Table 5A. Control Costs: Fabric Filter Cost Algorithm Appendix A

Parameters/Costs Equation

A. Parameters

1. Incinerator capacity, lb/hr (C)

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

3. Exhaust gas flow rate, dscfm (Q)

4. PM concentration, gr/dscf (PM)

5. 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)

 b. scfm = (lb/min) / (18 lb/lb-mol) x (385 ft3

/lb-mol)

6. 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)

 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)

 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]

 d. Cooling water

 i. Heat of vaporization at 77°F, Btu/lb

 ii. Sensible heat for vapor, Btu/lb

 iii. Total, Btu/lb water

7. Cooling water evaporated, lb/yr

 a. lb/yr = [enthalpy change (total gas stream, Btu/yr)] / [enthalpy change (cooling water, Btu/lb)]

 b. scfm = [cooling water evaporated (lb/yr)] / (18 lb/lb-mol) x (385 ft3/lb-mol) / (H * 60 min/hr)

8. 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]

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

10. Electricity cost, $/kWh (EC)

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

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

13. Dust disposal cost, $/ton (DDC)

14. 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

 b. Cage CRF, 4-yr life, 7% interest

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

15. Cost index

 a. 2008

 b. 1989

B. Total Capital Investment

1. $ = (47.0 x Q + 306,720) x (1.4 retrofit cost factor) x (525.4/357.5)

2. $/dscfm = $ / Q

C. Direct Annual Operating Costs, $/yr

1. Electricity = (0.746 kW/hp) x hp (0.0072 x Q + 3.20) x H x EC

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

4. Operating labor = (1 hr/shift) x (1 shift/8 hr) x H x LR

5. Supervisory labor = 0.15 x (operating labor)

6. Maintenance labor = (0.5 hr/shift) x (1 shift/8 hr) x H x (LR x 1.1)

7. Maintenance materials = 0.02 x TCI

8. Compressed air = AQ x (2 ft3

 air/1,000 ft3 filtered) x (60 min/hr) x H x CAC

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

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)

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

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

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

11. Cage replacement

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

 bag area)

 b. Cage replacement labor cost = bag replacement labor cost

 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)]

D. Indirect Annual Costs, $/yr

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

2. Property taxes, insurance, and administration = 0.04 x TCI

3. Capital recovery = Equipment CRF x (TCI - bag replacement cost - cage replacement cost)

E. Total Annual Cost

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

2. ($/yr) / dscfm = ($/yr) / Q

Sources:

1. Cost equations: Hospital/Medical/Infectious Waste Incinerators (HMIWI) [EPA-HQ-OAR-2006-0534] Model Plant Description and Cost Report (II-A-112); and Dry Injection Fabric Filter Cost 

Memorandum (IV-B-32).

2. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2008 National Industry-Specific Occupational Employment and Wage Estimates

3. Electricity cost: Energy Information Administration. Average Industrial Retail Price of Electricity: October 2009.

4. Water cost: Air Compliance Advisor, version 7.5.

5. Compressed air cost: P2Pays.org. Energy Tips – Compressed Air. Compressed Air Tip Sheet #1. August 2004.

6. Dust disposal cost: NSWMA’s 2005 Tip Fee Survey
Table 5B. Control Costs: Fabric Filter Costs For Energy Recovery Units (1 of 4) Appendix A

Table 5B. Control Costs: Fabric Filter Costs For Energy Recovery Units

 a. lb/min b. scfm

Bag CRF, 2-

yr life, 7% 

interest

Cage CRF, 4-

yr life, 7% 

interest

LADeltech HB-507 Energy recovery unit - Liquid/Gas 50 2160 8848 13103 0.06094 47.3 1012.1 51.26 0.070 0.31 42.14 0.5531 0.2952

LADeltech HB-512 Energy recovery unit - Liquid/Gas 194 2160 34331 50840 0.06094 183.6 3927.1 51.26 0.070 0.31 42.14 0.5531 0.2952

MDSeverstalSparrows 1BLR Energy recovery unit - Liquid/Gas 650 6900 109544 140464 0.06094 585.8 12530.6 51.26 0.070 0.31 42.14 0.5531 0.2952

MEPioneerPlastics Boiler #5/Thermal Oxidizer Energy recovery unit - Liquid/Gas 39.5 6250 28920 44243 0.11189 154.7 3308.1 51.26 0.070 0.31 42.14 0.5531 0.2952

WAEmeraldKalama U-2 Energy recovery unit - Liquid/Gas 53 8688 12075 17298 0.01000 64.6 1381.2 51.26 0.070 0.31 42.14 0.5531 0.2952

WAEmeraldKalama U-7 Energy recovery unit - Liquid/Gas 53 8688 10928 17092 0.01000 58.4 1250.0 51.26 0.070 0.31 42.14 0.5531 0.2952

ALIPRiverdale No. 2 Bark Boiler / BK02 Energy recovery unit - Solids 667 8400 158369 240472 0.00143 847.0 18115.6 51.26 0.070 0.31 42.14 0.5531 0.2952

ARDomtarIndustries PB1 Energy recovery unit - Solids 580 8049 47008 70122 0.00806 251.4 5377.2 51.26 0.070 0.31 42.14 0.5531 0.2952

ARDomtarIndustries PB2 Energy recovery unit - Solids 820 8520 189562 326271 0.01435 1013.8 21683.7 51.26 0.070 0.31 42.14 0.5531 0.2952

ARDomtarIndustries PB3 Energy recovery unit - Solids 790 8160 198151 352405 0.00806 1059.7 22666.3 51.26 0.070 0.31 42.14 0.5531 0.2952

ARPlantersCottonOil Boiler #3 (SN-72) Energy recovery unit - Solids 25 8760 6115 10883 0.02817 32.7 699.5 51.26 0.070 0.31 42.14 0.5531 0.2952

LAInternationalPaperRedRiverMill EQT011 Hogged Fuel Boiler No. 2 Energy recovery unit - Solids 940 8300 181354 270526 0.00883 969.9 20744.9 51.26 0.070 0.31 42.14 0.5531 0.2952

LAIPMansfield 1-78 - No. 1 Power Boiler / EQT005 Energy recovery unit - Solids 760 8700 108161 166714 0.02817 578.5 12372.5 51.26 0.070 0.31 42.14 0.5531 0.2952

LAIPMansfield 2-78 - No. 2 Power Boiler Energy recovery unit - Solids 760 8700 164972 254176 0.02817 882.3 18871.0 51.26 0.070 0.31 42.14 0.5531 0.2952

MEBoralex Boiler #1 Energy recovery unit - Solids 585.9 8256 125176 187513 0.01397 669.4 14318.8 51.26 0.070 0.31 42.14 0.5531 0.2952

MEHuberEngineeredWoodLLC Boiler No.1 Energy recovery unit - Solids 84 8400 20546 30627 0.00205 109.9 2350.3 51.26 0.070 0.31 42.14 0.5531 0.2952

MEHuberEngineeredWoodLLC Dryer Furnace Energy recovery unit - Solids 152 8000 37179 55421 0.00205 198.8 4252.9 51.26 0.070 0.31 42.14 0.5531 0.2952

MIHermanMiller EUBBLR Energy recovery unit - Solids 28 8234 13009 19392 0.13780 69.6 1488.1 51.26 0.070 0.31 42.14 0.5531 0.2952

MNFibrominn EU-001 Energy recovery unit - Solids 563.5 8000 169494 252835 0.00446 906.5 19388.2 51.26 0.070 0.31 42.14 0.5531 0.2952

NYBlackRiverGen E00001 Energy recovery unit - Solids 201.25 5431 116532 91835 0.00231 623.2 13330.0 51.26 0.070 0.31 42.14 0.5531 0.2952

NYBlackRiverGen E00002 Energy recovery unit - Solids 201.25 5431 116532 91835 0.00231 623.2 13330.0 51.26 0.070 0.31 42.14 0.5531 0.2952

NYBlackRiverGen E00003 Energy recovery unit - Solids 201.25 5431 116532 91835 0.00231 623.2 13330.0 51.26 0.070 0.31 42.14 0.5531 0.2952

OKIPValliant Bark Boiler EUG-D1 Energy recovery unit - Solids 900 8338 225741 336740 0.04801 1207.3 25822.3 51.26 0.070 0.31 42.14 0.5531 0.2952

ORGPToledo EU11 - Hog Fuel Boiler #4 Energy recovery unit - Solids 296.6 8600 39830 60002 0.00301 213.0 4556.2 51.26 0.070 0.31 42.14 0.5531 0.2952

PAKimberlyClarkChester Boiler #10 (ID 035) Energy recovery unit - Solids 975 800 163184 251522 0.01207 872.7 18666.4 51.26 0.070 0.31 42.14 0.5531 0.2952

TNEastman_NO_CBIDATA Boiler 18 Energy recovery unit - Solids 246 3700 61504 95487 0.02832 328.9 7035.3 51.26 0.070 0.31 42.14 0.5531 0.2952

TNEastman_NO_CBIDATA Boiler 19 Energy recovery unit - Solids 246 5500 52418 81382 0.03361 280.3 5996.1 51.26 0.070 0.31 42.14 0.5531 0.2952

TNEastman_NO_CBIDATA Boiler 20 Energy recovery unit - Solids 246 5500 52207 81054 0.03048 279.2 5971.9 51.26 0.070 0.31 42.14 0.5531 0.2952

TNPackagingCorpCounce Combination Boiler #2 Energy recovery unit - Solids 860 8566 180318 277933 0.00341 964.4 20626.4 51.26 0.070 0.31 42.14 0.5531 0.2952

TNTempleInland2426 5000F Energy recovery unit - Solids 527 8544 95909 142303 0.09593 512.9 10970.9 51.26 0.070 0.31 42.14 0.5531 0.2952

TXInternationalPaperQueenCity PB02 Energy recovery unit - Solids 487.075 8400 257292 369467 0.04720 1376.0 29431.4 51.26 0.070 0.31 42.14 0.5531 0.2952

