) 

2006 

Capacity 

1,000 US 

Tons

Facility LDAR 

Cost 

$/1,000Ton 

Facility LDAR 

Cost by Using 

Average Cost of 

40CFR61V x 2006 

Facility LDAR Cost 

by Using Average 

Cost of 

40CFR63UU x 2006 

Increase in LDAR Cost 

from V to UU 

PRV Cost 

Reduction TAC 

[1]

PRV Cost 

Reduction TC

[1]

Certain Teed Lake Charles 40CFR61 V $26,000 240.3 108 $ $55,860 $64,595 $8,736 $ 16,105 $ 113,116 

Formosa Baton Rouge 40CFR61 V - 458.6 - $106,595 $123,265 $16,670 $ 26,897 $ 188,913 Formosa Delaware City40CFR63 UU $20,000 71.7 279 $ $16,655 $19,260 $0 $ 26,897 $ 188,913 Formosa Point Comfort40CFR61 V $43,675 782.6 56 $ $181,929 $210,380 $28,451 $ 26,897 $ 188,913 Georgia Gulf Aberdeen 40CFR61 V - 500.4 - $116,332 $134,524 $18,193 $ 26,897 $ 188,913 Georgia Gulf Plaquemine 40CFR63 UU $155,000 599.7 $ 258 $139,393 $161,192 $0 $ 26,897 $ 188,913 OxyVinyls Deer Park 40CFR61 V $29,094 275.6 $ 106 $64,059 $74,077 $10,018 $ 26,897 $ 188,913 OxyVinyls Pasadena 40CFR61 V $85,277 1050.5 $ 81 $244,194 $282,383 $38,189 $ 26,897 $ 188,913 OxyVinyls Pedricktown 40CFR61 V $16,000 175.3 $ 91 $40,742 $47,113 $6,371 $ 26,897 $ 188,913 PolyOne Henry 40CFR61 V $2,160 62.8 $ 34 $14,606 $16,890 $2,284 $ 26,897 $ 188,913 PolyOne Pedricktown 40CFR61 V $20,000 65.0 $ 308 $15,118 $17,482 $2,364 $ 26,897 $ 188,913 Shintech Addis 40CFR61 V $14,000 312.0 $ 45 $72,515 $83,856 $11,340 $ 26,897 $ 188,913 Shintech Freeport 40CFR63 UU - 1598.3 - $371,544 $429,649 $0 $ 26,897 $ 188,913 Shintech Plaquemine 40CFR61 V $17,000 650.4 $ 26 $151,180 $174,823 $23,642 $ 26,897 $ 188,913 Dow Midland2 40CFR61 V $20,000 10.8 1,852 $ $2,511 $2,903 $393 $ 26,897 $ 188,913 Westlake Calvert City 40CFR61 V $10,000 400.1 $ 25 $93,014 $107,560 $14,546 $ 26,897 $ 188,913 Westlake Geismar 40CFR61 V $16,525 286.6 $ 58 $66,622 $77,040 $10,419 $ 26,897 $ 188,913 

Total $ 446,457 $ 3,135,72

[1] EPA supplied cost factors from "PVC_PRV_Cost_reductions_110310" option 4, average facility 40CFR61 V 232.5[2] Non CBI production data - Capacity information not available 40CFR63UU 268.8 Average $/KTon
Attachment L 

Wastewater Compliance Cost Algorithm 
Attachment L - Process Wastewater Compliance Cost Algorithm

Steam Stripper - PVC Resin - Cost Analysis - VC and TOH

Company Certain Teed Lake Charles Dow Midland Formosa Baton Rouge Formosa Delaware Formosa Point Comfort OxyVinyls Deer ParkProcess Type Bulk Other Other Dispersion Other OtherProcess Type Std BulkInlet Stream Flow, gal/yr 3600 677273.0019 13703040 4493214.091 49079723.14 17281592Inlet Stream Flow, liters/min 0.027039 5.086859 102.920738 33.747615 368.627789 129.798

A. Parameters (Inputs and Example 

Calculation)

