# TECHNICAL MEMORANDUM

TO: Jodi Howard, US EPA/OAQPS/SPPD/RCG

FROM: Eastern Research Group, Inc.

DATE: February 8, 2012

SUBJECT: Revised Beyond-the-Floor Analysis for the Polyvinyl Chlorid e and

Copolymers (PVC) Production Source Category

1.0 Introduction

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

Act (CAA), is required to establish emissions standards f or Hazardous Air Pollutants (NESHAP)

emitted from polyvinyl chloride and copolymers (PVC) producti on facilities. The complete set of

HAP is listed under CAA section 112(b). To do so, EPA must first determine the minimum

stringency “floor” requirements. A separate memorandum documents the revised maximum

achievable control technology (MACT) floor analysis for existing and new PVC units. 1



# EPA must also examine more stringent “beyond-the-floor” (BTF) regulatory options to

determine MACT. Unlike the minimum stringency requirements of the floor, EPA must consider

various impacts of the more stringent regulatory options such as costs and emissions reductions

in determining whether MACT standards are to reflect BTF requirements. This memorandum

describes the revised cost and emissions reductions for PVC units achieved by applying BTF

regulatory options.

Sections 2.0 and 3.0 discuss the selection of more stringe nt controls or emissions levels

than the floor level reviewed for this analysis for exi sting and new sources, respectively. Section

4.0 discusses the methodology used to estimate costs and emi ssions reductions of the more

stringent controls and Section 5.0 summarizes the result s of the BTF analysis.

2.0 Identification of More Stringent Controls for Existing S ources

The MACT floor analysis for existing sources results i n emissions levels that each

existing PVC unit is required to meet. As documented in a sepa rate memorandum 2 

# , the emissions

reductions and costs of the MACT floor level of control were estimated using the following

assumptions:

1. For each process vent subcategory, units that needed to mee t the MACT floors for

emissions of vinyl chloride (VC), hydrogen chloride (HCl), t otal organic HAP, and

chlorinated dibenzodioxins and chlorinate dibenzofurans (CDD/CDF) from process

vents would add a (an additional) refrigerated condenser;

1

# 2. For each resin subcategory, units that needed to meet the MACT floors for residual

VC and total non-vinyl chloride organic HAP (total non-VC or ganic HAP) in resin

would install a new resin stripper;

3. All units currently meet the MACT floor for equipment l eaks;

4. Units that need to meet the MACT floor for heat excha nge systems would implement

a leak detection and repair (LDAR) program with a leak act ion level of 50 parts per

billion (ppb) of VC;

5. All units currently meet the MACT floor for storage v essels;

6. All units currently meet the MACT floor for wastewate r; and

7. All units currently meet the MACT floor for other emis sion sources.

BTF options were evaluated and analyzed for each of the e mission sources listed above

from existing sources.

2.1 Process Vents

The control technologies that would be needed to achieve the MACT floor levels for

process vents (i.e., enhanced VC recovery) are generally the most effective controls available for

reducing VC, HCl, total organic HAP, and CDD/CDF. The incr emental costs and emission

reductions of all facilities meeting the new source MAC T floors were determined.

2.2 Resins

For stripped resins, it was determined that additional emiss ion reductions could be

achieved by routing vent streams from process components do wnstream of the stripper (e.g., the

PVC dryer vent(s)) to a thermal oxidizer (TO). The TO would theoretically achieve at least a

98 percent reduction of the residual HAP left in the resin (after the MACT floor levels have been

met by stripping the resin) that is emitted in the dryer vent stream(s). The incremental emissions

reductions and costs for installing a TO to control emiss ions from the PVC dryer vent(s) were

determined.

2.3 Equipment Leaks

For equipment leaks, the MACT floor level of control is the LDAR program in 40 CFR

part 61 subpart V. A BTF option equivalent to the hazardous organic national emission standards

for hazardous air pollutants (HON), which is considered the most effective control of emissions

from equipment leaks, was analyzed.