WALongviewFPP #12 Power Boiler Energy recovery unit - Solids 316.25 7000 97528 145378 0.00812 521.6 11156.1 51.26 0.070 0.31 42.14 0.5531 0.2952

WALongviewFPP #13 Power Boiler Energy recovery unit - Solids 316.25 7000 118936 177290 0.00726 636.1 13605.0 51.26 0.070 0.31 42.14 0.5531 0.2952

WALongviewFPP #20 Power Boiler Energy recovery unit - Solids 900 8000 104383 156236 0.00590 558.2 11940.3 51.26 0.070 0.31 42.14 0.5531 0.2952

WAPortTownsendPaper #10 Power Boiler Energy recovery unit - Solids 487.075 8201.952 98934 153735 0.04613 529.1 11316.9 51.26 0.070 0.31 42.14 0.5531 0.2952

WINSPWAshland B20 Energy recovery unit - Solids 275 8200 68567 106025 0.01249 366.7 7843.2 51.26 0.070 0.31 42.14 0.5531 0.2952

WINSPWAshland B21 Energy recovery unit - Solids 275 8200 71234 110150 0.01249 381.0 8148.4 51.26 0.070 0.31 42.14 0.5531 0.2952

Facility Name Combustor ID

Input Parameters

Compressed aircost,$/1,000 ft3(CAC)Dust disposal cost,$/ton (DDC)

Capital recovery factors

Design Capacity(mmbtu/hr)

Subcategory Annual operating

hours, hr/yr(H)Exhaust gas flowrate, dscfm (Q)Actual gas flow intofabric filter, acfm(AQ)PM, gr/dscf (PM)

Water vapor in gas 

from incinerator (7.1% 

by weight)

Operating laborrate, $/hr(LR)Electricity cost,$/kWh(EC)
Table 5B. Control Costs: Fabric Filter Costs For Energy Recovery Units (2 of 4) Appendix A

Table 5B. Control Costs: Fabric Filter Costs For Energy Recovery Units

LADeltech HB-507

LADeltech HB-512

MDSeverstalSparrows 1BLR

MEPioneerPlastics Boiler #5/Thermal Oxidizer

WAEmeraldKalama U-2

WAEmeraldKalama U-7

ALIPRiverdale No. 2 Bark Boiler / BK02

ARDomtarIndustries PB1

ARDomtarIndustries PB2

ARDomtarIndustries PB3

ARPlantersCottonOil Boiler #3 (SN-72)

LAInternationalPaperRedRiverMill EQT011 Hogged Fuel Boiler No. 2

LAIPMansfield 1-78 - No. 1 Power Boiler / EQT005

LAIPMansfield 2-78 - No. 2 Power Boiler

MEBoralex Boiler #1

MEHuberEngineeredWoodLLC Boiler No.1

MEHuberEngineeredWoodLLC Dryer Furnace

MIHermanMiller EUBBLR

MNFibrominn EU-001

NYBlackRiverGen E00001

NYBlackRiverGen E00002

NYBlackRiverGen E00003

OKIPValliant Bark Boiler EUG-D1

ORGPToledo EU11 - Hog Fuel Boiler #4

PAKimberlyClarkChester Boiler #10 (ID 035)

TNEastman_NO_CBIDATA Boiler 18

TNEastman_NO_CBIDATA Boiler 19

TNEastman_NO_CBIDATA Boiler 20

TNPackagingCorpCounce Combination Boiler #2

TNTempleInland2426 5000F

TXInternationalPaperQueenCity PB02

WALongviewFPP #12 Power Boiler

WALongviewFPP #13 Power Boiler

WALongviewFPP #20 Power Boiler

WAPortTownsendPaper #10 Power Boiler

WINSPWAshland B20

WINSPWAshland B21

Facility Name Combustor ID

Total Capital Investment

Equipment 

CRF, 20-yr 

life, 7% 

interest 2008 1989

Electricity Operating 

labor

Supervisory 

labor

Maintenance 

labor

Maintenance 

materials

Compressed 

air

Dust 

disposal

Bag cost Bag 

replacement 

labor cost

0.0944 575.4 357.5 $1,658,936 $187.49 7544.78 13840.47 2076.07 7612.26 33178.72 1055.87 210.36 18324.54 1599.23

0.0944 575.4 357.5 $4,435,287 $129.19 28234.52 13840.47 2076.07 7612.26 88705.74 4096.79 816.19 71099.21 6205.03

0.0944 575.4 357.5 $13,170,514 $120.23 285264.41 44212.61 6631.89 24316.94 263410.29 36157.42 8319.33 196436.94 17143.61

0.0944 575.4 357.5 $3,843,694 $132.91 68985.05 40047.66 6007.15 22026.21 76873.88 10316.03 3652.44 61873.87 5399.91

0.0944 575.4 357.5 $2,006,522 $166.17 40884.33 55669.45 8350.42 30618.20 40130.44 5606.60 189.46 24191.05 2111.22

0.0944 575.4 357.5 $1,884,734 $172.47 37138.14 55669.45 8350.42 30618.20 37694.68 5539.98 171.46 23903.58 2086.13

0.0944 575.4 357.5 $17,602,552 $111.15 501438.07 53824.05 8073.61 29603.23 352051.04 75357.80 343.37 336297.61 29349.65

0.0944 575.4 357.5 $5,849,908 $124.44 143566.29 51574.97 7736.25 28366.24 116998.15 21056.23 550.82 98064.87 8558.40

0.0944 575.4 357.5 $21,006,063 $110.81 608497.55 54592.97 8188.94 30026.13 420121.26 103705.60 4185.64 456286.35 39821.41

0.0944 575.4 357.5 $21,956,118 $110.81 609131.46 52286.22 7842.93 28757.42 439122.36 107279.28 2353.88 492833.89 43011.02

0.0944 575.4 357.5 $1,366,567 $223.48 21598.54 56130.80 8419.62 30871.94 27331.33 3556.67 272.50 15219.99 1328.29

0.0944 575.4 357.5 $20,066,844 $110.65 567178.33 53183.29 7977.49 29250.81 401336.88 83766.67 2400.05 378327.60 33017.73

0.0944 575.4 357.5 $13,619,072 $125.91 355160.09 55746.34 8361.95 30660.49 272381.43 54109.75 4786.85 233147.70 20347.46

0.0944 575.4 357.5 $18,314,980 $111.02 540940.64 55746.34 8361.95 30660.49 366299.60 82496.94 7301.09 355462.22 31022.20

0.0944 575.4 357.5 $16,120,361 $128.78 389837.28 52901.35 7935.20 29095.74 322407.21 57754.42 2607.95 262234.84 22885.98

0.0944 575.4 357.5 $2,926,136 $142.42 66276.94 53824.05 8073.61 29603.23 58522.73 9597.79 63.92 42831.85 3738.06

0.0944 575.4 357.5 $4,751,446 $127.80 113136.85 51261.00 7689.15 28193.55 95028.93 16540.41 110.16 77505.26 6764.10

0.0944 575.4 357.5 $2,108,604 $162.08 41640.08 52760.38 7914.06 29018.21 42172.08 5956.93 2665.99 27119.82 2366.82

0.0944 575.4 357.5 $18,792,575 $110.87 511014.98 51261.00 7689.15 28193.55 375851.50 75458.97 1091.34 353586.58 30858.51

0.0944 575.4 357.5 $13,337,825 $114.46 238797.88 34799.81 5219.97 19139.90 266756.50 18606.83 263.54 128430.25 11208.47

0.0944 575.4 357.5 $13,337,825 $114.46 238797.88 34799.81 5219.97 19139.90 266756.50 18606.83 263.54 128430.25 11208.47

0.0944 575.4 357.5 $13,337,825 $114.46 238797.88 34799.81 5219.97 19139.90 266756.50 18606.83 263.54 128430.25 11208.47

0.0944 575.4 357.5 $24,853,265 $110.10 708890.85 53426.78 8014.02 29384.73 497065.31 104746.62 16319.16 470926.35 41099.08

0.0944 575.4 357.5 $5,048,247 $126.74 130191.98 55105.58 8265.84 30308.07 100964.95 19250.79 186.29 83912.16 7323.25

0.0944 575.4 357.5 $18,122,968 $111.06 49203.89 5126.10 768.92 2819.36 362459.36 7506.72 284.48 351750.89 30698.30

0.0944 575.4 357.5 $7,536,974 $122.54 86155.37 23708.21 3556.23 13039.52 150739.48 13180.45 1163.97 133537.59 11654.20

0.0944 575.4 357.5 $6,480,721 $123.63 109285.86 35241.94 5286.29 19383.07 129614.43 16698.35 1749.99 113811.39 9932.64

0.0944 575.4 357.5 $6,456,466 $123.67 108849.13 35241.94 5286.29 19383.07 129129.32 16631.03 1580.41 113352.54 9892.60

0.0944 575.4 357.5 $19,965,361 $110.72 582021.79 54887.72 8233.16 30188.24 399307.22 88818.25 950.99 388686.08 33921.74

0.0944 575.4 357.5 $11,759,894 $122.62 309442.85 54746.75 8212.01 30110.71 235197.87 45358.57 14197.74 199009.12 17368.09

0.0944 575.4 357.5 $28,248,948 $109.79 813780.94 53824.05 8073.61 29603.23 564978.95 115781.39 18424.42 516695.09 45093.45

0.0944 575.4 357.5 $11,989,636 $122.94 257781.89 44853.38 6728.01 24669.36 239792.73 37964.77 1001.77 203309.44 17743.39

0.0944 575.4 357.5 $15,085,881 $126.84 314111.70 44853.38 6728.01 24669.36 301717.62 46298.50 1090.90 247938.38 21638.29

0.0944 575.4 357.5 $12,948,701 $124.05 315222.89 51261.00 7689.15 28193.55 258974.03 46628.80 889.85 218493.79 19068.57

0.0944 575.4 357.5 $12,313,954 $124.47 306380.22 52555.04 7883.26 28905.27 246279.09 47040.80 6760.80 214996.95 18763.40

0.0944 575.4 357.5 $8,374,620 $122.14 212707.99 52542.53 7881.38 28898.39 167492.39 32434.42 1268.71 148274.75 12940.36

