p.1 

OAR Box 1313 

Preppedby LaTeiaShed 

Document Number: 

91) ll-B-65 

Docket Number: 

A-88-02 

Printed 6/12/2008 9:03:31 AM Sheet 91 of 99 
MRI® 

P.2 

A-88-U£ 

MIDWEST RESEARCH INSTITUTE 

UL-fi-toC, Suite 350 

401 Harrison Oaks Boulevard 

Cary, North Carolina 27513 

Telephone (919) 467-5215 

FAX (919) 467-8060 

Date: June 22, 1989 

Subject: Summary of Chevron-Blade Mist Eliminator and Packed-Bed Scrubber 

Cost Oata for Hard and Decorative Chromium Electroplating and 

Chromic Acid Anodizing Model Plants 

Chromium Electroplating NESHAP 

EPA Contract No. 68-02-3817; ESD Project 85/02a 

MRI Project 7717-K 

From: Mary Jo Caldwell 

Robin Barker ^ •lS"S~r*"— —-:—-, 

7!Z.- :..- '-,.-• 

To: Andrew M. Smith :i.Z 

ESD/ISB/SSS (MD-13) \ JA M j 3 ;qq, 

U. S. Environmental Protection Agency

 -v ^ 

Research Triangle Park, N.C. 27711 .,,....„,.. 

I. Introduction **•* * -

This memorandum presents the capital and annualized costs of 

chevron-blade mist eliminators and packed-bed scrubbers used to control 

chromium emissions from the hard and decorative chromium electroplating 

and chromic acid anodizing model plants. Each model plant is composed of 

various sized model tanks. The mcdel tanks are arranged into five control 

device configurations. Figures 1 through 5 present the ventilation system 

schematics and ductwork specifications for each control device configuration. Table 1 presents the model plant parameters on which the installed 

capital and annualized costs are based. 

Capital cost estimates for each of five different sizes of mist 

eliminators and scrubbers specified in the mode"* ->'ants were obtained from 

three control device vendors (designated as venrjo's A, B, and C).'~ The 

vendors also provided operating parameters for mist eliminators and 

scrubbers (e.g., fan and recirculation pump motor horsepower [hpj 

requirements, water consumption rates, maintenance hours, and the life 

expectancy of control devices and scrubber packing material) that were 

used to calculate annualized costs. The cost estimates presented here are 

based on Vendor A estimates only, which were the highest cost estimates 

obtained from the three vendors. Vendor B provided installed capital cost 

estimates for mist eliminators and scrubbers that ranged from $10,000 to 

$20,000 lower than those provided by Vendor A. Annualized cost estimates 

calculated from the control device operating parameters provided by 

Vendor B ranged from $1,000 to $10,000 lower than the annualized cost 

estimates calculated from the control device operating parameters provided 

oy Vendor A. Capital cost estimates provided by Vendor C were incomplete 

because Vendor C did not provide installation costs. 

/ • 
P.3 

All cost data presented here are in November 1988 dollars. The 

capital costs originally received from Vendor A were in October 1986 

dollars. These costs were updated to November 1988 dollars by multiplying 

the costs by the ratio of the Chemical Engineering plant indices for 

October 1986 (319.3) and November 1988 (347.8)." Data sources used to 

calculate capital and annualized costs of the pollution control techniques 

are presented in Table 2. Cost factors used to calculate annualized costs 

are presented in Table 3. 

II. Mist Eliminator and Packed-Bed Scrubber Costs 

This section presents the installed capital and annualized cost 

estimates for each of the five different sizes of mist eliminators and 

scrubbers specified in the model plants. 

A. Capital Costs 

Tables 4 and 5 present capital costs for chevron-blade mist 

eliminators with single and double sets of blades, respectively; and 

Tables 6 and 7 present capital costs for single and double packed-bed 

scrubbers, respectively. Each table presents cost data for each of five 

different sizes of control devices specified in the model plants. 

The capital costs for mist eliminators and packed-bed scrubbers 

include the purchase cost of the control device and auxiliaries such as 

exhaust fans, motors, inlet and outlet transitions, and stack; direct 

installation costs for electrical panels and wiring, instrumentation and 

controls, and piping; indirect costs for erection, engineering services, 

contractor fees, and contingencies; and startup costs. Installation costs 

are based on the assumptions that the control device would be installed on 

the roof of the plating shop, the roof is 6.1 meters (m) (20 feet [ft]) 

high, and that the roof would require no major structural modifications to 

support the weight of the control device. Erection costs include the cost 

of renting a crane to hoist the control device onto the roof of the 

shop. The purchased equipment cost also includes taxes and freight costs, 

which are assymed to be 3 and 5 percent of the base equipment cost, 

respectively. The startup cost is assumed to be 1 percent of the 

purchased equipment cost. 

B. Annualized Costs 

Tables 8 and 9 present annualized costs for chevron-Made mist 

eliminators with single and double sets of blades, respectively; and 

Tables 10 and 11 present annualized costs for single and double packed-bed 

scrubbers, respectively. The annualized costs include direct operating 

costs such as utilities; operator, supervisor, and maintenance labor and 

materials; indirect operating costs such as overhead, property taxes, 

insurance and administration; and capital recovery costs. The annualized 

costs of packed-bed scrubbers also includes the cost of scrubber packing 

replacement and disposal. 

c2~ 
P.4 

3 

Utility costs include the costs of electricity and water required to 

operate mist eliminators and packed-bed scrubbers. The annual electrical 

cost attributable to pollution control results from the additional fan 

horsepower needed to overcome the pressure drop added to the ventilation 

system by the control device and the horsepower needed to operate the 

scrubber recirculation pumps. The incremental fan and recirculation pump 

electrical costs were calculated using the following equation: 

Electrical cost, $/yr = [(0-746

 kM)(hp)(t)][C] 

where, 

kW = kilowatt 

hp = horsepower of pump motor or incremental horsepower of fan motor 

t = operating time, h/yr 

C = electricity cost, $0.0461 kilowatt-hour (kWh)6 

For example, the single packed-bed scrubber that is sized for an 

exhaust gas flow rate of 280 actual cubic, meters per minute (m /min) 

(10,000 actual cubic feet per minute [ft /min]) (Column A in Table 10) 

requires an additional 5 hp to operate the fan, and the scrubber operates 

6,000 h/yr. Therefore, the incremental annual electrical cost to operate 

the fan is: 

[M4pw)[5 hp,[6,gai,][&M61] . $l,030/yr 

In addition, the single packed-bed scrubber requires a 1-hp pump to 

recirculate the scrubber water. The annual electrical cost to operate the 

pump is: 

|M4pW]U hp][«JffiJl] [fijO«l| . $ao/yr 

Therefore, the total annual electrical cost for the scrubber is 

$l,240/yr. 

Water consumption costs are associated with the washdown of mist 

eliminators and the operation of scrubbers. For the purposes of this 

analysis, it was assumed that water for washdown of mist eliminators is 

recycled to the process, as is typically the case. Scrubber water also 

was assumed to be recirculated for 8 hours of operation, at which time the 

water in the recirculation basin is drained to the process and the basin 

is replenished with clean water. Water costs were calculated using the 

following equations: 

(1) Mist eliminators 

Water cost, $/yr = [(V)(N)(S)][C] 

where, 

V = volume of washdown water, liters (a) (gallons [gal]) 

N = number of washdowns per 8-hour shift 

<3 
P.5 

S = number of 8-hour shifts per year 

C = water cost, $0.20/1,000 i ($0.77/1,000 gal) 

(2) Scrubbers 

Water cost, $/yr = [(V)(f)+(FR)(60 m1n/h)(t)]][C] 

where, 

V = recirculation tank volume, i (gal) 

f = frequency of washdowns, number per year 

FR = makeup water flow rate, n/min (gal/min) 

N = number of times per year water is replaced (t/8 h) 

t = operating time, h/yr 

C = water cost, $0.20/1,000 a ($0.77/1,000 gal) 

For example, for the single packed-bed scrubber used in the examples 

above, the recirculation tank volume is 450 a (120 gal); the makeup water 

flow rate is 5.7 liters per minute (1.5 gallons per minute); the scrubber 

is operated 6,000 hours per year; and the scrubber water is drained to the 

process and replaced with clean water every 8 hours of operation, or 

750 times per year. Therefore, the annual water cost for this unit is: 

[(120 gaT)(750)+(^^)(6P^)(6^]][TJ^ZZ_] . $490/yr 

The total annual cost of utilities for the scrubber is equal to the 

sum of the annual electrical and water costs, which is $l,730/yr. 