2.4 Heat Exchange Systems

As described in a separate memorandum 1 

# , the MACT floor analysis for heat exchange

systems was revised since proposal. Based on those revisi ons, the existing source MACT floor

level of control is an LDAR program with two differen t leak action levels for VOC and for vinyl

chloride, depending on which monitoring option a facility el ects to use. The MACT floor leak

action levels for existing sources and new sources were e valuated independently, but the

resulting action levels are the same. Furthermore, th e monitoring frequencies are the same. A

heat exchange system LDAR program is the most effecti ve control available for reducing leaks

2

# from heat exchange systems. A BTF option of having exist ing sources meet a more stringent leak

action level, such as a new source action level that may have been more stringent than the

existing source action level, could not be analyzed as th e leak action levels are the same (50

ppbw in the cooling water). EPA did not receive any commen ts on, or identify, any other control

options more stringent than the MACT floor to reduce HAP from heat exchange systems at PVC

production facilities. Furthermore, we assumed that all facilities would monitor for vinyl chloride

using Method 107, as they already do it in-house for resin and wastewater. We reviewed the

resin and wastewater data for Method 107 and it looks like the lowest that method can detect is

50 ppb. On that basis, it is not technically feasible t o perform vinyl chloride monitoring with

Method 107 at anything lower than 50 ppb.

2.5 Storage Vessels

As described in the MACT floor analysis 1 

# , 2 types of storage vessels were identified;

storage vessels storing material that are gasses at am bient conditions (vapor pressures greater

than 14.7 pounds per square inch, absolute (psia)) and storage v essels storing all other materials.

Information provided in the August 21, 2009 section 114 showed that m aterials with vapor

pressures greater than 14.7 psia are stored in pressure vesse ls. All other materials at all facilities

are stored in fixed roof tanks ranging in size from less than 5,000 gallons up to 30,000 gallons.

The following is a description of the BTF options analy zed for each type of storage vessel:

• Pressure vessels: The results of the MACT floor analy sis 1 

# showed that materials

with vapor pressures greater than 14.7 pounds per square inch a bsolute (psia) are

stored under pressure (i.e., pressure vessels); a closed v ent system that is routed to

a control device is used when filling or emptying the vessel s. Based information

provided in the August 21, 2009 section 114, no additional work prac tices or

control measures were identified that would be more effe ctive at reducing HAP

emissions from pressure vessels than those in the MACT floor; therefore no BTF

options for pressure vessels were analyzed.

• Fixed roof storage vessels: Several storage tanks with capa cities greater than

20,000 gallons (gal) were identified that have the potential t o emit several tons of

HAP per year depending on the vapor pressure of the materia l stored and the

number of turnovers. A BTF option of requiring floating r oof tanks meeting the

requirements of 40 CFR part 63 subpart WW for storage vessel s meeting the

specific vapor pressure and storage capacity parameters of 40 CFR part 60,

subpart Kb was analyzed. Based information provided in the August 21, 2009

section 114, no additional work practices or control measures were identified that

would be more effective at reducing HAP emissions from fi xed roof storage

vessels less than 20,000 gal in size than those in the MA CT floor; therefore no

BTF options were analyzed for fixed roof storage vessels less than 20,000 gal in

size.

2.6 Wastewater

For wastewater, a BTF option of routing all process w astewater, regardless of HAP

concentration, to a wastewater stripper was analyzed.

3

# As discussed in a separate memorandum, facilities indica ted a variety of work practices

to minimize emissions from maintenance wastewater inc luding collection on concrete secondary

containment pads, collection in trenches and pits, and r outing maintenance wastewater through

the facility clarification system. However, maintena nce wastewater activities result in generation

of wastewater in such a manner that it cannot be col lected, enclosed, and routed to a wastewater

treatment system or otherwise managed in a controlled or enclosed system as process wastewater

can.

Maintenance wastewater streams can vary considerably in HAP concentration.