0.0944 575.4 357.5 $8,697,553 $122.10 220930.16 52542.53 7881.38 28898.39 173951.05 33696.30 1318.07 154043.43 13443.81

Direct Annual Operating Costs, $/yr

Capital recovery factors TCI

$

Cost Index $/dscfm Operation and Maintenance Bag replacement
Table 5B. Control Costs: Fabric Filter Costs For Energy Recovery Units (3 of 4) Appendix A

Table 5B. Control Costs: Fabric Filter Costs For Energy Recovery Units

LADeltech HB-507

LADeltech HB-512

MDSeverstalSparrows 1BLR

MEPioneerPlastics Boiler #5/Thermal Oxidizer

WAEmeraldKalama U-2

WAEmeraldKalama U-7

ALIPRiverdale No. 2 Bark Boiler / BK02

ARDomtarIndustries PB1

ARDomtarIndustries PB2

ARDomtarIndustries PB3

ARPlantersCottonOil Boiler #3 (SN-72)

LAInternationalPaperRedRiverMill EQT011 Hogged Fuel Boiler No. 2

LAIPMansfield 1-78 - No. 1 Power Boiler / EQT005

LAIPMansfield 2-78 - No. 2 Power Boiler

MEBoralex Boiler #1

MEHuberEngineeredWoodLLC Boiler No.1

MEHuberEngineeredWoodLLC Dryer Furnace

MIHermanMiller EUBBLR

MNFibrominn EU-001

NYBlackRiverGen E00001

NYBlackRiverGen E00002

NYBlackRiverGen E00003

OKIPValliant Bark Boiler EUG-D1

ORGPToledo EU11 - Hog Fuel Boiler #4

PAKimberlyClarkChester Boiler #10 (ID 035)

TNEastman_NO_CBIDATA Boiler 18

TNEastman_NO_CBIDATA Boiler 19

TNEastman_NO_CBIDATA Boiler 20

TNPackagingCorpCounce Combination Boiler #2

TNTempleInland2426 5000F

TXInternationalPaperQueenCity PB02

WALongviewFPP #12 Power Boiler

WALongviewFPP #13 Power Boiler

WALongviewFPP #20 Power Boiler

WAPortTownsendPaper #10 Power Boiler

WINSPWAshland B20

WINSPWAshland B21

Facility Name Combustor ID

Bag 

replacement 

cost

11019.68

42756.34

118129.65

37208.58

14547.57

14374.70

202236.50

58972.46

274393.13

296371.42

9152.72

227511.72

140206.09

213761.36

157697.98

25757.43

46608.69

16308.82

212633.42

77233.03

77233.03

77233.03

283197.06

50461.56

211529.51

80304.39

68441.81

68165.87

233740.92

119676.46

310720.63

122262.51

149100.64

131393.79

129290.93

89166.75

92635.82

Bag replacement
Table 5B. Control Costs: Fabric Filter Costs For Energy Recovery Units (4 of 4) Appendix A

Table 5B. Control Costs: Fabric Filter Costs For Energy Recovery Units

LADeltech HB-507

LADeltech HB-512

MDSeverstalSparrows 1BLR

MEPioneerPlastics Boiler #5/Thermal Oxidizer

WAEmeraldKalama U-2

WAEmeraldKalama U-7

ALIPRiverdale No. 2 Bark Boiler / BK02

ARDomtarIndustries PB1

ARDomtarIndustries PB2

ARDomtarIndustries PB3

ARPlantersCottonOil Boiler #3 (SN-72)

LAInternationalPaperRedRiverMill EQT011 Hogged Fuel Boiler No. 2

LAIPMansfield 1-78 - No. 1 Power Boiler / EQT005

LAIPMansfield 2-78 - No. 2 Power Boiler

MEBoralex Boiler #1

MEHuberEngineeredWoodLLC Boiler No.1

MEHuberEngineeredWoodLLC Dryer Furnace

MIHermanMiller EUBBLR

MNFibrominn EU-001

NYBlackRiverGen E00001

NYBlackRiverGen E00002

NYBlackRiverGen E00003

OKIPValliant Bark Boiler EUG-D1

ORGPToledo EU11 - Hog Fuel Boiler #4

PAKimberlyClarkChester Boiler #10 (ID 035)

TNEastman_NO_CBIDATA Boiler 18

TNEastman_NO_CBIDATA Boiler 19

TNEastman_NO_CBIDATA Boiler 20

TNPackagingCorpCounce Combination Boiler #2

TNTempleInland2426 5000F

TXInternationalPaperQueenCity PB02

WALongviewFPP #12 Power Boiler

WALongviewFPP #13 Power Boiler

WALongviewFPP #20 Power Boiler

WAPortTownsendPaper #10 Power Boiler

WINSPWAshland B20

WINSPWAshland B21

Facility Name Combustor ID

Number 

of bags

Cage 

replacement 

labor cost

Cage 

replacement 

cost

208 1599.23 1348.75 34025 66357 155424 $337,822 38.18 1 4,129 79,778 30,720 26,335 2.3574 0.09439 1.08E+02

807 6205.03 5233.14 67341 177411 414130 $852,254 24.82 1 14,552 355,106 108,282 76,460 4.6436 0.09439 4.03E+02

2230 17143.61 14458.40 203143 526821 1230688 $2,761,553 25.21 1 118,003 3,753,410 878,048 487,665 7.7185 0.09439 4.08E+03

702 5399.91 4554.12 86973 153748 358875 $869,267 30.06 1 12,062 285,253 89,753 65,107 4.3318 0.09439 9.86E+02

275 2111.22 1780.54 80861 80261 187860 $546,759 45.28 1 4,915 98,387 36,573 30,478 2.7086 0.09439 5.84E+02

271 2086.13 1759.38 79400 75389 176383 $522,488 47.81 1 4,875 97,425 36,274 30,269 2.6925 0.09439 5.31E+02

3817 29349.65 24752.61 266131 704102 1640130 $3,876,760 24.48 2 18,717 475,159 139,268 94,976 10.0991 0.09439 1.59E+00

1113 8558.40 7217.90 122805 233996 545942 $1,338,783 28.48 1 24,238 638,958 180,352 118,874 5.4535 0.09439 1.78E+00

5179 39821.41 33584.17 307758 840243 1953753 $4,639,048 24.47 2 32,155 880,518 239,262 152,243 11.7635 0.09439 1.58E+00

5594 43011.02 36274.19 316805 878245 2041103 $4,815,572 24.30 2 37,585 1,049,722 279,661 174,681 12.2256 0.09439 1.58E+00

173 1328.29 1120.24 73652 54663 128025 $414,794 67.83 1 3,738 70,726 27,814 24,233 2.1485 0.09439 3.19E+00

4294 33017.73 27846.15 295049 802674 1870064 $4,368,238 24.09 2 22,752 594,441 169,295 112,502 10.7116 0.09439 1.58E+00

2646 20347.46 17160.44 220290 544763 1270690 $2,974,316 27.50 1 197,964 6,672,476 1,473,023 782,886 8.4088 0.09439 1.80E+00

4035 31022.20 26163.19 276641 732599 1706157 $4,047,129 24.53 2 20,477 526,877 152,365 102,664 10.3828 0.09439 1.59E+00

2976 22885.98 19301.35 247404 644814 1504941 $3,436,697 27.45 1 291,944 10,303,333 2,172,318 1,120,212 8.9179 0.09439 1.84E+00

486 3738.06 3152.57 90014 117045 273478 $735,410 35.79 1 7,931 173,992 59,011 45,590 3.6041 0.09439 2.03E+00

880 6764.10 5704.64 109304 190058 443565 $1,107,200 29.78 1 16,504 410,932 122,805 85,202 4.8482 0.09439 1.83E+00

308 2366.82 1996.11 79119 84344 197309 $561,205 43.14 1 5,334 108,502 39,689 32,642 2.8679 0.09439 2.32E+00

4013 30858.51 26025.13 277797 751703 1751358 $4,070,078 24.01 2 20,299 521,624 151,041 101,890 10.3554 0.09439 1.58E+00

1458 11208.47 9452.89 195550 533513 1250814 $2,650,147 22.74 1 41,026 1,158,227 305,267 188,753 6.2410 0.09439 1.64E+00

1458 11208.47 9452.89 195550 533513 1250814 $2,650,147 22.74 1 41,026 1,158,227 305,267 188,753 6.2410 0.09439 1.64E+00

1458 11208.47 9452.89 195550 533513 1250814 $2,650,147 22.74 1 41,026 1,158,227 305,267 188,753 6.2410 0.09439 1.64E+00

5345 41099.08 34661.73 352734 994131 2315969 $5,398,540 23.91 2 34,244 945,300 254,802 160,912 11.9508 0.09439 1.57E+00

952 7323.25 6176.21 116787 201930 471173 $1,190,800 29.90 1 18,659 473,482 138,841 94,724 5.0447 0.09439 1.81E+00

3992 30698.30 25890.02 222704 724919 1688269 $3,301,481 20.23 2 20,126 516,524 149,754 101,136 10.3285 0.09439 1.59E+00

1516 11654.20 9828.81 114626 301479 702929 $1,500,711 24.40 1 44,650 1,273,459 332,234 203,466 6.3639 0.09439 1.75E+00

1292 9932.64 8376.89 113715 259229 604483 $1,371,506 26.16 1 32,011 876,058 238,189 151,643 5.8751 0.09439 1.77E+00

1287 9892.60 8343.12 113424 258259 602223 $1,366,516 26.17 1 31,758 868,240 236,306 150,589 5.8632 0.09439 1.77E+00

4412 33921.74 28608.57 295570 798614 1859825 $4,380,766 24.29 2 23,849 627,288 177,460 117,211 10.8572 0.09439 1.58E+00

2259 17368.09 14647.73 196960 470396 1097372 $2,596,318 27.07 1 122,491 3,912,171 911,438 504,523 7.7688 0.09439 1.75E+00

5865 45093.45 38030.46 393888 1129958 2633581 $6,110,645 23.75 2 41,537 1,174,426 309,072 190,836 12.5180 0.09439 1.57E+00