Scrubber packing material replacement costs were included in 

annualized scrubber costs because the life of the packing material is less 

than the life of the control device. Vendor A estimates that most 

facilities will probably need to replace the packing material every3 

10 years. The packing material costs approximately $600/m ($17/ft ) of 

material. Annualized packing material replacement costs include the 

replacement cost of the packing and the transportation and disposal costs 

associated with the used packing. The replacement costs of the packing 

material were calculated based on the following equation: 

Replacement cost, $/yr = [(v)(c)](CRF ) 

where, 

v = volume of packing required for each control device, m (ft ) 

c = cost of packing material, $620/m ($17/ft ) 

CRF_ = capital recovery factor of 0.1628, based on an interest rate 

of 10 percent and a depreciable life of 10 years for the packing. 

The transportation and disposal costs for the packing material were 

calculated based on the following equation: 

Disposal and transportation cost, $/yr = [(N)(dc) + (N)(tc)](CRF ) 

Y 
P.6 

where, 

N = number of 55-gallon drums, V/V^, rounded to the nearest whole 

number 

V = volume of packing material disposed for each control device, m 

(ft ) (see Tables 6 and 7) 3 3 

V^ = volume of 55-gallon drum, 0.21 m (7.35 ft ) 

dc = disposal cost, $50.00/drum 

tc = transportation cost, $40.00/drum 

CRF_ = capital recovery factor of 0.1628, based on an interest rate 

of 10 percent and a depreciable life of 10 years for the packing material. 

The annual cost of operating labor is based on the amount of labor 

required to operate the control device plus supervision. The operator 

labor is based on vendor estimates for labor hours required per day of 

operation, and a labor rate of $8.37/hour. ° It was assumed that 

0.25 hour per day of operator labor is required for chevron-blade mist 

eliminators, and 0.5 hour per day of operator labor is required for 

packed-bed scrubbers. The operator labor is independent of the control 

device size and the number of operating hours per day. The supervisor 

labor cost is assumed to be 15 percent of the operator labor cost. 

The annual cost of maintenance labor for each control device is 

based on vendor estimates of the maintenance hours required per 

2,000 hours,of.operation and a maintenance labor rate of 

$9.21/hour. ' The annual cost of materials is assumed to be 

100 percent of the maintenance labor cost. 

Indirect costs include overhead, property taxes, insurance, and 

administration. The overhead cost was calculated based on 60 percent of 

the operator, supervisor, and maintenance labor plus any material 

costs. Property taxes, insurance, and administration were assumed to be 

4 percent of the total capital cost. 

Capital recovery costs, which are the costs of capital spread over 

the depreciable life of the control device, were calculated using the 

following equation: 

CRC = [TCC][(i{l+i}n)/({l+i}n-l)] 

where, 

CRC = capital recovery cost, $/yr 

TCC = total capital cost, $ 

i = annual interest rate, 10 percent 

n = depreciable life, 20 years 

III. Model Plant Costs 

This section presents the installed capital and annualized costs of 

chevron-blade mist eliminators and packed-bed scrubbers for the hard and 

decorative chromium plating and chromic acid anodizing model plants. The 

model plant costs are representative of control costs for new sources. 
P.7 

The capital costs for ventilation hoods and ductwork were not included in 

the capital costs for control devices because plants must typically 

install ventilation hoods and ductwork to comply with occupational health 

standards that regulate employee exposure to chromium emissions in the 

workplace. 

A. Model Plant Capital Costs 

Tables 12 through 14 present the purchased equipment, installation, 

startup, and total capital costs of chevron-blade mist eliminators and 

packed-bed scrubbers for the hard and decorative chromium plating and 

chromic acid anodizing model plants. The capital cost estimates were 

compiled from Tables 4 through 7 as described below. 

Hard Chromium Plating 

Small model plant = Column B costs 

Medium model plant = Column D costs 

Large model plant = 2(Column D) costs 

Decorative Chromium Plating 

Small model plant = Column B costs 

Medium model plant = 2(Column B) costs 

Large model plant = 2(Column C) + Column A costs 

Chromic Acid Anodizing 

Small model plant = Column B costs 

Large model plant = Column E costs 

B. Model Plant Annualized Control Costs 

The annualized costs for the model plants are presented in Tables 15 

through 17. The annualized cost estimates, with the exception of the 

labor requirements and indirect costs, were compiled from Tables 8 through 

11 as described below. 

Hard Chromium Plating 

Small model plant = Column B, costs 

Medium model plant = Column D, costs 

Large model plant = 2(Column D2) costs 

Decorative Chromium Plating 

Small model plant = Column B. costs 

Medium model plant = 2(Column B2) costs 

Large model plant = 2(Column C) + Column A costs 

6 
P.8 

Chromic Acid Anodizing 

Small model plant = Column Bt costs 

Large model plant = Column E costs 

The operator, supervisor, and maintenance labor requirements for 

each model plant were calculated based on the assumption that the labor 

required to operate and maintain more than one control device increased 

the labor requirement by only 30 percent for each additional control 

device, instead of increasing the labor requirement by 100 percent. For 

example, for the large decorative chromium plating model plant with 

chevron-blade mist eliminators with a single set of blades (which requires 

a total of three control devices), the operator and maintenance labor 

requirement was calculated as follows: 

Operator and maintenance labor, $/yr = ($1,290)(1.6) = $2,100 

instead of ($1,290)(3) = $3,870 

The material cost, which is based on 100 percent of the maintenance 

labor for each control device, was assumed to increase 100 percent for 

each additional control device for the model plants, and can be computed 

from Tables 10 through 13. 

The indirect costs for each model plant include overhead, property 

taxes, insurance, and administration. The overhead cost is based on 60 

percent of the sum of the operator and maintenance labor plus the material 

costs for each model plant. The property taxes, insurance, and 

administration are equal to 4 percent of the total capital cost for each 

model plant. For example, for the large decorative chromium plating model 

plant operating with chevron-blade mist eliminators with a single set of 

blades, the indirect costs were calculated as follows: 

Indirect costs, $/yr = 0.60 [(1.6)($l,290)+3($690)] 

+0.04[2(27,100)+20,600] = $2,480+$2,990 = $5,500 

The chromic acid recovery credits are calculated based on the 

estimated removal efficiency for chevron-blade mist eliminators and 

packed-bed scrubbers and 100 percent recovery of the chromic acid captured 

by the control device. The chromic acid recovery credit is calculated 

using the following equation: 

Chromic acid recovery credit, $/yr = [ER][Eff][1.923][C] 

where, 

ER = uncontrolled hexavalent chromium emission rate per plant, 

kg/yr (lb/yr) 

Eff = efficiency of control device, decimal percent 

1.923 = ratio of chromic acid molecular weight (100) to hexavalent 

chromium molecular weight (52) 

C = cost of chromic acid (Cr03), $3.28/kg ($1.49/lb) 

/ 
P.9 

8 

The critical variables influencing chevron-blade mist eliminator and 

packed-bed scrubber annualized costs are the labor and materials, capital 

recovery, and indirect costs. 

S 
P.10 

3'.1 5 « 

I 

m-£ 

•12' 

^Z 

fl—9»*— B 

WZm y 

x 

Contro I \ 

Oevi ce 

_/ 

B 

1 

fl—x B 

! Duct Component 

! Specification 

iGas flow rate, cfa 

!0uct diaaeter, in. 

iDuct length, ft. 

INo. of 30 degree entries 

!No. of one step tapers 

INo. of 90 degree elbows 

Duct Section Location 1 

fl 

2,625 

12 

12 

2 

0 

0 

B 

5,250 

13 

27 

3 

2 

1 

c : 

10,500 : 

2* ; 

so : 

0 1 

l : 

l i 

Figure 1. pian view and ductwork specifications for the small hard, 

small and medium decorative chromium plating, and 

small anodizing model tanks. 
m-C 

~*r *. 

-I 

l 

iz: 

•-•— B —•** -

4 

•*— o-*-" — E- V 

12' IB' 

il / / _ 

H_** |. 

y 

-25' 

x: s s H-**s: * I 

1 Duct Component ! 

1 Specification ti i 

IGas flow rate, cfa • 

• • 

•Duct diaaeter, in. ! 

1 1 

(Duct length, ft. ! 

j \ 

INo. of 30 degree entries! 

INo. of one step tapers ! 