Additionally, sufficient information was not available from industry regarding work practices to

manage and control fugitive emissions from maintenance wa stewater streams to prescribe or

enforce an emissions standard for maintenance wastewate r. The maintenance wastewater work

practices described by industry are generally equivalent to th e compliance requirements of 40

CFR 63.105 of subpart F; therefore, the MACT floor for ma intenance wastewater at PVC

production facilities consists of the requirements of 40 C FR 63.105 of subpart F. Based on

available information, no additional work practices or co ntrol measures beyond-the-floor were

identified.

2.7 Other Emissions Sources

For other emission sources, an additional work practice used to minimize emissions from

PVC facilities was identified. The work practice cons ists of installing floating objects in the

gasholder water seal to limit fugitive emissions.

3.0 Selection of More Stringent Controls for New Sources

Except for emissions from storage vessels, equipment le aks and other emission sources,

no technologies or methods were identified to achieve em ission limits that would be more

stringent than the MACT floor limits or work practices for new units based on the best

performing PVC facilities. The control technologies and work practices necessary to achieve the

MACT floor levels are generally the most effective con trols available.

Requiring floating roof tanks or fixed roof tanks routed to a clo sed vent system and

control device for storage vessels that (1) have a stor age capacity equal to or greater than

40,000 gal and store material with maximum true vapor pressures greater or equal to 0.75 pounds

per square inch absolute (psia) or (2) have a storage capaci ty equal to or greater than 20,000 gal

and less than 40,000 gal and store material with maximum true vapor pressures greater or equal

to 4 psia appears to be cost-effective ($2,000 to $12,000 per ton of HAP).

Requiring the LDAR program specified in 40 CFR part 63, subpart UU appears to be

cost-effective ($2,800 per ton of HAP).

Requiring floating objects covering the gasholder water sea l appears to be cost-effective

($1,000 per ton of HAP).

4

# 4.0 Methodology Used to Estimate Costs and Emission Reductions

The methodology used to calculate costs and emissions re ductions from applying the

more stringent controls followed the same procedures as those discussed in the memorandum

titled “Revised Cost and Emissions Reductions for Major S ources in the Polyvinyl Chloride and

Copolymers (PVC) Production Source Category 2 

# .”

4.1 Process Vents

The procedure used to asses MACT floor costs and emission r eductions (described in a

separate memorandum 2 

# ) was used to asses BTF costs and emission reductions for process vents

in each subcategory, except that instead of meeting the existing source MACT floor, refrigerated

condensers were sized such that all facilities could meet the new source MACT floor for the

appropriate process vent subcategory. This analysis can b e found in Attachment A.

4.2 Resins

Emissions reductions from application of the BTF contro ls relative to the MACT floor

limits were calculated for facilities in each resin s ubcategory using the following procedure.

First, the reduction efficiency of the BTF control fo r VC was applied to the uncontrolled

concentration of VC estimated in the stripped resin exiti ng the resin stripping operation to

determine the total reduction the control would achieve for facilities in each resin subcategory. It

was assumed that all VC remaining in the resin after bei ng stripped would be removed by the

drying operation and exit the process through the dryer vent( s). The reduction in VC

concentration from current actual concentration level s to the MACT floor limits was previously

calculated for the MACT floor cost and emissions reduct ion analysis 2 

# for each resin subcategory.

For VC and total organic HAP, the incremental reduction be tween the more stringent BTF

control and the MACT floor was calculated by subtractin g the MACT floor emissions reductions

from the reductions achieved by the more stringent control for all facilities in each resin

subcategory.

The EPA Air Compliance Advisor (ACA) 3 

# program was used to estimate the cost of a

regenerative thermal oxidizer (RTO) for each facility . The main inputs to the program are:

• Dryer exhaust total organic HAP flow rate (mass);

• Dryer exhaust volumetric flow rate; and

• Dryer exhaust temperature and moisture content.

The above inputs were calculated as follows:

• Pounds per hour of total organic HAP at MACT floor emission levels were

used as the initial pollutant input to the program. To yield a conservative

fuel cost estimate, it was assumed that all total orga nic HAP was comprised

of VC; therefore combustion properties of VC were assi gned to total organic

HAP.