2308 17743.39 14964.24 189626 479585 1118784 $2,538,014 26.02 1 130,328 4,191,053 969,757 533,866 7.8523 0.09439 1.76E+00

2814 21638.29 18249.08 226781 603435 1408204 $3,145,239 26.44 1 241,733 8,339,899 1,798,707 940,998 8.6714 0.09439 1.81E+00

2480 19068.57 16081.86 207671 517948 1208345 $2,790,299 26.73 1 161,645 5,324,253 1,202,781 650,008 8.1403 0.09439 1.77E+00

2440 18763.40 15824.48 201374 492558 1148652 $2,683,504 27.12 1 153,900 5,041,320 1,145,151 621,435 8.0749 0.09439 1.78E+00

1683 12940.36 10913.51 154089 334985 781058 $1,873,438 27.32 1 56,700 1,662,825 421,894 251,720 6.7058 0.09439 1.74E+00

1748 13443.81 11338.10 157964 347902 811173 $1,940,231 27.24 1 62,131 1,841,154 462,312 273,195 6.8350 0.09439 1.74E+00

Duct Diameter

Indirect Annual Costs, $/yr Total Annual Cost

($/yr) / 

dscfm

CRF-DUCTelec (Mw)

Property 

taxes, 

insurance, 

and 

administrati

on

Capital 

recovery

Number of DuctlinesTAC - DuctTCI - Duct - FRPTCI - Duct - SSTCI - Duct - CS

Cage replacement Overhead TAC

$/yr
Table 5C. Control Costs: Packed-Bed Scrubber Cost Algorithm Appendix A

Parameters/Costs Equation

A. Parameters

1. Incinerator capacity, lb/hr (C)

2. Temperature into quench, F (T1)

3. Temperature out of PB to ID fan, F (T2)

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

5. Exhaust gas flow rate, dscfm (Qd)

6. Assumed moisture content in gas entering quench, % (M) 

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

8. Water added in quench, scfm (Qh) = ((7.010 x (T1 - 77°F) - 6.958 x (T2 - 77°F)) x 0.9 + (8.154 x (T1 - 77°F) - 8.064 x (T2 - 

77°F)) x 0.1) x (lb-mole/385 scf) x Qw / (1,160 Btu/lb) / (18 lb/lb-mole) x (0.7302 ft3-atm/lbmol-°R) x 528°R / 1 atm

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

10. HCl concentration, ppmvd (HCl)

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

12. Electricity cost, $/kWh (EC)

13. Caustic cost, $/ton (CC)

14. Sewage disposal cost, $/1,000 gal (SDC)

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

16. Assumed pressure drop through control system, inches 

of water (ΔP)

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

Raschig rings, ft2/ft3 (SAV)

18. Minimum packing wetting rate, ft2/hr (WR)

19. Water density, lb/ft3 (Wd)

20. Water circulation flow rate, lb/hr-ft2 (Gs) = SAV x Wd x WR

21. Estimated column cross-sectional area from separate 

analysis, ft2 (A)

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

23. Water head, ft of water (Head)

24. Wastewater (blowdown) flow, gpm (B) = (HCl/1000000) x (Qd) x (lb-mole/385 ft3

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

NaCl/lb-mole NaCl) x (1 lb wastewater/0.1 lb NaCl) x (1 gal/8.33 lb)

25. Capital recovery factor, 15-yr equipment life, 7% interest 

(CRF)

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

26. Chemical Engineering plant cost index

 a. 2008

 b. 1989

B. Total Capital Investment

1. $ = (27.6 x Qd + 109,603) x (525.4/357.5) x (1.4 retrofit factor)

2. $/dscfm = $ / Qd

C. Direct Annual Costs, $/yr

1. Operating labor = (if Qa < 20,000, then 0, otherwise 0.5 hr/shift) x H x LR

2. Supervisory labor = 0.15 x (operating labor)

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

4. Maintenance materials = 0.02 x TCI

5. Electricity = (0.000181 x Qa x ΔP x H x EC) + (0.000289 x GPM x Head x H x EC)

6. Caustic = HCl x (3.117E-9) x Q x H x CC

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

8. Makeup water = (B + Qh x (lb-mole/385 scf) x (18 lb/lb-mole) x (gal/8.33 lb)) x (60 min/hr) x H x WC

D. Indirect Annual Costs, $/yr

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

2. Property taxes, insurance, and administration = 0.04 x TCI

3. Capital recovery = CRF x TCI

E. Total Annual Cost

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

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

Sources:

1. Cost equations: Hospital/Medical/Infectious Waste Incinerators (HMIWI) [EPA-HQ-OAR-2006-0534]-Model Plant Description 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.
Table 5D. Control Costs: Selective Non-Catalytic Reduction (SNCR) Cost Algorithm Appendix A

Parameters/Costs Equation

A. Parameters

1. Incinerator capacity, lb/hr (C)

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

3. Exhaust gas flow rate, dscfm (Q)

4. NOX, lb/MMBtu

5. Heating value, Btu/lb (HV)

6. Urea solution cost, $/gal (U)

7. Electricity cost, $/kWh (EC)

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

9. 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

10. Cost index

 a. 2008

 b. 1998

B. Total Capital Investment (TCI)

1. Total Direct Capital Cost, $ (DC) = [$950/(MMBtu/hr)] x [(C x HV) / 106

] x [(2,375 MMBtu/hr / (C x HV)]0.577 x 

(0.66 + 0.85 x 45% NOX removal efficiency) x (1.2 retrofit factor) x 

(575.4/390.6)

2. Indirect Installation Costs, $ (IC) = 0.2 x DC

3. Other Capital Costs, $ (OC) = [0.173 x (DC + IC)] + (119.3 gal x U)

4. Total

 a. $ = DC + IC + OC

 b. $/dscfm = $ / Q

C. Direct Annual Costs, $/yr

1. Maintenance = 0.015 x TCI

2. Reagent = (0.36 gal/hr) x H x U

3. Electricity = kW [0.47 x NOX x (C x HV) / 106

] / 9.5 x H x EC

4. Water = (1.62 gal/hr) x H x WC

D. Indirect Annual Costs, $/yr

1. Capital recovery = CRF x TCI

E. Total Annual Cost

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

2. ($/yr) / dscfm = ($/yr) / Q

Sources:

6. Assumed the same dscfm to lb/hr ratio as the "large HMIWI" model if unit's capacity is not given in lb/hr.

1. Cost equations, urea solution cost: OAQPS Control Cost Manual. Section 4.2: NOX Post-Combustion, Chapter 1: Selective Noncatalytic Reduction.

2. Hospital/Medical/Infectious Waste Incinerators (HMIWI) [EPA-HQ-OAR-2006-0534] Heating value: Process Description Report (II-A-110).

3. Electricity cost: Energy Information Administration. Average Industrial Retail Price of Electricity: October 2009.

4. Water cost: Air Compliance Advisor, version 7.5.

5. NOX removal efficiency: Clean Air Technology Center. EPA Technical Bulletin: Nitrogen Oxides (NOX)--Why and How They Are Controlled. 456/F-99-006R. November 

1999.
Table 5E. Control Costs: Activated Carbon Injection (ACI) Cost Algorithm Appendix A

Parameters/Costs Equation

A. Parameters

1. Incinerator capacity, lb/hr (C)

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

3. Exhaust gas flow rate, dscfm (Q)

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

5. Activated carbon cost, $/lb (ACC)

6. Dust disposal cost, $/ton (DDC)

7. 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

8. Cost index

 a. 2008

 b. 1990

9. ACI Adjustment Factor (AF)

B. Total Capital Investment

1. $ = 4,500 x (Q/1,976)0.6 x (1.2 retrofit factor) x (575.4/361.3)

2. $/dscfm = $ / Q

C. Direct Annual Costs, $/yr

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

2. Supervisory labor = 0.15 x (operating labor)

3. Maintenance = 0.2 x TCI

4. Activated carbon = 0.00127 x Q x H x ACC x AF

5. Dust disposal = 0.00127 x Q x (1 ton/2,000 lb) x H x DDC x AF

D. Indirect Annual Costs, $/yr

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

2. Property taxes, insurance, and administration = 0.04 x TCI

3. Capital recovery = CRF x TCI

E. Total Annual Cost

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

2. ($/yr) / dscfm = ($/yr) / Q

Sources:

1. Cost equations: Hospital/Medical/Infectious Waste Incinerators (HMIWI) [EPA-HQ-OAR-2006-0534] Model Plant Description and 

Cost Report (II-A-112).

2. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2007 National Industry-Specific 

Occupational Employment and Wage Estimates. 3. Activated carbon cost: The Innovation Group. Chemical Profiles: Carbon, Activated. 2002. Assumed 20% price increase based on 

online information from Norit, an activated carbon vendor.