1. Stripper inlet flow rate, lpm (Q) 500 0.027 5.087 102.921 33.748 368.628 1292. Annual operating hours, hr/yr (H) 8400 8400 8400 8400 8400 8400 83. Steam to Feed Ratio, kg / l (S) 0.096 0.096 0.096 0.096 0.096 0.096 04. Electricity use, kWhr/day (EU) 260 260 260 260 260 260 5. Operating labor rate, $/hr (LR) [2] $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $346. Electricity cost, $/kWh (EC) [3] $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $07. Water cost, $/1,000 gal (WC) [4] $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $08. Steam cost, $/1,000 lb (SC) [4] $4.65 $4.65 $4.65 $4.65 $4.65 $4.65 $4

9. Capital recovery factor = [i x (1 + i)a] / [(1 + i)a - 1], where i = 

interest rate, a = equipment life

 a. Equipment CRF, 20-yr life, 7% 

interest

0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09

10. Cost index a. 2010 641.1 641.1 641.1 641.1 641.1 641.1 64 b. 1989 356.0 356.0 356.0 356.0 356.0 356.0 3511. VCM Concnetration, ppm [C] 0.40 0.54 0.14 0.54 0.54 012. VCM limit, ppm [L] 20.0 0.11 0.11 0.11 0.11 0.11 013. VCM recovery percentage, % 99.0 72.5 79.6 21.4 79.6 79.6 -614. VOC recovery value, $/lb [RV] $0.313 $0.313 $0.313 $0.313 $0.313 $0.313 $0

B. Total Capital Investment

1. $ = 0.3731 x Q^0.267 x 10^6 $0 $0 $1 $2 $3 $4 2. $ / lpm = $ / Q $0 $0 $0 $0 $0 $0 

C. Direct Annual Operating Costs, $/yr

1. Electricity = EU / (24 hr/day) x H x EC $6,079 $0 $1 $2 $3 $4 

2. Steam = Q x S x (2.2 lb/kg) x (60 min/hr) x H x 

SC / 1000

$247,484 $13 $2,518 $50,943 $16,704 $182,459 $64

3. Water = Q x (5220 liters water-min / liters feedday) x (1 day / 24 hr) x H x (0.264 

gal/liter) x WC / 1000

$0 $0 $0 $0 $0 $0 

4. Operating labor = (1 hr/shift) x (1 shift/8 hr) x H x LR $36,330 $0 $0 $0 $0 $0 5. Supervisory labor = 0.15 x (operating labor) $5,450 $0 $0 $0 $0 $0 6. Maintenance labor = (0.5 hr/shift) x (1 shift/8 hr) x H x (LR x $19,982 $0 $0 $0 $0 $0 7. Maintenance materials = 0.02 x TCI $0 $0 $0 $0 $0 $0 

D. Indirect Annual Costs, $/yr

1. Overhead = 0.6 x (labor + maintenance materials) $37,057 $0 $0 $0 $0 $0 2. Property taxes, insurance, and = 0.04 x TCI $0 $0 $0 $0 $0 $0 

Parameters/Costs Equation

2. Property taxes, insurance, and administration

= 0.04 x TCI $0 $0 $0 $0 $0 $0 

3. Capital recovery = Equipment CRF x TCI $0 $0 $0 $0 $0 $0 

E. Recovery Credit, $/yr

a. Recovered vinyl chloride, kg/yr [VCR] = C x 10^-6 x Q x (1 kg/l) x (60 min/hr) x 

H x RP

0.00 0.00 1.10 1.56 7.29 79.65 (2

b. Value of recovered vinyl chloride, $/yr = VCR x (2.2 lb/kg) x RV $0 $0 $1 $1 $5 $55 

F. Include in Annual Cost? Yes Yes Yes Yes Yes NoF. Total Annual Cost

1. $/yr

= Direct Annual Costs + Indirect Annual 

Costs - Recovery Credit

$352,381 $13 $2,518 $50,944 $16,702 $182,409 0

2. ($/yr) / lpm = ($/yr) / Q $705 $495 $495 $495 $495 $495

Sources:

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 Estimates

3. 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)
Attachment L - Process Wastewater Compliance Cost Algorithm

Steam Stripper - PVC Resin - Cost Analysis - VC and TOH

CompanyProcess TypeProcess Type StdInlet Stream Flow, gal/yrInlet Stream Flow, liters/min

A. Parameters (Inputs and Example 

Calculation)

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] $4.65

9. Capital recovery factor = [i x (1 + i)a] / [(1 + i)a - 1], where i = 

interest rate, a = equipment life

 a. Equipment CRF, 20-yr life, 7% 

interest

0.09439

10. Cost index a. 2010 641.1 b. 1989 356.011. VCM Concnetration, ppm [C]12. VCM limit, ppm [L] 20.013. VCM recovery percentage, % 99.014. VOC recovery value, $/lb [RV] $0.313