5

# • Dryer exhaust flow rates were calculated first by dete rmining a flow rate

factor calculated from an average value of dryer flow r ate divided by annual

resin production. Dryer exhaust flow rates and non-confide ntial resin

production rates were extracted from facility submitted survey information 4



# . This average was then multiplied by 2006 facility capacity i nformation to

obtain a theoretical maximum flow rate for each faci lity. In instances where

facilities 2008 production was greater than the 2006 capacity, t he 2008 nonconfidential production information was used.

• Waste stream temperature and moisture content was calcu lated as an

average of the data provided by OxyVinyls - Pedricktown. OxyVin yls –

Pedricktown was the only facility for which industry provided supplemental

dryer exhaust testing information.

An RTO cost scenario was completed for each facility . Costs were calculated in 2008 and

2010 dollars (based on Chemical Engineering general cost inde x). This analysis can be found in

Attachment B.

4.3 Equipment Leaks

The BTF option for equipment leaks consists of a mor e stringent LDAR program. The

cost of all facilities complying with the National Emi ssions Standards for Equipment Leaks –

Control Level 2, subpart UU of 40 CFR part 63 was estimate d using costs previously developed

and documented in the memorandum “Analysis of Emissions Reduction Techniques for

Equipment Leaks 5 

# .” In the memorandum, RTI International developed model c hemical facilities

and costs for complying with various equipment leak option s. A medium complexity chemical

facility was used to model major source PVC facilities. Option 1 for valves, pumps, and

connectors were determined to be equivalent with subpart UU of 40 CFR part 63. Equipment

leak emissions of VOC, which for this analysis were c onsidered analogous to total organic HAP,

were estimated using previously developed emissions factor s, equipment counts, and the control

effectiveness of LDAR programs used by each facility. A description of emission factors and

equipment counts can be found in a separate memorandum 5 

# . Emission factors were developed

using facility data from the Miscellaneous Organic NESHAP MACT floor development and the

EPA Office of Air Quality and Planning Standards Protocol fo r Equipment Leak Emission

Estimates 6 

# . This analysis can be found in Attachment C.

4.4 Storage Vessels

The vapor pressure and storage capacity parameters for the BTF option are those from 40

CFR part 60 subpart Kb: (1) the material stored has a maximu m true vapor pressure greater or

equal to 0.75 psia (5.2 kilopascal (kPa)) and the storage vessel has a capacity equal to or greater

than 40,000 gal (151 cubic meters), or (2) the material stored has a maximum true vapor pressure

greater or equal to 4 psia (27.7 kPa) and the storage vesse l has a capacity equal to or greater than

20,000 gal (75.5 cubic meters) but less than 40,000 gal (151 cubic meters) . Data supplied by

industry via EPA’s section 114 survey were analyzed to identif y storage vessels meeting the

aforementioned criteria. However; no storage vessels meeting the subpart Kb criteria were

6

# identified. Although a test method such as ASTM D2879-10 or API Publication 2517 would be

used to determine vapor pressure, it was assumed that facil ities currently incur a cost to

determine vapor pressure, therefore, no additional cost was estimated. As a theoretical case, the

emission reduction and cost of retrofitting a fixed roof t ank with an internal floating roof was

calculated for a 40,000 gal tank storing methanol using EPA cost estimation equations 7 

# . This

analysis can be found in Attachment D.

4.5 Wastewater

To asses BTF costs for wastewater, data supplied by industr y via EPA’s section 114

survey were analyzed to identify wastewater streams th at are currently not controlled by a

stripping operation. The cost of installing hard piping and pu mping equipment to collect and

convey the water to the wastewater stripper was estima ted using “Plant Design and Economics

for Chemical Engineers 8 

# .” The cost of installing and operating a sufficiently si zed wastewater

stripper was also estimated for each facility using capi tal cost estimates supplied by industry

regarding resin strippers. Only the incremental annual costs such as capital recovery, increased

steam, and electrical usage were included in the annual cos t estimate. The wastewater analysis

can be found in Attachment E.