4. Dust disposal cost: NSWMA’s 2005 Tip Fee Survey.
Table 5F. Control Costs: Activated Carbon Injection (ACI) Cost Algorithm for Energy Recov

Parameters/Costs Equation

A. Parameters

1. Type of Coal

2. Incinerator capacity, Btu/hr (C) 

3. Exhaust gas flow rate, acfm (Q)

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

5. Carbon Feed Rate, lb/hr (CFR) = [(Q x 60 x a) / 1,000,000], where a = 5 lb/Mmacf for ESP 

applications

6. Carbon Waste Rate, lb/hr (CWR) = CFR

7. Fly Ash Waste Rate, ton/hr (FAWR) = [(C / 1000) x (1 - a) / (2 x b)], where a = Unit Ash Removal, 

and b = Fly Ash Waste Rate Factor

8. Total Waste Rate, ton/hr (TWR) = [CWR + (FAWR / 2000)]

9. Activated Carbon Cost, $/ton (ACC)

10. Waste Disposal Cost, $/ton (WDC)

B. Total Capital Investment

1. Base Cost for ACI (BMC) =[1350000 x a x CFR0.15], where a = Retrofit Factor

2. Engineering and Construction Management costs, $ 

(A1)

= 5% of BMC

3. Labor adjustment for 6 x 10 hour shift premium, per 

diem, etc., $ (A2)

= 5% of BMC

4. Contractor profit and fees, $ (A3) = 5% of BMC

5. Capital, Engineering and Construction Cost 

Subtotal, $ (CECC)

= BMC + A1+ A2 + A3

6. Owners costs including all 'borne office" costs 

(owners engineering, management, and procurement 

activities), $ (B)

= 5% of CECC

7. Total Capital Investment, $ (TCI) = CECC + B

8. Total Capital Investment, $/dscfm = TPC / Q

C. Fixed Annual Costs, $/yr

1. Maintenance material and operating labor = 0.005 x TCI

2. Administrative labor = 0.03 x 0.4 x (maintenance material and operating labor)

3. Capital Recovery (7%, 20-yr) = TCI x [(0.07 x (1 + 0.07)20) / ((1 + 0.07)20-1)]

D. Variable Annual Costs, $/yr

1. Carbon Sorbent = CFR x H x (ACC / 2000)

2. Waste disposal (includes carbon and fly ash waste) = TWR x H x WDC

E. Total Annual Cost

1. $/yr = Fixed Annual Costs + Variable Annual Costs

2. ($/yr) / dscfm = ($/yr) / Q

Sources:

IPM Model - Revisions to Cost and Performance for APC Technologies, Mercury Control Cost Development Methodology , March 2011, 

Project 12301-009, Sargent & Lundy LLC.
hm for Energy Recovery Units
Table 5F. Control Costs: Afterburner Retrofit Cost Algorithm Appendix A

Parameters/Costs Equation

A. Parameters

1. Incinerator capacity, lb/hr (C)

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

3. Exhaust gas flow rate, dscfm (Q)

4. Waste charging hours, hr/d (WCH)

5. Downtime days (DD)

6. Natural gas cost, $/1,000 ft3 (NGC)

7. 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

8. Cost index

 a. 2008

 b. 1989

B. Total Capital Investment

1. $ = (28.80 x Q + 33,568) x (525.4/357.5)

2. $/dscfm = $ / Q

C. Downtime Cost, $ = $0.3/lb disposal cost x (525.4/357.5) x (C x 0.67) x WCH x DD

D. Direct Annual Costs, $/yr

1. Refractory replacement = 0.01 x TCI for 1-sec secondary chamber

2. Auxiliary fuel = (0.32 Btu/lb/°F) x (28.5 lb/lbmole) x (100°F) x (lbmole/385 ft3

) x 

(ft3/1,000 Btu) x (Q/0.9) x (60 min/hr) x H x NGC

3. Maintenance materials = 0.02 x TCI

E. Indirect Annual Costs, $/yr

1. Overhead = 0.6 x maintenance materials

2. Property taxes, insurance, and administration = 0.04 x TCI

3. Capital recovery = CRF x TCI

4. Annualized downtime cost = CRF x downtime cost

F. Total Annual Cost

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

2. ($/yr) / dscfm = ($/yr) / Q

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 Secondary Chamber Retrofit Cost Memorandum (IV-B-33).

2. Hospital/Medical/Infectious Waste Incinerators (HMIWI) [EPA-HQ-OAR-2006-0534] Waste charging hours, downtime days: Model Plant Description and 

Cost Report (II-A-112).

3. Natural gas cost: Energy Information Administration. Natural Gas Prices: 2008.
Table 5H. Control Costs: DIFF Costs For Energy Recovery Units

ALIPRiverdale No. 2 Bark Boiler / BK02 ERU - Solids 667 8400 158368.556 4.566666667

ARDomtarIndustries PB1 ERU - Solids 580 8049 47008 90.06533174

ARDomtarIndustries PB2 ERU - Solids 820 8520 189561.534 90.06533174

ARDomtarIndustries PB3 ERU - Solids 790 8160 198150.825 90.06533174

ARPlantersCottonOil Boiler #3 (SN-72) ERU - Solids 25 8760 6115.01822 90.06533174

LAInternationalPaperRe

dRiverMill

EQT011 Hogged Fuel 

Boiler No. 2 ERU - Solids 940 8300 181353.75 57

LAIPMansfield

1-78 - No. 1 Power 

Boiler / EQT005 ERU - Solids 760 8700 108161.333 367.3517456

LAIPMansfield

2-78 - No. 2 Power 

Boiler ERU - Solids 760 8700 164971.887 173.9393643

MEBoralex Boiler #1 ERU - Solids 585.9 8256 125176.402 9.996666667

MEHuberEngineeredWo

odLLC Boiler No.1 ERU - Solids 84 8400 20546.4612 2.028771646

MEHuberEngineeredWo

odLLC Dryer Furnace ERU - Solids 152 8000 37179.3107 2.028771646

MIHermanMiller EUBBLR ERU - Solids 28 8234 13009.4706 108.7666667

MNFibrominn EU-001 ERU - Solids 563.5 8000 169494.012 58.37666667

NYBlackRiverGen E00001 ERU - Solids 201.25 5431 116532.075 90.06533174

NYBlackRiverGen E00002 ERU - Solids 201.25 5431 116532.075 90.06533174

NYBlackRiverGen E00003 ERU - Solids 201.25 5431 116532.075 90.06533174

OKIPValliant Bark Boiler EUG-D1 ERU - Solids 900 8338 225741.447 2.19

ORGPToledo

EU11 - Hog Fuel Boiler 

#4 ERU - Solids 296.6 8600 39830.395 79.03333333

PAKimberlyClarkCheste

r Boiler #10 (ID 035) ERU - Solids 975 800 163183.5 256.5077216

TNEastman_NO_CBIDA

TA Boiler 18 ERU - Solids 246 3700 61503.75 458.0721333

TNEastman_NO_CBIDA

TA Boiler 19 ERU - Solids 246 5500 52418.25 458.0721333

TNEastman_NO_CBIDA

TA Boiler 20 ERU - Solids 246 5500 52207 458.0721333

TNPackagingCorpCoun

ce Combination Boiler #2 ERU - Solids 860 8566 180318.417 235.8303878

TNTempleInland2426 5000F ERU - Solids 527 8544 95909 79.16

TXInternationalPaperQu

eenCity PB02 ERU - Solids 487.075 8400 257292.252 1.213649811

WALongviewFPP #12 Power Boiler ERU - Solids 316.25 7000 97527.65 55.4

WALongviewFPP #13 Power Boiler ERU - Solids 316.25 7000 118936.25 18.63333333

WALongviewFPP #20 Power Boiler ERU - Solids 900 8000 104383.19 5.666666667

WAPortTownsendPaper #10 Power Boiler ERU - Solids 487.075 8201.9524 98933.8427 2.200809537

Facility Name Combustor ID

Unit 

Subcategory Incinerator capacity,

M

M

Btu/hr

Annual o

perating

hours, hr/yr (H)E

xhaust gas flo

w rate,

dscfm (Q)H

Cl or S

O2

concentration,whichever is higherp

p

m

v

d
WINSPWAshland B20 ERU - Solids 275 8200 68566.5 33.83566667

WINSPWAshland B21 ERU - Solids 275 8200 71234.1023 29.38666667

LADeltech HB-507 ERU - Liquid/Gas 50 2160 8848.23555 641.3523743

LADeltech HB-512 ERU - Liquid/Gas 194 2160 34331.154 641.3523743

MDSeverstalSparrows 1BLR ERU - Liquid/Gas 650 6900 109543.865 641.3523743

MEPioneerPlastics

Boiler #5/Thermal 

Oxidizer ERU - Liquid/Gas 39.5 6250 28920.0833 641.3523743

WAEmeraldKalama U-2 ERU - Liquid/Gas 53 8688 12075 641.3523743

WAEmeraldKalama U-7 ERU - Liquid/Gas 53 8688 10927.8571 641.3523743

Sources:

1. Cost equations: Model Plant Description and Cost Report (II-A-112); and Dry Injection Fabric Filter Cost Memorandum (IV-B

2. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2007 National Industry-Specific O

3. Electricity cost: Energy Information Administration. Average Retail Price of Electricity: 2006.

4. Lime cost: U.S. Geological Survey. Mineral Commodity Summaries 2008. Hydrated Lime Average Value, 2007.

5. Water cost: Air Compliance Advisor, version 7.5.

6. Compressed air cost: P2Pays.org. Energy Tips – Compressed Air. Compressed Air Tip Sheet #1. August 2004.

7. Dust disposal cost: NSWMA’s 2005 Tip Fee Survey.
a. lb/min b. scfm

a. Dry gas 

from 

incinerator, 

Btu/lb air

b. Water vapor 

from incinerator, 

Btu/lb water vapor

0.007371453 4.916759297 0.001429166 17.415 302.418367

2,077.4 44,434 5 14

0.007371453 4.275442867 0.008060621 18.9859858 400 672.3 14,379 30 64

0.007371453 6.04459164 0.014349692 11.1127143 400 1,586.7 33,939 30 64

0.007371453 5.823448043 0.008060621 18.9859858 400 2,833.8 60,611 30 64

0.007371453 0.18428633 0.028166263 18.9859858 400 87.5 1,870 30 64

0.007371453 6.929166026 0.008828487 21.7 312.646986

2,964.3 63,403 7 20

0.007371453 5.602304447 0.028166263 19.4466667 400

1,584.4 33,888 30 64

0.007371453 5.602304447 0.028166263 19.818239 400

2,462.7 52,675 30 64

0.003083333 1.806525 0.013972611 21.973299 400 2,071.8 44,314 30 64

0.002333333 0.196 0.002050665 18.9859858 400

293.8 6,285 30 64

0.003083333 0.468666667 0.002050665 18.9859858 400

531.7 11,373 30 64

0.003083333 0.086333333 0.137803074 7.005 339.003333 68.6 1,468 14 33

0.003833333 2.160083333 0.004456419 27.1730952 400 3,469.2 74,203 30 64

0.003083333 0.620520833 0.002305677 11.1127143 400 975.4 20,864 30 64

0.02404304 4.838661731 0.002305677 11.1127143 400 975.4 20,864 30 64

0.02404304 4.838661731 0.002305677 11.1127143 400 975.4 20,864 30 64

0.02404304 21.63873569 0.048005985 18.9859858 152.266667 3,228.4 69,051 34 62

0.02404304 7.131165562 0.003011301 17.0914076 368.809524

512.8 10,968 22 48

0.02404304 23.44196366 0.012065637 8.575 400

1,054.0 22,544 30 64

0.02404304 5.914587755 0.028321089 10.65 395.5

493.4 10,553 29 62

0.007371453 1.813377492 0.03360944 12.18 400

480.9 10,286 30 64

0.007371453 1.813377492 0.03047532 12.63 400

496.7 10,623 30 64

0.007371453 6.339449769 0.00340902 11.5285714 363.113131

1,565.9 33,492 21 45

0.007371453 3.884755847 0.095933317 26.06 148.809375 1,882.7 40,268 35 64

0.007371453 3.590450577 0.047201814 19.9377551 135.777778

3,864.0 82,647 39 71

0.007371453 2.331222081 0.008124801 17.912 139 1,315.9 28,145 38 69

0.007371453 2.331222081 0.007255094 16.2107143 400 1,452.3 31,063 30 64

0.007371453 6.634307898 0.005900227 17.2827586 137 1,358.9 29,065 38 70

0.007371453 3.590450577 0.046132489 16.7778652 400

1,250.3 26,743 30 64

P

M concentration,

lb/m

m

btu

P

M concentration,

lb/hr (P

M)