B. Total Capital Investment

1. $ = 0.3731 x Q^0.267 x 10^6 $0 2. $ / lpm = $ / Q $0 

C. Direct Annual Operating Costs, $/yr

1. Electricity = EU / (24 hr/day) x H x EC $6,079 

2. Steam = Q x S x (2.2 lb/kg) x (60 min/hr) x H x 

SC / 1000

$247,484 

3. Water = Q x (5220 liters water-min / liters feedday) x (1 day / 24 hr) x H x (0.264 

gal/liter) x WC / 1000

$0 

4. Operating labor = (1 hr/shift) x (1 shift/8 hr) x H x LR $36,330 5. Supervisory labor = 0.15 x (operating labor) $5,450 6. Maintenance labor = (0.5 hr/shift) x (1 shift/8 hr) x H x (LR x $19,982 7. Maintenance materials = 0.02 x TCI $0 

D. Indirect Annual Costs, $/yr

1. Overhead = 0.6 x (labor + maintenance materials) $37,057 2. Property taxes, insurance, and = 0.04 x TCI $0 

Parameters/Costs Equation

OxyVinyls Pasadena OxyVinyls Pedricktown PolyOne Henry PolyOne Pedricktown Shintech Addis Shintech FreeportOther Other Other/Dispersion Dispersion Other Other

64000000 10991092.93 4953600 247101 14839200 27000000

480.690945 82.551857 37.205479 1.855925 111.454204 202.791492

480.691 82.552 37.205 1.856 111.454 202.791

8400 8400 8400 8400 8400 8400

0.096 0.096 0.096 0.096 0.096 0.096

260 260 260 260 260 260

$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 $4.65

0.09439 0.09439 0.09439 0.09439 0.09439 0.09439

641.1 641.1 641.1 641.1 641.1 641.1356.0 356.0 356.0 356.0 356.0 356.0

0.04 0.54 1.40 1.46 0.01 0.010.11 0.11 0.11 0.11 0.11 0.11

-175.0 79.6 92.1 92.5 -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 

2. Property taxes, insurance, and $0 $0 $0 $0 $0 $0 administration

= 0.04 x TCI $0 

3. Capital recovery = Equipment CRF x TCI $0 

E. Recovery Credit, $/yr

a. Recovered vinyl chloride, kg/yr [VCR] = C x 10^-6 x Q x (1 kg/l) x (60 min/hr) x 

H x RP

0.00

b. Value of recovered vinyl chloride, $/yr = VCR x (2.2 lb/kg) x RV $0 

F. Include in Annual Cost?F. Total Annual Cost

1. $/yr

= Direct Annual Costs + Indirect Annual 

Costs - Recovery Credit

$352,381 

2. ($/yr) / lpm = ($/yr) / Q $705

Sources:

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 Estimates

3. 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 $1 $1 $1 $1 $1 $1 

(16.96) 17.84 24.19 1.27 (5.84) (10.63)

($12) $12 $17 $1 ($4) ($7)

No Yes Yes Yes No No

0 $40,856 $18,408 $928 0 0

$495 $495 $500
Attachment L - Process Wastewater Compliance Cost Algorithm

Steam Stripper - PVC Resin - Cost Analysis - VC and TOH

CompanyProcess TypeProcess Type StdInlet Stream Flow, gal/yrInlet Stream Flow, liters/min

A. Parameters (Inputs and Example 

Calculation)

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] $4.65

9. Capital recovery factor = [i x (1 + i)a] / [(1 + i)a - 1], where i = 

interest rate, a = equipment life

 a. Equipment CRF, 20-yr life, 7% 

interest

0.09439

10. Cost index a. 2010 641.1 b. 1989 356.011. VCM Concnetration, ppm [C]12. VCM limit, ppm [L] 20.013. VCM recovery percentage, % 99.014. VOC recovery value, $/lb [RV] $0.313