!No. of 90 degree elbow t 

fl 

2,000 

10 

11 

1 

0 

0 

D u e 

B 

5,000 

16 

6 

1 

1 

0 

sssaacsma 

t 

c 

8,000 

20 

12 

1 

1 

0 

n»»T IIIL1U 

Se 

D 

11,000 

24 

6 

1 

1 

0 

ctio n 

E 

14,000 

26 

9 

2 

1 

0 

F 

2,344 

12 

12 

2 

2 

0 

L o c a 

6 

4,688 

16 

12 

2 

2 

0 

tio n 

H 

7,032 

20 

12 

2 

2 

0 

1 

9,376 

22 

24 

3 

3 

1 

J 

18,752 

32 

16 

0 

1 

0 

I 

K : 

32,752 ! 

42 ! 

20 : 

0 i 

1 i 

1 : 

Figure 2. plan view and ductwork specifications of the medium and large hard chromium 

plating model plant. 

<b 
11 

P.12 

/ \ 

Devi c e 

! Duct Component 

! Specification 

!6as flow rate, cfa 

IDuct dianeter, in. 

IDuct length, ft. 

INo. of 30 degree entries 

INo. of one step tapers 

INo. of 90 degree elbows 

Duct 

Locat 

fl 

4,500 

16 

6 

1 

0 

0 

Section • 

ion ! 

B : 

9,000 ! 

22 : 

29 : 

1 ! 

i : 

2 : 

Figure 3. Plan view and ductwork specifications of the one 12-foot 

tank of the large decorative chromium plating model plant. 

¥ 
P.13 

12 

i Duct Component 

i Specification 

•6as flow rate, cfa 

IDuct diaaeter, in. 

'.Duct length, ft. 

INo. of 30 degree entries 

INo. of one step tapers 

INo. of 90 degree elbows 

Duct Section Location 1 

fl 

4,500 

16 

12 

2 

0 

0 

B 

9,000 

22 

40 

3 

2 

1 

C 

18,0C0 ! 

32 1 

20 1 

0 1 

i ; 

I : 

Figure 4. plan view and ductwork specifications of two 12-foot 

tanks for the large decorative chromium plating model plant. 

A

2-
D *»« -»*- F-

-9B' 

.t 

-ae* 

t-*«— a1 Duct Component • 

: ! 

•Bas flow rate, cfa I 

t l 

IDuct diaaeter, in. 1 

> • 

IDuct length, ft. 1 

1 l 

INo. of 30 degree entries* 

INo. of one step tapers ! 

INo. of 90 degree elbows I 

fl 

3,750 

14 

6 

1 

0 

0 

aas-rTfrr 

D u 

B 

7,500 

20 

6 

1 

1 

0 

ct Sectio n 

C 

11,250 

24 

6 

1 

1 

0 

D 

15,000 

28 

6 

1 

1 

E 

18,750 

32 

12 

I 

1 

F 

22,500 

34 

6 

1 

1 

Asasasasc 

L o c a 

6 

26,250 

38 

6 

t 

1 

t i 

H 

o n 

30,000 

40 

6 

1 

1 

I 

33,750 

42 

6 

1 

1 

J 

37,500 : 

44 : 

29 1 

I 1 

1 1 

0 0 0 0 0 0 2 i 

Figure 5. plan view and ductwork specifications of the large chromic ad d anodizing model plant. 

£ 
K 

^ N 

TABLE 1. MODEL PLANT PARAMETERS FOR THE HARD 

Model operation 

Hard chromium platin g 

Operating time , h/yr 

Percent time electrode s are energized 

Total ampere-hours per year 

No. of tanks 

Dimensions of tanks , (i,w,d ) m (ft ) 

Ventilatio n rat e per tank , m/mi n (ft/min ) 

No. of contro l devices 

Control device configuratio n 

Size of each contro l device , m/mi n (ft/min ) 

Uncontrolled hexavalent chromium emission rate , 

Decorative chromium platin g 

Operating time , h/yr 

Percent time electrode s are energized 

Total ampere-hours per year 

No. of tanks 

Dimensions of tanks , (l,w,d, ) m (ft ) 

Ventilatio n rat e per tank , m/mi n (ft/min ) 

No. of contro l devices 

Control device configuratio n 

Size of each contro l device, m/mi n (t t /min) 

Uncontrolled hexavalent chromium emission rate , 

Chromic acid anodizing 

Operating time , h/yr 

Percent time electrode s are energized 

No. of tanks 

Dimensions of tanks , (l,w,d, ) m (ft ) 

Ventilatio n rat e per tank , m/mi n (ft/min) . 

No. ot contro l devices 

Control device configuratio n 

Size o* each contro l device , m/mi n (ft/min ) 

Uncontrolled hexavalent chromium emission rate . 

ACID 

kg/yr 

kg/yr 

kg/yr 

ANODIZING 

(lb/yr) 

(lb/yr) 

(lb/yr) 

AND DECORATIVE 

MODEL PLANTS 

Smal 1 

2,000 

7 0

 fi 5.0x10° 

1 

3.6 , 1.1 , 1.8 

(12.0 , 3.5 , 6. 

297 (10,500) 

1 

Figure 1 

340 (12,000) 

50 (110) 

2,000 

6 0

 fi 3.0x10° 

1 

3.6 , 1.1 , 1.8 

(12.0 , 3.5 , 6. 

297 (10,500) 

1 

Figure 1 

340 (12,000) 

6.0 (13.0) 

2,000 

70 

1 

3.6 , 1.1 , 1.8 

(12.0 , 3.5 , 6 

297 (10,500) 

1 

Figure 1 

340 (12,000) 

3.3 (7.2) 

0) 

0) 

0) 

CHROMIUM PLATING 

Plant size 

Med i um 

3,500 

7 0

 f. 

42x10° 

4 

1.2, 1.2, 3.0 

(4.0 , 4.0 , 10.0) 

2 § 3.6 , 1.2, 1.8 

(12.0 , 4.0 , 6.0) 

7.6 , 0.9 , 1.8 

(25.0 , 3.0 , 6.0) 

57 (2,000) 

2 S 170 (6,000) 

531 (18,750) 

1 

F igure 2 

990 (35,000) 

420 (925) 

4,000 

6 0

 fi 12x10° 

2 

2 § 3.6 , 1.1 , 1.8 

(12.0 , 3.5 , 6.0) 

2 S 297 (10,500) 

2 

Figure 1 

340 (12,000) 

24 (53) 

AND CHROMIC 

Large 

6,000 

8 0

 fi 160x10° 

8 

2 % 1.2, 1.2, 3.0 

(4.0 , 4.0 , 10.0) 

4 6 3.6 , 1.2, 1.8 

(12.0 , 4.0 , 6.0) 

2 i 7.6 , 0.9 , 1.8 

(25.0 , 3.0 , 6.0) 

2 S 57 (2,000) 

4 6 170 (6,000) 

2 g 531 (18,750) 

2 

Figure 2 

2 € 990 (35,000) 

1,600 (3,530) 

6,000 

6 0

 fi 120x10° 

5 

5 8 3.6 , 1.8, 2.7 

(12.0 , 6.0 , 9.0) 

5 6 255 (9,000) 

3 

Figures 3 and 4 

280 (10,000) 

2 6 510 (18,000) 

240 (530) 

6,000 

40 

2 

2 S 9.1 , 1.5, 2.7 

(30.0 , 5.0 , 9.0) 

2 g 531 (18,750) 

1 

Figure 5 

1,130 (40,000) 

40 (88) 

i—• 
TABLE 2. CAPITAL AND ANNUALIZED COST DATA SOURCES FOR POLLUTION CONTROL TECHNIQUES 

Cost item Source Date Ref, 

A. Capiljl Costs 

1. Chevron-blade mist eliminators 

2. Packed-bed scrubbers 

B. Annualized Costs 

1. Electrici ty 

2. Water 

3. Chromic acid 

4. Labor 

a. Operator 

b. Supervisor and maintenance 

5. Replacement packing material 

6. Transportation and disposal 

of old packing 

7. Overhead, property tax, 

insurance, administration 

8. Capital recovery 

Vendor A 

Vendor A 

Department of Energy 

American Water Works 

Association 

Ashland Chemical Company 

Bureau of Labor Statistics 

EPA/OAQPS/EAB 

Vendor A, EPA/OAQPS/EAB 

Chemical Waste Management 

EPA/OAQPS/EAB 

EPA/OAQPS/EAB 

October 1986 updated to November 1988a 

October 1986 updated to November 1988a 

October 1988 

March 1989 

June 1989a 

August 1988, January 1989 

August 1988, January 1989 

March 1989, February 1987 

April 1989 

February 1987 

February 1987 

6 

7 

12 

10, I 1 

5, 10, I I 

8. 5 

9 

Costs were updated by multiplying base year costs by the ratio of the Chemical Engineering plant indices for November 1988 and 

the base year. 