Water vapor in gas 

from incinerator 

(10% by weight)

Enthalpy change in 

P

M concentration,

gr/dscf (P

M)

Percent M

oisture

Tem

perature
0.007371453 2.027149635 0.012494133 18.9859858 400 980.6 20,973 30 64

0.007371453 2.027149635 0.012494133 18.9859858 400 1,018.7 21,789 30 64

0.060942787 5.46793651 400 36.4 779 30 64

0.060942787 5.46793651 400 141.4 3,024 30 64

0.060942787 5.46793651 350

451.2 9,650 17 39

0.111885782 4.69166667 350

102.2 2,186 17 39

0.009999792 6.1 400 55.5 1,187 30 64

0.009999792 5.61214286 400 46.2 988 30 64

abric Filter Cost Memorandum (IV-B-32).

ay 2007 National Industry-Specific Occupational Employment and Wage Estimates

me Average Value, 2007.

 Sheet #1. August 2004.
c. Total gas 

stream, 

Btu/yr

Cooling Water - i. 

Heat of 

vaporization at 

77°F, Btu/lb

Cooling Water - 

ii. Sensible 

heat for vapor, 

Btu/lb

Cooling 

Water - iii. 

Total, Btu/lb 

water a. lb/yr b. scfm

3.76E+10 1,050 85 1,135 3.31E+07 1,405

66811.9601

$51 $0.07

6.27E+10 1,050 85 1,135 5.52E+07 2,446 66811.9601 $51 $0.07

2.68E+11 1,050 85 1,135 2.36E+08 9,865 66811.9601 $51 $0.07

2.68E+11 1,050 85 1,135 2.36E+08 10,312 8815.46696 $51 $0.07

8.88E+09 1,050 85 1,135 7.82E+06 318 11599.2986 $51 $0.07

6.42E+10 1,050 85 1,135 5.66E+07 2,430

11599.2986

$51 $0.07

1.56E+11 1,050 85 1,135 1.37E+08 5,629

3309.66654

$51 $0.07

2.38E+11 1,050 85 1,135 2.10E+08 8,586

3818.48911

$51 $0.07

1.71E+11 1,050 85 1,135 1.51E+08 6,515 104954.396 $51 $0.07

2.86E+10 1,050 85 1,135 2.52E+07 1,069

126385.367

$51 $0.07

4.93E+10 1,050 85 1,135 4.34E+07 1,935

104954.396

$51 $0.07

8.55E+09 1,050 85 1,135 7.53E+06 326 104954.396 $51 $0.07

2.25E+11 1,050 85 1,135 1.98E+08 8,821 126385.367 $51 $0.07

1.05E+11 1,050 85 1,135 9.24E+07 6,065 104954.396 $51 $0.07

1.05E+11 1,050 85 1,135 9.24E+07 6,065 5844.0078 $51 $0.07

1.05E+11 1,050 85 1,135 9.24E+07 6,065 5844.0078 $51 $0.07

3.45E+11 1,050 85 1,135 3.04E+08 12,992 5844.0078 $51 $0.07

4.17E+10 1,050 85 1,135 3.67E+07 1,523

2549.21772

$51 $0.07

2.16E+10 1,050 85 1,135 1.91E+07 8,493

2549.21772

$51 $0.07

3.63E+10 1,050 85 1,135 3.20E+07 3,078

514.872466

$51 $0.07

4.78E+10 1,050 85 1,135 4.21E+07 2,728

1546.57315

$51 $0.07

4.76E+10 1,050 85 1,135 4.19E+07 2,717

47108.6182

$51 $0.07

1.76E+11 1,050 85 1,135 1.55E+08 6,442

43304.0482

$51 $0.07

1.54E+11 1,050 85 1,135 1.36E+08 5,667 51036.914 $51 $0.07

4.46E+11 1,050 85 1,135 3.93E+08 16,685

1546.57315

$51 $0.07

1.38E+11 1,050 85 1,135 1.21E+08 6,185 3216.87215 $51 $0.07

1.38E+11 1,050 85 1,135 1.22E+08 6,190 3464.32386 $51 $0.07

1.71E+11 1,050 85 1,135 1.51E+08 6,713 28556.2109 $51 $0.07

1.34E+11 1,050 85 1,135 1.18E+08 5,149

6263.62126

$51 $0.07

Input Parameters

Enthalpy change in quench Cooling water 

evaporated, lb/yr

Actual gas flo

w into

fabric filter, acfm (A

Q)

O

perating lab

or rate,

$/hr (L

R)

Electricity cost, $/kWh(E

C)
9.32E+10 1,050 85 1,135 8.21E+07 3,568 7330.75673 $51 $0.07

9.68E+10 1,050 85 1,135 8.53E+07 3,707 28147.6313 $51 $0.07

3.17E+09 1,050 85 1,135 2.79E+06 460 28147.6313 $51 $0.07

1.23E+10 1,050 85 1,135 1.08E+07 1,787 28147.6313 $51 $0.07

7.20E+10 1,050 85 1,135 6.34E+07 3,278

28147.6313

$51 $0.07

1.72E+10 1,050 85 1,135 1.52E+07 865

28147.6313

$51 $0.07

1.74E+10 1,050 85 1,135 1.53E+07 628 28147.6313 $51 $0.07

1.57E+10 1,050 85 1,135 1.39E+07 569 28147.6313 $51 $0.07
Bag CRF, 2-

yr life, 7% 

interest

Cage CRF, 4-

yr life, 7% 

interest

Equipment 

CRF, 20-yr 

life, 7% 

interest

2008 1989

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

Capital recovery factors (CRF) Cost index

Lime cost, $/ton (L

C)

Water cost, $/1,000 gal(W

C)

C

o

m

pressed air cost,

$/1,000 ft3 (C

A

C)

Dust disp

osal cost,

$/ton (D

D

C)
$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5

$95 $0.20 $0.31 $42.14 0.55309 0.29523 0.09439 575.4 357.5
Electricity Makeup 

lime

Evaporative 

cooler water

Operating 

labor

Supervisory 

labor

Maintenance 

labor

Maintenance 

materials

$23,851,301 $150.61 $550,188 $4,155 $1,609,863 $53,823 $8,073 $29,603 $477,026

$7,841,943 $166.82 $157,523 $23,309 $459,455 $51,574 $7,736 $28,366 $156,839

$28,335,649 $149.48 $667,656 $99,496 $1,954,011 $54,592 $8,189 $30,026 $566,713

$29,429,889 $148.52 $668,351 $99,609 $1,956,142 $52,285 $7,843 $28,757 $588,598

$1,826,063 $298.62 $23,698 $3,300 $67,165 $56,130 $8,419 $30,871 $36,521

$27,018,642 $148.98 $622,319 $58,686 $1,821,233 $53,182 $7,977 $29,250 $540,373

$16,486,314 $152.42 $389,689 $236,445 $1,139,526 $55,745 $8,362 $30,660 $329,726

$24,654,076 $149.44 $593,531 $170,759 $1,736,780 $55,745 $8,362 $30,660 $493,082

$19,325,684 $154.39 $427,737 $7,066 $1,251,122 $52,900 $7,935 $29,095 $386,514

$4,528,035 $220.38 $72,720 $240 $210,892 $53,823 $8,073 $29,603 $90,561

$6,675,092 $179.54 $124,136 $413 $361,642 $51,260 $7,689 $28,193 $133,502

$3,200,400 $246.01 $45,688 $7,969 $131,731 $52,759 $7,914 $29,018 $64,008

$25,940,955 $153.05 $560,696 $54,143 $1,640,755 $51,260 $7,689 $28,193 $518,819

$18,082,963 $155.18 $262,014 $38,989 $766,288 $34,799 $5,220 $19,140 $361,659

$17,692,670 $151.83 $262,014 $38,989 $766,288 $34,799 $5,220 $19,140 $353,853

$17,692,670 $151.83 $262,014 $38,989 $766,288 $34,799 $5,220 $19,140 $353,853

$33,392,771 $147.92 $777,809 $2,820 $2,276,806 $53,426 $8,014 $29,384 $667,855

$6,662,068 $167.26 $142,849 $18,517 $416,316 $55,105 $8,266 $30,307 $133,241

$24,395,492 $149.50 $53,987 $22,905 $157,975 $5,126 $769 $2,819 $487,910

$9,775,337 $158.94 $94,531 $71,301 $276,016 $23,708 $3,556 $13,039 $195,507

$8,470,522 $161.59 $119,910 $90,331 $349,910 $35,241 $5,286 $19,383 $169,410

$8,521,051 $163.22 $119,431 $89,967 $348,506 $35,241 $5,286 $19,383 $170,421

$26,928,388 $149.34 $638,606 $249,158 $1,868,883 $54,887 $8,233 $30,188 $538,568

$14,815,118 $154.47 $339,527 $44,369 $992,593 $54,746 $8,212 $30,110 $296,302

$37,923,511 $147.39 $892,897 $1,794 $2,613,994 $53,823 $8,073 $29,603 $758,470

$14,957,492 $153.37 $282,843 $25,870 $826,912 $44,853 $6,728 $24,669 $299,150

$18,035,512 $151.64 $344,650 $10,611 $1,008,003 $44,853 $6,728 $24,669 $360,710

$15,979,590 $153.09 $345,869 $3,237 $1,011,316 $51,260 $7,689 $28,193 $319,592

$15,163,220 $153.27 $336,166 $1,222 $982,836 $52,554 $7,883 $28,905 $303,264

Operation and Maintenance

Total Capital Investment Direct Annual Operating C

TCI ($) $/dscfm
$10,798,843 $157.49 $233,387 $13,012 $681,695 $52,542 $7,881 $28,898 $215,977

