Estimated Costs For Potential Fugitive Particulate Control Modifications 

at Eramet Marietta Inc. (as of 11/22/2013) 

The costs estimates below represent the current estimates of the costs to implement and 

operate additional fugitive particulate controls at the Eramet Marietta Inc. facility. These 

estimates are necessarily general due to the fact that control strategies are conceptual and no 

detailed design work has been conducted. Although a 30% contingency has been incorporated in 

the estimates due to the status of the design, no contingency to account for anticipated start-up 

and shakedown costs has been included and EMI therefore believes the actual costs of 

implementing the described controls are likely to be higher. 

Furnace 1: 

 Tapping Hood – Modify hood to increase capture efficiency, vented to existing tapping 

baghouse. 

 Casting Hood – Install capture system (hood) for casting operations, vented to existing 

tapping baghouse. 

 Roof Ventilation – Partition roof canopy (above crane rails) to contain fugitive emissions, 

vented through roof monitors to existing furnace baghouse via ducts. 

1) Furnace 1: Tapping Fan Upgrade 

a. Equipment/materials costs 

i. Ductwork, ID Fan, Dampers, Actuators, Electrical $ 228,000 

ii. Instrumentation 11,000 

iii. Taxes 12,000 

iv. Freight 13,000 

b. Installation cost (inc. labor) 26,000 

c. Engineering & design costs 53,000

 Subtotal $ 343,000 

2) Furnace 1: Casting Hood 

a. Equipment/materials costs 

i. Hood, Ductwork, Dampers, Actuators, Electrical $ 432,000 

ii. Instrumentation 22,000 

iii. Taxes 26,000 

iv. Freight 22,000 

b. Installation cost (inc. labor) 130,000 
‐ 2 ‐ 

c. Engineering & design costs 100,000

Subtotal $ 732,000 

3) Furnace 1: Roof Ventilation 

a. Equipment/materials costs 

i. Ductwork, Hood, Dampers, Structural Steel, Electrical $ 1,093,000 

ii. Instrumentation 109,000 

iii. Taxes 66,000 

iv. Freight 55,000 

 

b. Installation cost (inc. labor) 1,335,000 

c. Engineering & design costs 423,000

Subtotal $ 3,081,000 

 Furnace 1 Total Equipment, Installation, Engineering $ 4,156,0001

 Furnace 1 Retrofit Costs (Downtime) CBI2

 Furnace 1 Annualized Capital Cost Recovery3 $ 392,297 

 Furnace 1 Annual O&M Costs $ 461,211 

 Furnace 1 Annualized Costs (Capital plus O&M) $ 853,508

 

                                                           

1

 Estimate does not include an additional contingency that would be appropriate to account for 

expected start-up and shakedown costs associated with integration of new abatement equipment. 

2

 Downtime costs based on estimated lost sales, which involves confidential business 

information (CBI). These costs are provided under separate cover and should be treated as CBI. 

3

 Calculated in 2012 dollars for 20-year useful life at 7% interest rate in accordance with 

methodology provided in “Engineering Review of Proposed Ferroalloy NESHAP Requirements 

for Eramet Marietta Inc.” (ENVIRON International Corp. 2012), included as Appendix B to 

EMI’s January 31, 2012 comments on proposed NESHAP. The estimated annualized capital 

cost presented does not include any portion of estimated retrofit costs attributable to furnace 

downtime. 
‐ 3 ‐ 

Furnace 12: 

 Tapping Hood – Modify hood to increase capture efficiency, vented to existing scrubber. 

 Roof Ventilation – Partition roof canopy (above crane rails) to contain fugitive emissions, 

vented through roof monitors to existing scrubber via ducts. 

 Upgrades to existing scrubber OR installation of secondary dust collector 

1) Furnace 12: Roof Ventilation/Tap System Capture 

a. Equipment/materials costs 

i. Ductwork, Hood, Dampers, Structural Steel, Electrical $ 1,385,000 

ii. Scrubber Upgrades OR Dust Collector 7,318,000 

iii. Instrumentation 261,000 

iv. Taxes 522,000 

v. Freight 435,000 

 

b. Installation cost 4,956,000 

c. Engineering & design costs 2,183,000

Furnace 12 Total Equipment, Installation, Engineering $ 17,060,0004

 Furnace 12 Retrofit Costs (Downtime) CBI5

 Furnace 12 Annualized Capital Cost Recovery6 $ 1,474,377 

 Furnace 12 Annual O&M Costs $ 2,178,599 

 Furnace 12 Annualized Costs (Capital plus O&M) $ 3,652,975

 

                                                           

4

 Estimate does not include an additional contingency that would be appropriate to account for 

expected start-up and shakedown costs associated with integration of new abatement equipment. 

5

 Downtime costs based on estimated lost sales, which involves confidential business 

information (CBI). These costs are provided under separate cover and should be treated as CBI. 

6

 Calculated in 2012 dollars for 20-year useful life at 7% interest rate in accordance with 

methodology provided in “Engineering Review of Proposed Ferroalloy NESHAP Requirements 

for Eramet Marietta Inc.” (ENVIRON International Corp. 2012), included as Appendix B to 

EMI’s January 31, 2012 comments on proposed NESHAP. The estimated annualized capital 

cost presented does not include any portion of estimated retrofit costs attributable to furnace 

downtime. 
‐ 4 ‐ 

MOR: 

 Casting Hood – Modify hood to increase capture efficiency, vented to existing MOR 

baghouse. 

 Roof Ventilation – Partition roof canopy (above crane rails) to contain fugitive emissions, 

vented through roof monitors to existing MOR baghouse via ducts. 

1) MOR: Roof Ventilation/Casting Hood 

a. Equipment/materials costs 

i. Roof Modification/Repair $ 650,000 

ii. Ductwork, Hood, Dampers, Structural Steel, Electrical 801,000 

iii. Instrumentation 145,000 

iv. Taxes 87,000 

v. Freight 73,000 

b. Installation cost (inc. labor) 1,613,000 

c. Engineering & design costs 562,000

MOR Total Equipment, Installation, Engineering $ 3,931,0007

 MOR Retrofit Costs (Downtime) CBI8

 MOR Annualized Capital Cost Recovery9 $ 371,059 

 MOR Annual O&M Costs $ 329,586 

 MOR Annualized Costs (Capital plus O&M) $ 700,644

                                                           

7

 Estimate does not include an additional contingency that would be appropriate to account for 

expected start-up and shakedown costs associated with integration of new abatement equipment. 

8

 Downtime costs based on estimated lost sales, which involves confidential business 

information (CBI). These costs are provided under separate cover and should be treated as CBI. 

9

 Calculated in 2012 dollars for 20-year useful life at 7% interest rate in accordance with 

methodology provided in “Engineering Review of Proposed Ferroalloy NESHAP Requirements 

for Eramet Marietta Inc.” (ENVIRON International Corp. 2012), included as Appendix B to 

EMI’s January 31, 2012 comments on proposed NESHAP. The estimated annualized capital 

cost presented does not include any portion of estimated retrofit costs attributable to furnace 

downtime.