$ Tl 
P.17 

. 

16 

TABLE 3. ANNUAL OPERATING COST FACTORS 

Cost categories 

Direct operating costs 

1. Operating labor 

a. Operator' ' 

b. Supervisor 

2. Maintenance , „ ,, . , 5:01 1 

a. Labor ' .' 

b. Materials3 

3. Replacement parts 

(packing material) 

4. Transportation and 

disposal of used 

packing 

5. Utilities 

a. Electricity 

b. Water 

Indirect operating costs 

7. Overhead 

8. Property tax 

9. Insurance 

10. Administration 

11. Capital recovery 

Credits 

12 Chromic acid recovery 

aBased on an interest rate of 

,10 years. 

Based on an interest rate of 

20 years. 

10 

10 

Cost factors 

$8.37/man-h 

15 percent of la 

$9.21/h 

100 percent of 3a 

16.3 percent of the total replacement 

cost at $17.50/ft

 a 

$50/drum disposal (plus 10 percent tax) 

$40/drum transportation (plus 10 percent 

tax) 

$0.0461/kWh 

$0.77/1,000 gal 

60 percent of la+lb+3a+3b 

1 percent of capital cost 

1 percent of capital cost 

2 percent of capital cost 

11.7 percent of capital cost 

$3.28/kg 

percent and a scrubber packing life of 

percent and an equipment life of 

/ * 
17 

TABLE 4. CAPITAL COSTS OF CHEVRON-BLADE MIST ELIMINATOR 

(SINGLE SET OF BLADES) 

Mist eliminator sizea 

Control device parameters 

Design gas flow rate, nr/min 

(ft3/min)b 

Pressure drop, kPa (in. w.c.) 

Fan static pressure, kPa 

(in. w.c) c 

Fan motor size, hp (kw) 

Cost datae 

1. Basic mist eliminator 

2. Inlet and outlet transition 

3. Fan and motor 

4. Stack 

5. Base equipment 

6. Sales taxes and freight^ 

7. Total purchased equipment 

8. 

9. Startup-* 

280 

(10,000) 

0.19 

(0.75) 

0.62 

(2.5) 

7.5 

(5.6) 

340 

(12,000) 

0.19 

(0.75) 

0.75 

(3.0) 

10 

(7.5) 

510 

(18,000) 

0.19 

(0.75) 

0.87 

(3.5) 

20 

(15) 

990 

(35,000) 

0.19 

(0.75) 

1.4 

(5.5) 

50 

(37) 

1,130 

(40,000) 

0.19 

(0.75) 

1.2 

(5.0) 

50 

(37) 

2,560 

640 

4,250 

590 

8,040 

640 

8,680 

11,870 

90 

2,970 

660 

5,000 

720 

9,350 

750 

10,100 

12,340 

100 

4,040 

840 

6,480 

910 

12,270 

980 

13,250 

13,740 

130 

6,540 

1,800 

13,090 

1,180 

22,610 

1,810 

24,420 

20,840 

240 

7,170 

1,980 

15,300 

1,230 

25,680 

2,050 

27,730 

20,590 

280 

\0.Total capital cost k 20,60022,50027,10045,50048,60 0 

a, Mist eliminator sizes are ranked from the lowest gas flow rate (Column A) to the highest gas 

flow rate (Column E) . 

Gas stream temperature is 27"C (80*F), gas stream moisture content is 2 percent, and 

altitude is 305 m (1,000 ft). 

""Static pressures were estimated by the vendor and were based on the ventilation system 

specifications presented in Figures 1 through 5. 

Vendor A provided motor sizes based on the static pressures and gas flow rates specified 

above. 

eCapital costs presented in this table are based on Vendor A estimates only. Vendor A 

provided base equipment and installation costs in October 1986 dollars. Costs were updated 

,to November 1988 dollars and were rounded to nearest $10. 

Sum of 1 through 4. 

j^Sales taxes and freight costs are 3 and 5 percent, respectively, of base equipment costs. 

.Sum of 5 and 6. 

'includes all costs associated with installing instrumentation, electrical components, and 

piping; erection and contingencies; and fee. Assumed that control devices are installed on 

the roof of a plant that is 6.' m (20 ft) high and no structural modifications are 

.necessary. 

j^One percent of total purchased equipment cost. 

Sum of 7, 8, and 9. Costs were rounded to nearest $100. 

/ / 
P.19 

18 

TABLE 5. CAPITAL COSTS OF CHEVRON-BLADE MIST ELIMINATOR 

(DOUBLE SETS OF BLADES) 

Mist eliminator size3 

Control device parameters 

Design gas flow rate, m/min 

(ft3/min)b 

Pressure drop, kPa (in. w.c.) 

Fan static pressure, kPa 

(in. w.c.)c 

Fan motor size, hp (kw) 

280 

10,000) 

0.5 (2) 

0.87 

(3.5) 

10 

(7.5) 

340 

(12,000) 

0.5 (2) 

1.0 

(4.0) 

15 

(11) 

510 

(18,000) 

0.5 (2) 

1.1 

(4.5) 

25 

(19) 

990 

(35,000) 

0.5 (2) 

1.6 

(6.5) 

60 

(45) 

1,130 

(40,000) 

0.5 (2) 

1.5 

(6.0) 

60 

(45) 

Cost < 

1. 

2. 

3. 

4. 

5. 

6. 

7. 

8. 

9. 

10. 

iatae 

Basic mist eliminator 

Inlet and outlet transition 

Fan and motor 

Stack 

Base equipment 

Sales taxes and freight^ 

Total purchased equipment 

Installation' 

StartupJ 

Total capital costK 

3,080 

640 

4,380 

590 

8.690 

690 

9,380 

12,310 

90 

21,800 

3,910 

660 

5,250 

720 

10,540 

850 

11,390 

12,340 

110 

23,800 

4,970 

840 

6,760 

910 

13,480 

1,070 

14,550 

14,120 

150 

28,800 

8,380 

1,800 

15,230 

1,180 

26,590 

2,t30 

28,720 

20,840 

290 

49,900 

9,260 

1,980 

14,880 

1,230 

27,350 

2,190 

29,540 

20,590 

300 

50,400 

aMist eliminator sizes are ranked from the lowest gas flow rate (Column A) to the highest gas 

flow rate (Column E) . 

Gas stream temperature is 27°C (80'F), gas stream moisture content is 2 percent, and 

altitude is 305 m (1,000 ft). 

cStatic pressures were estimated by the vendor and were based on the ventilation system 

specifications presented in Figures 1 through 5. 

Vendor A provided motor sizes based on the static pressures and gas flow rates specified 

above. 

eCapital costs presented in this table are based on Vendor A estimates only. Vendor A 

provided base equipment and installation costs in October 1986 dollars. Costs were updated 

,to November 1988 dollars and were rounded to nearest $10. 

Sum of 1 through 4. 

^Sales taxes and freight costs are 3 and 5 percent, respectively, of base equipment costs. 

.Sum of 5 and 6. 

'includes all costs associated with installing instrumentation, electrical components, and 

piping; erection and contingencies; and fee. Assumed that control devices are installed on 

the roof of a plant that is 6.1 m (20 ft) high and no structural modifications are 

.necessary. 

j^One percent of total purchased equipment cost. 

Sum of 7, 8, and 9. Costs were rounded to nearest $100. 

A 
19 

TABLE 6. CAPITAL COSTS OF SINGLE PACKED-BED HORIZONTAL-FLOW SCRUBBER 

— — — ' ^— — x—xxxx.mm.— 

Scrubber size3 

Control device parameters 

Design gas flow rate, m/min 

(ft3/min)b 

Pressure drop, kPa (in. w.c.) 

Fan static pressure, kPa 

(in. w.c.)c 

Fan motor size, hp (kw) 

Amount of packing, nr (ft3) 

280 

(10,000) 

0.5 (2) 

0.87 

(3.5) 

10 

(7.5) 

0.68 

(24) 

340 

(12,000) 

0.5 (2) 

1.0 

(4.0) 

15 

(11) 

0.82 

(29) 

510 

(18,000) 

0.5 (2) 

1.1 

(4.5) 

25 

(19) 

1.2 

(42) 

(35 

0. 

990 

,000) 

5 (2) 

1.6 

(6.5) 

60 

(45) 

2.1 

(74) 

1,130 

(40,000) 

0.5 (2) 

1.5 

(6.0) 

60 

(45) 

2.4 

(86) 

Cost datae 

1. 

2. 

3. 

4. 

5. 

6. 

7. 

8. 

9. 

10. 

11. 

12. 