B. Total Capital Investment

1. $ = 0.3731 x Q^0.267 x 10^6 $0 2. $ / lpm = $ / Q $0 

C. Direct Annual Operating Costs, $/yr

1. Electricity = EU / (24 hr/day) x H x EC $6,079 

2. Steam = Q x S x (2.2 lb/kg) x (60 min/hr) x H x 

SC / 1000

$247,484 

3. Water = Q x (5220 liters water-min / liters feedday) x (1 day / 24 hr) x H x (0.264 

gal/liter) x WC / 1000

$0 

4. Operating labor = (1 hr/shift) x (1 shift/8 hr) x H x LR $36,330 5. Supervisory labor = 0.15 x (operating labor) $5,450 6. Maintenance labor = (0.5 hr/shift) x (1 shift/8 hr) x H x (LR x $19,982 7. Maintenance materials = 0.02 x TCI $0 

D. Indirect Annual Costs, $/yr

1. Overhead = 0.6 x (labor + maintenance materials) $37,057 2. Property taxes, insurance, and = 0.04 x TCI $0 

Parameters/Costs Equation

Shintech Plaquemine Westlake Calvert City Westlake Geismar Georgia Gulf Aberdeen Georgia Gulf PlaquemineOther Other Other Other Other

3801600 28908000 13225138.43 10584000 37604745.62

28.553042 217.122091 99.331317 79.494265 282.441574

28.553 217.122 99.331 79.494 282.442

8400 8400 8400 8400 8400

0.096 0.096 0.096 0.096 0.096

260 260 260 260 260

$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 $4.65

0.09439 0.09439 0.09439 0.09439 0.09439

641.1 641.1 641.1 641.1 641.1356.0 356.0 356.0 356.0 356.0

0.01 0.05 1.72 0.70 1.000.11 0.11 0.11 0.11 0.11

-1000.0 -120.0 93.6 84.3 89.0

$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 

2. Property taxes, insurance, and $0 $1 $1 $1 $1 administration

= 0.04 x TCI $0 

3. Capital recovery = Equipment CRF x TCI $0 

E. Recovery Credit, $/yr

a. Recovered vinyl chloride, kg/yr [VCR] = C x 10^-6 x Q x (1 kg/l) x (60 min/hr) x 

H x RP

0.00

b. Value of recovered vinyl chloride, $/yr = VCR x (2.2 lb/kg) x RV $0 

F. Include in Annual Cost?F. Total Annual Cost

1. $/yr

= Direct Annual Costs + Indirect Annual 

Costs - Recovery Credit

$352,381 

2. ($/yr) / lpm = ($/yr) / Q $705

Sources:

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 Estimates

3. 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 $1 $1 $1 $1 $1 $1 $1 $1 $2 

(1.44) (6.57) 80.75 23.64 126.69 

($1) ($5) $56 $16 $87 

No No Yes Yes Yes

0 0 $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 High Average

Cost of US EPA Method 8260B [1] $201 $400 $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 outlet tests (assume cost of 8260B) $901.50

Total initial Cost $3,305.50

CRF (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 $901.50

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 

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

THC Concentration Analysis 
Attachment 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_IDEquip_ID Date_Std Total Ln Average TOHAP Rank

Formosa Baton RougePVC 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 CityWD710 Thermal Oxidizer Scrubber1/12/2010 0.2307589 -1.4663819 0.0769196 2

1/13/2010 0

1/14/2010 0

OxyVinyls Deer Park C-301A LaPorte Thermal Oxidizer12/10/2009 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 5
Attachment 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 1.68639895
Attachment 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 - New
Attachment N - THC Concentration Analysis

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

Packed Bed Scrubber Cost Algorithm 
Attachment 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 - 

77°F)) x 0.1) x (lb-mole/385 scf) x Qw / 

(1,160 Btu/lb) / (18 lb/lb-mole) x (0.7302 ft3-

atm/lb-mol-°R) x 528°R / 1 atm

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, ft2/ft3 

(SAV)

58

18. Minimum packing wetting rate, 

ft2/hr (WR)

1

19. Water density, lb/ft3 (Wd) 62.4

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

(Gs)

= SAV x Wd x WR 4,705

21. Estimated column cross-sectional 

area, ft2 (A)

19.2

22. 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 ft3

) x 

(1 lb-mole NaCl/1 lb-mole HCl) x (58.2 lb 

NaCl/lb-mole NaCl) x (1 lb wastewater/0.1 

lb NaCl) x (1 gal/8.33 lb)

0.397

25. Capital recovery factor, 15-yr 

equipment life, 7% interest (CRF)

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

rate, a = equipment life

0.10979

26. 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).

Parameters/Costs Equation Georgia Gulf Plaquemine