$11,213,274 $157.41 $242,409 $11,741 $708,128 $52,542 $7,881 $28,898 $224,265

$2,244,590 $253.68 $8,278 $8,384 $23,695 $13,840 $2,076 $7,612 $44,892

$5,908,052 $172.09 $30,979 $32,531 $90,209 $13,840 $2,076 $7,612 $118,161

$16,720,742 $152.64 $312,998 $331,581 $915,289 $44,212 $6,632 $24,316 $334,415

$5,130,149 $177.39 $75,691 $79,293 $220,155 $40,047 $6,007 $22,026 $102,603

$2,708,474 $224.30 $44,859 $46,021 $129,184 $55,668 $8,350 $30,618 $54,169

$2,543,559 $232.76 $40,748 $41,649 $117,141 $55,668 $8,350 $30,618 $50,871
Compressed 

air

Dust 

disposal

Bag cost Bag 

replacement 

labor cost

Bag 

replacement 

cost

Number of 

bags

Cage 

replacement 

labor cost

Cage 

replacement 

cost

$20,877 $2,540 $93,436 $8,154 $56,189 1061 $8,154 $6,877 $341,115

$20,005 $12,872 $93,436 $8,154 $56,189 1061 $8,154 $6,877 $146,709

$21,176 $56,780 $93,436 $8,154 $56,189 1061 $8,154 $6,877 $395,712

$2,676 $55,009 $12,328 $1,076 $7,414 140 $1,076 $907 $406,490

$3,780 $2,017 $16,221 $1,416 $9,755 184 $1,416 $1,194 $79,165

$3,581 $33,422 $16,221 $1,416 $9,755 184 $1,416 $1,194 $378,470

$1,071 $129,774 $4,629 $404 $2,783 53 $404 $341 $254,696

$1,236 $97,566 $5,340 $466 $3,211 61 $466 $393 $352,709

$32,234 $6,343 $146,777 $12,809 $88,266 1666 $12,809 $10,803 $285,867

$39,493 $191 $176,748 $15,425 $106,290 2006 $15,425 $13,009 $109,236

$31,234 $328 $146,777 $12,809 $88,266 1666 $12,809 $10,803 $132,386

$32,148 $6,879 $146,777 $12,809 $88,266 1666 $12,809 $10,803 $92,219

$37,612 $29,712 $176,748 $15,425 $106,290 2006 $15,425 $13,009 $363,577

$21,204 $20,873 $146,777 $12,809 $88,266 1666 $12,809 $10,803 $252,491

$1,181 $20,873 $8,173 $713 $4,915 93 $713 $602 $247,807

$1,181 $20,873 $8,173 $713 $4,915 93 $713 $602 $247,807

$1,813 $17,810 $8,173 $713 $4,915 93 $713 $602 $455,207

$816 $9,975 $3,565 $311 $2,144 40 $311 $262 $136,151

$76 $12,392 $3,565 $311 $2,144 40 $311 $262 $297,974

$71 $38,854 $720 $63 $433 8 $63 $53 $141,486

$316 $49,500 $2,163 $189 $1,301 25 $189 $159 $137,592

$9,638 $49,138 $65,881 $5,749 $39,618 748 $5,749 $4,849 $138,199

$13,799 $132,659 $60,560 $5,285 $36,419 687 $5,285 $4,457 $379,125

$16,221 $37,652 $71,374 $6,229 $42,922 810 $6,229 $5,253 $233,622

$483 $19,373 $2,163 $189 $1,301 25 $189 $159 $509,982

$838 $14,677 $4,499 $393 $2,705 51 $393 $331 $225,239

$902 $6,700 $4,845 $423 $2,913 55 $423 $357 $262,176

$8,498 $2,601 $39,936 $3,485 $24,016 453 $3,485 $2,939 $244,040

$1,911 $7,407 $8,760 $764 $5,268 99 $764 $645 $235,564

Bag replacement Cage replacement

ect Annual Operating Costs, $/yr

Indirect 

Annual 

Overhead

Indirect Annual Costs, $/yr
$2,236 $8,147 $10,252 $895 $6,165 116 $895 $755 $183,178

$8,586 $7,525 $39,364 $3,435 $23,672 447 $3,435 $2,897 $188,152

$2,262 $4,642 $39,364 $3,435 $23,672 447 $3,435 $2,897 $41,052

$2,262 $18,012 $39,364 $3,435 $23,672 447 $3,435 $2,897 $85,014

$7,225 $183,597 $39,364 $3,435 $23,672 447 $3,435 $2,897 $245,745

$6,544 $45,567 $39,364 $3,435 $23,672 447 $3,435 $2,897 $102,410

$9,097 $24,517 $39,364 $3,435 $23,672 447 $3,435 $2,897 $89,283

$9,097 $22,188 $39,364 $3,435 $23,672 447 $3,435 $2,897 $87,304
$954,052 $2,245,441 $6,382,102

$40.30 1 22,280 580,359 165,782

$313,678 $734,271 $2,197,683 $46.75 1 22,280 580,359 165,782

$1,133,426 $2,668,732 $7,741,852 $40.84 1 22,280 580,359 165,782

$1,177,196 $2,777,188 $7,831,852 $39.52 1 3,388 62,716 25,213

$73,043 $171,334 $570,254 $93.25 1 3,862 73,592 28,738

$1,080,746 $2,549,335 $7,193,387

$39.66 1 3,862 73,592 28,738

$659,453 $1,555,896 $4,796,674

$44.35 1 2,508 42,595 18,660

$986,163 $2,326,830 $6,859,614

$41.58 1 2,587 44,448 19,252

$773,027 $1,814,856 $5,229,126 $41.77 1 55,359 1,619,068 411,919

$181,121 $416,154 $1,419,569

$69.09 1 88,165 2,716,101 656,024

$267,004 $620,730 $1,912,946

$51.45 1 55,359 1,619,068 411,919

$128,016 $292,744 $1,045,522 $80.37 1 55,359 1,619,068 411,919

$1,037,638 $2,437,382 $6,974,939 $41.15 1 88,165 2,716,101 656,024

$723,319 $1,697,552 $4,357,976 $37.40 1 55,359 1,619,068 411,919

$707,707 $1,669,542 $4,135,835 $35.49 1 2,906 51,752 21,626

$707,707 $1,669,542 $4,135,835 $35.49 1 2,906 51,752 21,626

$1,335,711 $3,151,521 $8,786,598 $38.92 1 2,906 51,752 21,626

$266,483 $628,625 $1,851,445

$46.48 1 2,388 39,772 17,770

$975,820 $2,302,535 $4,325,083

$26.50 1 2,388 39,772 17,770

$391,013 $922,677 $2,174,294

$35.35 1 2,049 31,013 15,246

$338,821 $799,420 $2,118,808

$40.42 1 2,228 35,836 16,576

$340,842 $800,130 $2,183,749

$41.83 1 13,100 314,155 97,474

$1,077,136 $2,537,991 $7,581,843

$42.05 1 11,736 276,233 87,325

$592,605 $1,393,895 $4,102,661 $42.78 1 14,632 357,375 108,877

$1,516,940 $3,579,573 $9,988,693

$38.82 1 2,228 35,836 16,576

$598,300 $1,411,595 $3,767,202 $38.63 1 2,493 42,255 18,551

$721,420 $1,702,116 $4,499,339 $37.83 1 2,532 43,160 18,840

$639,184 $1,505,816 $4,201,652 $40.25 1 7,403 160,351 55,087

$606,529 $1,430,743 $4,003,868

$40.47 1 2,973 53,272 22,123

Indirect Annual 

Property taxes, 

insurance, and 

administration

Capital 

recovery

TAC

$/yr

($/yr) / dscfm

Num

ber of Ductlines

Indirect Annual Costs, $/yr Total Annual Cost

T

A

C - Duct

T

CI - Duct - FR

P

T

CI - Duct - S

S
$431,954 $1,018,681 $2,887,654 $42.11

1 3,145 57,173 23,401

$448,531 $1,055,946 $3,018,475 $42.37

1 7,302 157,749 54,333

$89,784 $209,365 $489,754 $55.35

1 7,302 157,749 54,333

$236,322 $555,170 $1,226,060 $35.71

1 7,302 157,749 54,333

$668,830 $1,575,812 $4,684,523

$42.761 7,302 157,749 54,333

$205,206 $481,742 $1,421,162

$49.141 7,302 157,749 54,333

$108,339 $253,153 $887,130 $73.47

1 7,302 157,749 54,333

$101,742 $237,586 $836,835 $76.58

1 7,302 157,749 54,333
110,469 5.3232 0.09439293

110,469 5.3232 0.09439293

110,469 5.3232 0.09439293

22,321 1.9336 0.09439293

24,905 2.2180 0.09439293

24,905 2.2180 0.09439293

17,334 1.1848 0.09439293

17,798 1.2726 0.09439293

246,395 6.6719 0.09439293

374,348 7.3214 0.09439293

246,395 6.6719 0.09439293

246,395 6.6719 0.09439293

374,348 7.3214 0.09439293

246,395 6.6719 0.09439293

19,627 1.5744 0.09439293

19,627 1.5744 0.09439293

19,627 1.5744 0.09439293

16,632 1.0398 0.09439293

16,632 1.0398 0.09439293

14,594 0.4673 0.09439293

15,676 0.8099 0.09439293

69,868 4.4699 0.09439293

63,600 4.2856 0.09439293

76,820 4.6525 0.09439293

15,676 0.8099 0.09439293

17,249 1.1681 0.09439293

17,475 1.2122 0.09439293

43,015 3.4802 0.09439293

20,005 1.6299 0.09439293

C

RF-D

U

C

T

T

CI - Duct - C

S

Duct Diameter
20,969 1.7633 0.09439293

42,518 3.4552 0.09439293

42,518 3.4552 0.09439293

42,518 3.4552 0.09439293

42,518 3.4552 0.09439293

42,518 3.4552 0.09439293

42,518 3.4552 0.09439293

42,518 3.4552 0.09439293
Table 5I. Control Costs: RTO Costs For Waste-Burning Kilns