Basic scrubber 

Inlet and outlet transition 

Fan and motor 

Remote recirculation tank 

Recirculation water pump 

and motor 

Stack 

Base equipment^ 

Sales taxes and freight 

Total purchased equipment' 

Installation^ 

Startupk 

Total capital cost1 

7,160 

900 

4,380 

410 

2,070 

590 

15,510 

1,250 

16,760 

16,560 

170 

33,500 

8,530 

1,000 

5,250 

410 

2,180 

720 

18,090 

1,440 

19,530 

16,990 

200 

36,700 

12,250 

1,860 

6,760 

770 

2,210 

910 

24,760 

1,980 

26,740 

18,590 

270 

45,600 

20,340 

3,900 

15,230 

840 

2,290 

1,180 

43,780 

3,500 

47,280 

26,430 

470 

74,200 

23,260 

4,540 

14,880 

. 840 

3,450 

1,230 

48,200 

3,860 

52,060 

26,090 

520 

78,700 

aScrubber sizes are ranked from the lowest gas flow rate (Column A) to the highest gas flow 

rate (Column E) . 

Gas stream temperature is 27°C (80*F), gas stream moisture content is 2 percent, and 

altitude is 305 m (1,000 ft). 

""Static pressures were estimated by the vendor and were based on the ventilation system 

specifications presented in Figures 1 through 5. 

Vendor A provided motor sizes based on the static pressures and gas flow rates specified 

above. 

eCapital costs presented in this table are based on Vendor A estimates only. Vendor A 

provided base equipment and installation costs in October 1986 dollars. Costs were updated 

to November 1988 dollars and were rounded to nearest $10. 

Includes cost of initial packing material. 

jjSum of 1 through 6. 

.Sales taxes and freight costs are 3 and 5 percent, respectively, of base equipment costs. 

'.Sum of 7 and 8. 

•'includes all costs associated with installing instrumentation, electrical components, and 

piping; erection and contingencies; and fee. Assumed that control devices are installed on 

the roof of a plant that is 6.1 m (20 ft) high and no structural modifications are 

necessary, 

iOne percent of total purchased equipment cost. 

Sum of 9, 10, and 11. Costs were rounded to nearest $100. 

/f 
20 

TABLE 7. CAPITAL COSTS OF DOUBLE PACKED-BED HORIZONTAL-FLOW SCRUBBER 

Scrubber size3 

P.21 

Control device parameters 

Design gas flow rate, m/mi n 

(ft3 /min)b 

Pressure drop, kPa (in. w.c.) 

Fan static pressure, kPa 

(in. w.c.) c 

Fan motor size, hp (kw) 

Amount of packing, m (ft3) 

280 

(10,000) 

0.75 (3) 

1.1 

(4.5) 

15 

(11) 

1.4 

(48) 

340 

(12,000) 

0.75 (3) 

1.2 

(5.0) 

15 

(11) 

1.6 

(58) 

510 

(18,000) 

0.75 (3) 

1.4 

(5.5) 

30 

(22) 

2.4 

(84) 

990 

(35,000) 

0.75 (3) 

1.9 

(7.5) 

75 

(56) 

4.19 

(148) 

1,130 

(40,000) 

0.75 (3) 

1.7 

(7.0) 

75 

(56) 

4.87 

(172) 

Cost datae 

1. 

2. 

3. 

4. 

5. 

6. 

7. 

8. 

9. 

10. 

11. 

12. 

Basic scrubber 

Inlet and outlet transition 

Fan and motor 

Remote recirculation tank 

Recirculation water pump 

and motor 

Stack 

Base equipments 

Sales taxes and freight 

Total purchased equipment1 

InstallationJ 

Startupk 

Total capital cost 

9,530 

960 

4,650 

520 

2,210 

590 

18,460 

1,470 

19,930 

16,560 

200 

36,700 

11,160 

1,060 

5,250 

640 

2,270 

720 

21,100 

1,690 

22,790 

16,990 

230 

40,000 

15,780 

1,960 

6,740 

850 

3,450 

910 

29,690 

2,370 

32,060 

18,590 

320 

51,000 

27,120 

4,140 

17,490 

1,230 

4,030 

1,180 

55,190 

4,420 

59,610 

26,430 

600 

86,600 

31,030 

4,800 

15,880 

1,320 

4,190 

1,230 

58,450 

4,670 

63,120 

26,090 

630 

89,800 

aScrubber sizes are ranked from the lowest gas flow rate (Column A) to the highest gas flow 

rate (Column E) . 

Gas stream temperature is 27*C (80*F), gas stream moisture content is 2 percent, and 

altitude is 305 m (1,000 ft). 

cStatic pressures were estimated by the vendor and were based on the ventilation system 

.specifications presented in Figures 1 through 5. 

Vendor A provided motor sizes based on the static pressures and gas flow rates specified 

above. 

eCapital costs presented in this table are based on Vendor A estimates only. Vendor A 

provided base equipment and installation costs in October 1986 dollars. Costs were updated 

to November 1988 dollars and were rounded to nearest $10. 

Includes cost of packing material. 

pSum of 1 through 6. 

.Sales taxes and freight costs are 3 and 5 percent, respectively, of base equipment costs. 

'.Sum of 7 and 8. 

•^Includes all costs associated with installing instrumentation, electrical components, and 

piping; erection and contingencies; and fee. Assumed that control devices are installed on 

the roof of a plant that is 6.1 m (20 ft) high and no structural modifications are 

. necessary. 

One percent of total purchased equipment cost. 

Sum of 9, 10, and 11. Costs were rounded to the nearest $100. 

*20 
TABLE 8. ANNUALIZED COSTS OF CHEVRON-BLADE MIST ELIMINATOR (SINGLE SET OF BLADES) 

"B" TU is: 

Mist eliminator size8 

c 1 

Control device parameters 

Design gas flow rate, m/min 

(ft3/min) 

Operating hours/yr 

Frequency of washdown, No. times/8 h 

of operation 

Volume of water per washdown, 8. (gal) 

Incremental fan motor size, hp

 c 

Maintenance hours/yr 

Life expectancy, yr 

280 

(10,000) 

6,000 

2 

38 (10) 

2.5 

75 

20 

340 

(12,000) 

2.000 

57 (15) 

0 

25 

20 

340 

(12,000) 

4.000 

57 (15) 

0 

50 

20 

510 

(18,000) 

6,000 

2 

57 (15) 

5 

75 

20 

990 

(35,000) 

3,500 

2 

95 (25) 

10 

53 

20 

990 

(35,000) 

6,000 

2 

95 (25) 

10 

90 

20 

1,130 

(40,000) 

6,000 

2 

114 (30) 

0 

90 

20 

Cost data 

1. Utilities 

2. Operator and maintenance Ial 

3. Maintenance materials 

4. Indirect costs 

5. Capital recovery 

6. Total annualized cost, $9 

aMist eliminator sizes are ranked 

)ore 

from the low 

530 

1,290 

690 

2,010 

2,410 

6,900 

est gas f 1 ow 

10 

830 

230 

1,540 

2,630 

5,200 

rate (Col umn 

10 

1,060 

460 

1,810 

2,630 

6,000 

A) to the 

1,050 

1,290 

690 

2,270 

3,170 

8,500 

highest gas f 1 

1,220 

1,080 

480 

2,760 

5,320 

10,900 

ow rate (Col 

2,090 

1,430 

830 

3,180 

5,320 

12,900 

umn E). Col 

30 

1,430 

830 

3,300 

5,690 

11,300 

umns B. 

3 , pi 

2tti\ 

based on operating times of 2,000 and 4,000 hours/year. 

respefctiveiy. Columns D. and D_ present annualized costs for the 990-m /min (35,000-ft /min) unit based on operating times of 

3,500 and 6,000 hours/year, respectively. 

Value for parameter provided by Vendor A. 

The incremental fan motor size is the additional horsepower required to operate the control device over the horsepower required 

to operate the ventilation system. 

Annualized costs are presented in November 1988 dollars and were calculated from the control device parameters provided by 

Vendor A and the operating hours specified above. All costs were rounded to the nearest $10. 

eIncludes operator, supervisor, and maintenance labor. 

Includes overhead, property tax, insurance, and administration. 

^Numbers may not add exactly due to independent rounding. Cost data were rounded to nearest $100. 

ro 

1* 
^ 

V 

TABLE 9. ANNUALIZED COSTS OF CHEVRON-BLADE MIST ELIMINATOR (DOUBLE SETS OF BLADES) 

Mist eliminator size3 

Control device parameters 

Desigq gas flow rate, m/mi n 

(ft-* /min) 

Operating hours/yr 

Frequency of washdown, No. times/8 h 

of operation 

Volume of water per washdown, 2. (gal) 

Incremental fan motor size, hp

 c 

Maintenance hours/yr 

Life expectancy, yr 

A 

280 

(10,000) 

6,000 

3 

38 (10) 

5 

75 

20 

**, 

340 

(12,000) 

2,000 

3 

57 (15) 

5 

25 

20 

*2 

340 

(12,000) 

4,000 

3 

57 (15) 

5 

50 

20 

C 

510 

(18,000) 

6,000 

3 

57 (15) 

10 

75 

20 

D, 

990 

(35,000) 

3,500 

3 

95 (25) 

20 

53 

20 

D 2 

990 

(35,000) 

6,000 

3 

95 (25) 

20 

90 

20 

E 

1,130 

(40,000) 

6,000 

3 

114 (30) 

10 

90 

20 

Cost datad 

1. 

2. 

3. 

4. 

5. 

UtiIities 

Operator and maintenance labor6 

Maintenance materials 

Indirect costs 

Capital recovery 

1,050 

1,290 

690 

2,060 

2,550 

350 

830 

230 

1,590 

2,780 

710 

1,060 

460 

1,860 

2,780 

2,090 

1,290 

690 

2,340 

3,370 

2,440 

1,080 

480 

2,940 

5,840 

4,170 

1,430 

830 

3,360 

5,840 

2,110 

1,430 

830 

3,380 

5,900 

ro 

ro 

6. Total annualized cost, $3 7,600 5,800 6,900 9,800 12,800 15,600 13,700 

Mist eliminator sizes are ranked from the lowest gas flow rate (Column A) to the highest gas flow rate (Column E) . Columns B. 

and B^ present annualized costs for the 340-nr/min (12,000-ft3/min) unit based on operating times of 2,000 and 4,000 hours/year, 

respectively. Columns D. and D_ present annualized costs for the 990-m /min (35,000-ft /min) unit based on operating times of 

.3,500 and 6,000 hours/year, respectively. 

Value for parameter provided by Vendor A. 

The incremental fan motor size is the additional horsepower required to operate the control device over tlie horsepower required 

to operate the ventilation system. 

Annualized costs are presented in November 1988 dollars and were calculated from the control device parameters provided by 

Vendor A and the operating hours specified above. All cost were rounded to the nearest $10. 

eIncludes operator, supervisor, and maintenance labor. 

Includes overhead, property tax, insurance, and administration. 

^Numbers may not add exactly due to independent rounding. Cost data were rounded to nearest $100. 
TABLE 10. ANNUALIZED COSTS OF SINGLE PACKED-BED HORIZONTAL-FLOW SCRUBBER 

Scrubber size3 

1 ^ B^ C D~| DJ" 

Control device parameters 

Desigo gas flow rate, m3/min 280 340 340 510 990 990 1,130 

(ft-Vmin) (10,000) (12,000) (12,000) (18,000) (35,000) (35,000) (40,000) 

Operating hours/yr 6,000 2,000 4,000 6,000 3,500 6,000 6,000 

Incremental fan motor size, hpb c 5 5 5 10 20 20 10 

Volume of remote recirculation tank, 454 454 454 1,010 1,500 1,500 1,500 

8, (gal)b (120) (120) (120) (290) (396) (396) (396) 

Recirculation pump motor, hp 1 1.5 2 3 3 3 5 

Maintenance hours/yrb 150 50 100 150 110 195 210 

Life expectancy (unit), yrb 20 20 20 20 20 20 20 

Life expectancy (packing), yrb 10 10 10 10 10 10 10 

Cost datad 

1. Utilities 

2. Operator and maintenance labore 

3. Maintenance materials 

4. Packing material replacement 

5. Indirect costs^ 

6. Capital recovery 

~~T. Total annualized cost, $n 13,500 10,000 12,100 17,100 21,100 26,200 25,900 

aPacked-bed scrubber sizes are ranked from the lowest gas flow rate (Column A) to the highest gas flow rate (Column E). 

Columns B. and B~ present annualized costs for the 340-m /min (12,000-ft /min) unit based,on operating times of 2,000 and 

4,000 hours/year, respectively. Columns D. and D- present annualized costs for the 990-m /min (35,000-ft-Vmin) unit based on 

operating times of 3,500 and 6,000 hours/year, respectively. 

Value for parameter provided by Vendor A. 

cThe incremental fan motor size is the additional horsepower required to operate the control device over the horsepower required 

to operate the ventilation system. 

Annualized costs are presented in November 1988 dollars and were calculated from the control device parameters provided by 

Vendor A and the operating hours specified above. All cost were rounded to the nearest $10. 

eIncludes operator, supervisor, and maintenance labor. 

Includes cost of packing replacement and disposal and transportation of old packing. 

^Includes overhead, property tax, insurance, and administration. 

Numbers may not add exactly due to independent rounding. Cost data were rounded to nearest $100. 

1,730 

2,590 

1,380 

130 

3,720 

3,920 

630 

1,670 

460 

160 

2,750 

4,290 

1,280 

2,130 

920 

160 

3,300 

4,290 

3,390 

2,590 

1,380 

210 

4,200 

5,340 

3,760 

2,260 

1,050 

380 

4,960 

8,680 

6,400 

3,010 

1,800 

380 

5,860 

8,680 

4,980 

3,140 

1,930 

430 

6,190 

9,210 

ro 

CO 
A 

280 

(10,000) 

6,000 

10 

680 

(180) 

2 

225 

20 

10 

B, 

340 

(12,000) 

2,000 

5 

830 

(220) 

3 

75 

20 

10 

*"2 

340 

(12,000) 

4,000 

5 

830 

(220) 

3 

150 

20 

10 

Scrubber size3 

C 

510 

(18,000) 

6,000 

15 

1,225 

(324) 

5 

225 

20 

10 

Dl 

990 

(35,000) 

3,500 

35 

2,385 

(630) 

7.5 

175 

20 

10 

D2 

990 

(35,000) 

6,000 

35 

2,385 

(630) 

7.5 

300 

20 

10 

E 

1,130 

(40,000) 

6,000 

25 

2,725 

(720) 

7.5 

300 

20 

10 

TABLE 11. ANNUALIZED COSTS OF DOUBLE PACKED-BED HORIZONTAL-FLOW SCRUBBER 

Control device parameters. 

Design gas flow rate, irr/min 

(ft-5/min) 

Operating hours/yr 

b c Incremental fan motor size, hp 

Volume of remote recirculation tank, 

«. (gal)b

 b 

Recirculation pump motor, hp 

Maintenance hours/yr 

Life expectancy (unit), yr 

Life expectancy (packing material), yr 

Cost datad 

1. Utilities 3,410 930 1,850 5,820 7,020 12,040 10,450 £ 

2. Operator and maintenance labore 

3. Maintenance materials 

4. Packing material replacement 

5. Indirect costs^ 

6. Capital recovery 

~T. Total annualized cost, $n 18,000 11,700 14,800 22,800 28,500 37,200 36,200 

aPacked-bed scrubber sizes are ranked from the lowest gas.flow rate (Column A) to the highest gas flow rate (Column E). 

Columns B. and B_ present annualized costs for the 340-m /min (12,000-ft-vmin) unit based,on operating times of 2,000 and 

4,000 hours/year, respectively. Columns D. and D_ present annualized costs for the 990-m3/min (35,000-ft3/min) unit based on 

operating times of 3,500 and 6,000 hours/year, respectively. 

Value for parameter provided by Vendor A. 

The incremental fan motor size is the additional horsepower required to operate the control device over the horsepower required 

to operate the ventilation system. 

Annualized costs are presented in November 1988 dollars and were calculated from the control device parameters provided by 

Vendor A and the operating hours specified above. All costs were rounded to the nearest $10. 

eIncludes operator, supervisor, and maintenance labor. 

Includes cost of packing replacement and disposal and transportation of old packing. 

^Includes overhead, property tax, insurance, and administration. 

Numbers may not add exactly due to independent rounding. Cost data were rounded to nearest $100. 