Facility Name Combustor ID Subcategory

Exhaust gas flow 

rate, dscfm

Annual operating 

hours, hr/yr

ALNationalCementRagland Kiln Waste-burning kiln 180543 7920

CACAPortlandCementColton K-1 Waste-burning kiln 69432 8322

CACAPortlandCementColton K-2 Waste-burning kiln 137503 8322

CALehighSouthwestReddingPlant In-Line Kiln/Raw Mill (S260) Waste-burning kiln 116607 8760

FLCemexMiami Cement Kiln Waste-burning kiln 214185 7900

IALafargeBuffalo Kiln 1 Waste-burning kiln 167620 7800

IALehighCementMasonCity 302.203 Waste-burning kiln 186169 8760

MDLehighCementUnionBridge E02-001 Waste-burning kiln 267395 8322

MILafargeMidwestAlpena 19 Waste-burning kiln 91716 7540

MILafargeMidwestAlpena 20 Waste-burning kiln 94947 7540

MILafargeMidwestAlpena 21 Waste-burning kiln 97242 7540

MILafargeMidwestAlpena 22 Waste-burning kiln 165415 7540

MILafargeMidwestAlpena 23 Waste-burning kiln 165017 7540

PALafargeWhitehallPlant Kiln 2 Waste-burning kiln 68392 6000

PALafargeWhitehallPlant Kiln 3 Waste-burning kiln 46357 5000

PALehighCementEvansville 121 Waste-burning kiln 86526 8760

PALehighCementEvansville 122 Waste-burning kiln 89750 8760

PALehighCementYork 200 Waste-burning kiln 45633 8760

TXAshGroveMidlothian Kiln 1 Waste-burning kiln 53451 8322

TXAshGroveMidlothian Kiln 2 Waste-burning kiln 66402 8322

TXAshGroveMidlothian Kiln 3 Waste-burning kiln 68794 8322

TXHolcimMidlothianPlant Kiln 1 Waste-burning kiln 299660 6437

TXHolcimMidlothianPlant Kiln 2 Waste-burning kiln 326892 6955

UTHolcimDevilsSlide Kiln 1 Waste-burning kiln 185361 7861

Source: "Summary of Environmental and Cost Impacts of Final Amendments to Portland Cement NESHAP"
TCI 

($)

TCI 

($)/dscfm

TAC 

($)

TAC 

($)/dscfm

NG Fuel Requirement 

(scfm)

Annual NG 

requirement 

(MMscf/yr)

13,681,740 76 4,008,233 22 276 131.122

7,711,334 111 1,997,012 29 106 52.986

11,619,307 85 3,274,814 24 210 104.932

10,525,136 90 2,901,800 25 178 93.669

15,158,866 71 4,556,892 21 327 155.162

13,085,462 78 3,792,214 23 256 119.892

13,935,979 75 4,101,303 22 285 149.548

17,317,485 65 5,392,264 20 409 204.056

9,112,970 99 2,437,625 27 140 63.414

9,304,280 98 2,499,341 26 145 65.648

9,438,521 97 2,542,868 26 149 67.235

12,981,866 78 3,755,010 23 253 114.371

12,963,136 79 3,748,294 23 252 114.096

7,641,808 112 1,975,696 29 105 37.629

6,051,509 131 1,502,738 32 71 21.255

8,799,957 102 2,337,454 27 132 69.506

8,995,234 100 2,399,830 27 137 72.095

5,994,594 131 1,486,344 33 70 36.657

6,591,226 123 1,660,059 31 82 40.790

7,507,599 113 1,934,699 29 101 50.673

7,668,720 111 1,983,941 29 105 52.498

18,542,582 62 5,883,522 20 458 176.881

19,535,985 60 6,290,742 19 500 208.483

13,899,668 75 4,087,975 22 283 133.620
Table 5I. Control Costs: Incremental Control Cost Algorithms Appendix A

Parameters/Costs Equation

A. Parameters

1. Incinerator capacity, lb/hr (C)

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

3. Exhaust gas flow rate, dscfm (Q)

4. Unc. HCl concentration, ppmvd (HClu)

5. Cont. HCl concentration, ppmvd (HClc)

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

7. Wastewater (blowdown) flow, gpm (B)

8. Caustic cost, $/ton (CC)

9. Sewage disposal cost, $/1,000 gal (SDC)

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

11. Lime cost, $/ton (LC)

12. Sodium bicarbonate cost, $/ton (SBC)

13. Dust disposal cost, $/ton (DDC)

14. Activated carbon cost, $/lb (ACC)

15. Natural gas cost, $/1,000 ft3 (NGC)

16. Electricity cost, $/kWh (EC)

17. 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

 b. Cage CRF, 4-yr life, 7% interest

18. Total bag cost, $/yr

19. Bag replacement labor cost, $/yr

20. Total cage cost, $/yr

21. Cage replacement labor cost, $/yr

22. Urea solution cost, $/gal (U)

B. Increase Caustic Flow

1. Caustic = HCl x (3.117E-9) x Q x H x CC

2. Sewage disposal = B x (60 min/hr) x H x SDC

3. Makeup water = B x (60 min/hr) x H x WC

4. Total cost

 a. $/yr = Caustic + Sewage disposal + Makeup water

 b. ($/yr) / dscfm = ($/yr) / Q

C. Increase Lime Flow

1. Makeup lime = (2.4E-7 lb/dscf) x HCl x Q x (1 ton/2000 lb) x (60 min/hr) x H x LC

2. Dust disposal = HCl x Q x (60 min/hr) x (2.86E-7 lb/dscf) x (1 ton/2,000 lb) x H x DDC

3. Total cost

 a. $/yr = Makeup lime + Dust disposal

 b. ($/yr) / dscfm = ($/yr) / Q

D. Increase NaHCO3 Flow

1. Makeup NaHCO3 = (2.73E-7 lb/dscf x HCl x Q) x (1 ton/2000 lb) x (60 min/hr) x H x SBC

2. Dust disposal = [(HCl x Q x 60 min/hr x 2.10E-7 lb/dscf)] x (1 ton/2,000 lb) x H x DDC

3. Total cost

 a. $/yr = Makeup NaHCO3 + Dust disposal

 b. ($/yr) / dscfm = ($/yr) / Q

E. Increase Carbon Flow

1. Activated carbon = (1.27E-3) x Q x H x ACC

2. Dust disposal = (1.27E-3) x Q x (1 ton/2,000 lb) x H x DDC

3. Total cost

 a. $/yr = Activated carbon + Dust disposal

 b. ($/yr) / dscfm = ($/yr) / Q

F. Increase Natural Gas

1. Natural gas

 a. $/yr = (0.32 Btu/lb/°F) x (28.5 lb/lbmole) x (100°F) x (lbmole/385 ft3

) x (ft3/1,000 Btu) x (Q/0.9) x (60 min/hr) x H x NGC

 b. ($/yr) / dscfm = ($/yr) / Q

G. Increase Scrubber Horsepower

1. Fan electricity = 0.746 x (0.0205 x Q) x H x EC

2. Pump electricity =0.746 x (0.00267 x Q + 4.554) x H x EC

3. Total cost

 a. $/yr = Fan electricity + pump electricity

 b. ($/yr) / dscfm = ($/yr) / Q

H. Improve FF Performance

1. Bag replacement = Bag CRF x [(total bag cost) + (bag replacement labor cost)]

2. Cage replacement = Cage CRF x [(total cage cost) + (cage replacement labor cost)]

3. Total cost

 a. $/yr = Bag replacement + Cage replacement

 b. ($/yr) / dscfm = ($/yr) / Q

I. Increase NOX Reagent

1. Reagent

 a. $/yr = (0.36 gal/hr) x H x U

 b. ($/yr) / dscfm = ($/yr) / Q

Sources:

7. Water cost, sewage disposal cost: Air Compliance Advisor, version 7.5.

8. Activated carbon cost: The Innovation Group. Chemical Profiles: Carbon, Activated. 2002. Assumed 20% price increase based on online information from Norit, an activated carbon vendor.

9. Sodium bicarbonate cost: Purchasing.com. April 5, 2007. Sodium bicarbonate market supports level pricing—for now.

1. Cost equations: Hospital/Medical/Infectious Waste Incinerators (HMIWI) [EPA-HQ-OAR-2006-0534] Model Plant Description and Cost Report (II-A-112); Wet Scrubber Cost Memorandum (IV-B-30); Dry Injection 

Fabric Filter Cost Memorandum (IV-B-32); and Secondary Chamber Retrofit Cost Memorandum (IV-B-33).

2. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2008 National Industry-Specific Occupational Employment and Wage Estimates.

3. Lime cost: U.S. Geological Survey. Mineral Commodity Summaries 2008. Hydrated Lime Average Value, 2007.

4. Dust disposal cost: NSWMA’s 2005 Tip Fee Survey.

5. Natural gas cost: Energy Information Administration. Natural Gas Prices: 2008.

6. Electricity cost: Energy Information Administration. Average Industrial Retail Price of Electricity: October 2009.