3,410 

3,280 

2,070 

260 

4,680 

4,290 

930 

1,900 

690 

320 

3,150 

4,680 

1,850 

2,590 

1,380 

320 

3,980 

4,680 

5,820 

3,280 

2,070 

430 

5,250 

5,970 

7,020 

2,820 

1,610 

760 

6,120 

10,130 

12,040 

3,970 

2,760 

760 

7,500 

10,130 

10,450 

3,970 

2,760 

860 

7,630 

10,510 

K-

^ 
25 

TABLE 12. CAPITAL COSTS OF MIST ELIMINATORS AND PACKED-BED 

SCRUBBERS FOR HARD CHROMIUM PLATING MODEL PLANTSa 

(November 1988 Dollars) 

Model plant size 

Chevron-blade 

mist eliminator 

Single 

set of 

blades 

Double 

set of 

blades 

Scrubber 

Single 

packed-bed 

Double 

packed-bed 

Small1 

Purchased equipment 10,100 11,400 

Installation 12,300 12,300 

Startup0 100 100 

Total capital costa 22,500 23,800 

Mediume 

19,500 

17,000 

200 

36,700 

22,800 

17,000 

200 

40,000 

Purchased equipment 

Installation 

Startup0 . 

Total capital cost 

Large 

Purchased equipment 

Installation 

Startup0 . 

Total capital cost 

24,400 

20,800 

200 

45,400 

48,800 

41,700 

500 

91,000 

28,700 

20,800 

300 

49,800 

57,400 

41,700 

600 

99,700 

47,300 

26,400 

500 

74,200 

94,600 

52,900 

900 

148,400 

59,600 

26,400 

600 

86,600 

119,200 

52,900 

1,200 

173,300 

Capital costs for mist eliminators are from Tables 4 and 5, and capital 

.costs for scrubbers are from Tables 6 and 7. 

Small model plant costs for each control device type are from Column B in 

Tables 4 through 7. 

°Startup costs are based on 1 percent of the purchased equipment cost. 

Total capital cost is the sum of purchased equipment, installation, and 

startup costs. Costs were rounded to the nearest $100. 

eMedium model plant costs for each control device type are from Column D 

in Tables 4 through 7. 

Large model plant costs for each control device type are two times medium 

model plant costs. 

3.S 
26 

P.27 

TABLE 13. CAPITAL COSTS OF MIST ELIMINATORS AND PACKED-BED SCRUBBERS 

FOR DECORATIVE CHROMIUM ELECTROPLATING MODEL PLANTSa 

(November 1988 Dollars) 

Model plant size 

Smallb 

Purchased equipment 

Installation 

Startup0 . 

Total capital cost 

Mediume 

Purchased equipment 

Installation 

Startup0 . 

Total capital cost 

Larqe 

Purchased equipment 

Installation 

Startup0 . 

Total capital cost 

Chevron-blade • 

mist eliminator 

Single Double 

set of set of 

blades blades 

10,100 

12,300 

100 

22,500 

20,200 

24,700 

200 

45,100 

35,200 

39,400 

400 

75,000 

11,400 

12,300 

100 

23,800 

22,800 

24,700 

200 

47,700 

38,500 

40,600 

400 

79,500 

Scrubber 

Single 

packed-bed 

19,500 

17,000 

200 

36,700 

39,100 

34,000 

400 

73,500 

70,200 

53,700 

700 

124,600 

Double 

packed-bed 

22,800 

17,000 

200 

40,000 

45,600 

34,000 

500 

80,100 

84,100 

53,700 

800 

138,600 

Capital costs 

costs for scru 

'Small model pl 

'Startup costs 

Total capital 

^startup costs. 

:Medium model p 

Large model pl 

Column C plus 

through 7. 

for mist eliminators are from Tables 4 and 5, and capital 

bbers are from Tables 6 and 7. 

ant costs are presented in Column B in Tables 4 through 7. 

are based on 1 percent of the purchased equipment cost, 

cost is the sum of purchased equipment, installation, and 

The costs were rounded to the nearest $100. 

Iant costs are two times small model plant costs, 

ant costs are two times the control device costs in 

the control device costs in Column A from Tables 4 

JL& 
P.28 

27 

TABLE 14. CAPITAL COSTS OF MIST ELIMINATORS AND PACKED-BED SCRUBBERS 

FOR CHROMIC ACID ANODIZING MODEL PLANTSa 

(November 1988 Dollars) 

Chevron-blade 

mist eliminator 

Model plant size 

Single 

set of 

blades 

Double 

set of 

blades 

Scrubber 

Single 

packed-bed 

Double 

packed-bed 

Smallb 

Purchased equipment 

Installation 

Startup0 . 

Total capital cost 

Largee 

Purchased equipment 

Installation 

Startup0 . 

Total capital cost 

10,100 

12,300 

100 

22,500 

27,700 

20,600 

300 

48,600 

11,400 

12,300 

100 

23,800 

29,500 

20,600 

300 

50,400 

19,500 

17,000 

200 

36,700 

52,100 

26,100 

500 

78,700 

22,800 

17,000 

200 

40,000 

63,100 

26,100 

600 

89,800 

aCapital costs for mist eliminators are from Tables 4 and 5, and capital 

.costs for scrubbers are from Tables 6 and 7. 

Small model plant costs for each control device type are from Column B in 

Tables 4 through 7. 

°Startup costs are 1 percent of the purchased equipment cost. 

Total capital cost is the sum of the purchased equipment, installation, 

and startup costs. The costs were rounded to nearest $100. 

eLarge model plant costs for each control device type are from Column E in 

Tables 4 through 7. 

*7 
28 

TABLE 15. ANNUALIZED COSTS OF MIST ELIMINATORS AND PACKED-BED 

SCRUBBERS FOR HARD CHROMIUM PLATING MODEL PLANTS

 a 

(November 1988 Dollars) 

Sma11D 

Utilitiesc 

Operator and maintenance 

labor" 

Maintenance materials 

Packing replacement6 

Indirect costs 

Capital recovery • 

Annualized cost, $ 

Chromic acid recovery^ 

Net annualized costs, $ 

Med i um' 

Utilities0 

Operator and maintenance 

labord 

Maintenance materials 

Packing replacement6 

Indirect costs 

Capital recovery 

Annualized cost, $ 

Chromic acid recovery^ 

Net annualized costs, $ 

LargeJ 

Utilitiesc 

Operator and maintenance 

labor" 

Maintenance materials 

Packing replacement6 

Indirect costs 

Cap i ta1 recovery 

Annualized cost, $ 

Chromic acid recovery^ 

Net annualized costs, $ 

Chevror 

mist el 

Single 

set of 

blades 

0 

800 

200 

— 

1,500 

2,600 

5,100 

(300) 

4,800 

1,200 

1,100 

500 

— 

2,800 

5,300 

10,900 

(2,400) 

a; 500 

4,200 

1,900 

1,700 

— 

5,800 

10,600 

24,200 

(9,100) 

15,100 

l-blade 

minator 

Double 

set of 

blades 

400 

800 

200 

— 

1,600 

2.800 

5,800 

(300) 

5,500 

2,400 

1,100 

500 

— 

2,900 

5,800 

12,700 

(2,500) 

10,200 

8,300 

1,900 

1,700 

— 

6,100 

11,700 

29;700 

(9,600) 

20,100 

Scrubber 

Single 

packed-bed 

600 

1,700 

500 

200 

2,800 

4,300 

io;ioo (300) 

9,800 

3,800 

2,300 

1,100 

400 

5,000 

8,700 

2i;300 

(2,600) 

1S,700 

12,900 

3,900 

3,600 

800 

10,400 

17.400 

49!000 

(10,000) 

39,000 

Double 

packed-bed 

900 

1,900 

700 

300 

3,200 

4.700 

11,700 

(300) 

11,400 

7,000 

2,800 

1,600 

800 

6,100 

10,100 

28,400 

(2,600) 

25;AOO 

24,100 

5,200 

5,500 

1,500 

13,300 

20,300 

69,900 

(10,000) 

59[$00 

Annualized costs for mist eliminators are from Tables 8 and 9, and annualized costs for 

bscrubbers are from Tables 10 and 11. 

Small model plant costs for each control device type are from Column B, in Tables 8 through 

Utility costs for mist eliminators were rounded to zero if utility cos+s were less than or 

.equal to $50 per year. 

21 ncludes operator, supervisor, and maintenance labor. 

Packing replacement costs include the cost associated with purchasing new packing material 

fand transportation and disposal of the old material. 

l.lncludes overhead, property tax, insurance, and administration. 

^Chromic acid recovery credit for the mist eliminator with a single set of blades is based on 

a control efficiency of 90 percent. Chromic acid recovery credit for the mist eliminator 

with double sets of blades is based on a control efficiency of 95 percent. Chromic acid 

recovery credit for the packed-bed scrubbers is based on a control efficiency of 

h99 percent. Parentheses indicate negative values. Rounded to nearest $100. 

Numbers may not add exactly due to independent rounding. Cost data were rounded to nearest 

; $100. 

Medium model plant costs for each control device type are from Column D. in Tables 8 througn 

rlt. ' 

JLarge model plant costs for each control device type are two times the annualized costs from 

Column D_ in Tables 8 through 11. 

j- f 
29 

TABLE 16. ANNUALIZED COSTS OF MIST ELIMINATORS AND PACKED-BED SCRUBBERS 

FOR DECORATIVE CHROMIUM ELECTROPLATING MODEL PLANTSa 

(November 1988 Dollars) 

Sma11° 

Utilities 

Operator and maintenance 

laborc 

Maintenance materials 

Packing replacement 

Indirect costse 

Capital recovery 

Annualized cost, $ , 

Chromic acid recovery 

Net annualized cost, $3 

Med i um 

Utilities 

Operator and maintenance 

laborc 

Maintenance materials 

Packing replacement*-

Indirect costse 

Capital recovery 

Annualized cost, $ 

Chromic acid recovery 

Net annualized cost, $9 

Large' 

Utilities 

Operator and maintenance 

1aborc 

Maintenance materials 

Packing replacement 

Indirect costse 

Capital recovery 

Annualized cost, $ 

Chromic acid recovery 

Net annualized cost, $y 

Chevron-blade 

mist e 

Single 

set of 

blades 

0 

800 

200 

— 

1,500 

2,600 

5.100 

(0) 

5,100 

0 

1,400 

900 

— 

3,200 

5,300 

10,800 

(100) 

10,700 

2,600 

2,100 

2,100 

— 

5,500 

8,800 

21,100 

(1,400) 

19,700 

iminator 

Double 

set of 

blades 

400 

800 

200 

— 

1,600 

2,800 

5;aoo 

(0) 

5,800 

1,400 

1,400 

900 

— 

3,300 

5,600 

12,600 

(100) 

12,500 

5,200 

2,100 

2,100 

— 

5,700 -

9,300 

24,400 

(1,400) 

23 000 

Scrubber 

Single 

packed-bed 

600 

1,700 

500 

200 

2,800 

4,300 

10,100 

(0) 

10,100 

2,600 

2,800 

1,800 

300 

5,700 

8,600 

2I;BOO 

(200) 

21,600 

8,500 

4,100 

4,100 

600 

10,000 

14,600 

41,900 

(1,500) 

40,400 

Double 

packed-bed 

900 

1,900 

700 

300 

3,200 

4,700 

ii;700 

(0) 

11,700 

3,700 

3,400 

2,800 

600 

6,900 

9,400 

26[800 

(200) 

26,600 

15,100 

5,200 

6,200 

1,100 

12,400 

16.200 

56[200 

(1,500) 

54[700 

Annualized costs for mist eliminators are from Tables 8 and 9, and annualized costs for 

scrubbers are from Tables 10 and 11. 

Small model plant costs are from Column B. in Tables 8 through 11. 

^Includes operator, supervisor, and maintenance labor. 

Packing replacement costs include the cost associated with purchasing new packing material 

and transportation and disposal of the old material. 

?Includes overhead, property tax, insurance, and administration. 

Chromic acid recovery credit for single-blade chevron-blade mist eliminators is based on a 

control efficiency of 90 percent. Chromic acid recovery credit for double-blade chevronblade mist eliminators is based on a control efficiency of 95 percent. Chromic acid 

recovery credit for packed-bed scrubbers is based on a control efficiency of 97 percent. 

Parentheses indicate negative values. Rounded to nearest $100. 

^Numbers may not add exactly due to independent rounding. Cost were rounded to nearest 

$100. 

Medium model plant costs are two times the costs presented in Column B, in Tables 8 through 

.11. 

'Large model plant costs are two times the costs in Column C plus the costs in Column A in 

Tables 8 through 11. 

<*f 
P.31 

30 

TABLE 17. ANNUALIZED COSTS OF MIST ELIMINATORS AND PACKED 

SCRUBBERS FOR CHROMIC ACID ANODIZING MODEL PLANTS3 

(November 

Model plant size 

Small5 

Utilities0 

Operator and maintenance 

labord 

Maintenance materials 

Packing replacement6 

Indirect costs 

Capital recovery 

Annualized cost, $ 

Chromic acid recovery^ 

Net.annualized cost, $h 

Large1 

Utilities0 

Operator and maintenance 

labor0 

Maintenance materials 

Packing replacement6 

Indirect costs 

Capital recovery 

Annualized cost, $ 

Chromic acid recovery^ 

Net annualized cost, $ 

Annualized costs for mist 

1988 Dollars 

Chevron-blade 

mist ( 

Single 

set of 

blades 

0 

800 

200 

— 

1,500 

2,600 

5,100 

(0) 

5,100 

0 

1,400 

800 

— 

3,300 

5,700 

11,200 

(200) 

11,000 

eliminator 

Double 

set of 

blades 

400 

800 

200 

— 

1,600 

2,800 

5,800 

(0) 

5,800 

2,100 

1,400 

800 

— 

3,400 

5,900 

13,600 

(200) 

13,400 

) 

-BED 

Scrubber 

Single 

packed-bed 

600 

1,700 

500 

200 

2,800 

4,300 

10,100 

(0) 

10,100 

5,000 

3,100 

1,900 

400 

6,200 

9,200 

25,800 

(300) 

25,500 

Double 

packed-bed 

900 

1,900 

700 

300 

3,200 

4,700 

11,700 

(0). 

11,700 

10,500 

4,000 

2,800 

900 

7,600 

10,500 

36,300 

(300) 

36,000 

eliminators are from Tables 8 and 9 and 

hannualized costs for scrubbers are 

Small model plant costs for each cc 

presented in Tables 8 through 11. 

cUtility costs for mist eliminators 

.were less than or equal to $50 per 

plncludes operator, supervisor, and 

ePacking replacement costs 

fpacking material and trans 

^Includes overhead, propert 

from Tables 

>ntrol device 

were rounded 

year. 

maintenance 

10 and 11. 

type are from Column Bi 

to zero if util 

labor. 

ity costs 

include the cost associated with purchasing new 

portation and disposal of old materia 

y tax, insurance, and 

"Chromic acid recovery credit for chevron-blade 

single and double sets of 

and 95 percent, respective 

bed scrubbers is based on 

hParentheses indicate negat 

administration. 

mist eliminators 

1. 

with 

blades are based on control efficiencies of 90 

ly. Chromic acid recovery credit for 

a control efficiency 

ive values. Rounded 

Numbers may not add exactly due to 

pounded to nearest $100. 

independent 

Large model plant costs for each control device 

Tables 8 through 11. 

of 97 percent. 

to nearest $100. 

packedrounding. Cost data were 

type are from Column E in 

3o 
• • * 

IV. 

1. 

2. 

3. 

4. 

5. 

6. 

7. 

8. 

9. 

10. 

11. 

12. 

31 

References 

Cost Enclosure for Control Equipment Vendors: Vendor A. Prepared 

for U. S. Environmental Protection Agency, Research Triangle Park, 

North Carolina. December 31, 1986. p. 1-2. 

Cost Enclosure for Control Equipment Vendors: Vendor B. Prepared 

for U. S. Environmental Protection Agency, Research Triangle Park, 

North Carolina. February 18, 1987. 

Cost Enclosure for Control Equipment: Vendor C. Prepared for U. S. 

Environmental Protection Agency, Research Triangle Park, North 

Carolina. August 25, 1987. 

Chemical Engineering. McGraw-Hill Company, Volume 96, Number 2, 

February 1989, p. 208. 

EAB Control Cost Manual (Third Edition), U. S. Environmental 

Protection Agency, Research Triangle Park, North Carolina. 

Publication No. EPA 450/5-87-001A. February 1987. 

Monthly Energy Review. Energy Information Administration. 

Department of Energy. Washington, D.C. October 1988. 

Telecon. Caldwell, M. J., MRI, with Kraft, G., American Water Works 

Association. March 13, 1989. Information concerning nationwide 

residential and commercial water rates for January 1989. 

Telecon. Barker, R., MRI, to Vendor A. March 30, 1989. Information 

concerning scrubber packing life expectancy and replacement cost. 

Telecon. Caldwell, M. J., MRI, with Glovenor, S., Chemical Waste 

Management. April 13, 1989. Information on disposal and 

transportation costs for hexavalent chromium solid waste. 

Supplement to Employment and Earnings, Bureau of Labor Statistics. 

August 1988. p. 55. 

Monthly Labor Review, Bureau of Labor Statistics, Volume 112, 

Number 1. January 1989. 

Telecon. Barker, R., MRI, to Jones, R., Ashland Chemical Corp., 

Raleigh, North Carolina. June 1, 1989. Information concerning 

industrial grade chromic acid costs. 

•a/