4.6 Other Emission Sources

The assessment for BTF costs for other emission sourc es was based on data submitted by

industry regarding gasholders and appropriate work practices. Indus try supplied estimates for

emissions from gasholder water seals and the capital c ost of installing floating objects on the

water seal. Annual costs of maintaining the floating objec ts were estimated using factors from

“Plant Design and Economics for Chemical Engineers 8 

# .” This analysis can be found in

Attachment F.

5.0 Results

5.1 Process Vents

Applying BTF control to further reduce emissions from PVC- only process vents would

result in a total capital investment (TCI) of approximate ly $6.9 million (2010$), an additional

total annualized cost (TAC) of $3.1 million (2010$), and would achi eve additional VC, HCl,

CDD/CDF and total organic HAP reductions of 2.0E-02, 2.2, 8.9E- 011 and 2.8E-01 tons per

year respectively beyond the MACT floor level of contr ol. The incremental cost-effectiveness

was estimated to be $11.2 million per ton of total organic H AP reduced.

Applying BTF control to further reduce emissions from PVC- combined process vents

would result in a total capital investment (TCI) of approxi mately $3.6 million (2010$), an

additional total annualized cost (TAC) of $1.5 million (2010$), and would achieve additional

VC, HCl, CDD/CDF and total organic HAP reductions of 1.2E-01, 76, 2.4E-8 and 1.3 tons per

year respectively beyond the MACT floor level of contr ol. The incremental cost-effectiveness

was estimated to be $1.2 million per ton of total organic HAP reduced.

7

# 5.2 Resins

Applying BTF control to further reduce emissions from resi ns would result in a TCI

(2010$) of approximately $332 million, $6.4 million, $803,000 and $2.6 milli on for suspension,

dispersion, suspension blending and copolymer resins respecti vely. Applying BTF control to

further reduce emissions from resins would result in an additional total annualized cost (TAC)

(2010$) of $128 million, $2.5 million, $388,000 and $1.0 million for suspens ion, dispersion,

suspension blending and copolymer resins respectively. BTF co ntrol would achieve additional

VC reductions of 47, 20, 1.6 and 16 tons per year for suspension, dispersion, suspension

blending and copolymer resins respectively. BTF control wo uld achieve additional total organic

HAP (including VC) reductions of 674, 19, 1.4 and 16 tons per year for suspension, dispersion,

suspension blending and copolymer resins respectively. The in cremental cost-effectiveness was

estimated to be $190,000, $132,000, 283,000 and $64,800 per ton of total organic H AP reduced

(including VC) for suspension, dispersion, suspension blending and copolymer resins

respectively. Bulk resin was not analyzed since there ar e currently no major sources that produce

bulk resin.

5.3 Equipment Leaks

Applying a BTF LDAR program for equipment leaks using the previ ously mentioned

options results in an industry wide TCI of $1.0 million an d a TAC of $238,000 per year for

facilities currently complying with 40 CFR part 61, subpart V to comply with 40 CFR part 63,

subpart UU. The BTF LDAR program would achieve an additio nal 85 tons per year of total

organic HAP reduction for a cost effectiveness of $2,800 doll ars per ton of total organic HAP.

5.3 Storage Vessels

The results of the BTF analysis for storage vessels sh ow that cost effectiveness ranged

from $2,000 to $12,000 per ton of HAP reduced by this option, depending o n the number of

turnovers assumed. Based on information submitted by PVC a nd copolymer production

facilities, no storage vessels from affected sources t hat meet the capacity levels (20,000 gallons

or 40,000 gallons) and store material that meet the vapor pre ssure levels of subpart Kb were

identified. Therefore, no additional costs and emission r eductions were estimated for this option.

5.4 Wastewater

Based on the analysis, applying BTF control to further re duce emissions from wastewater

would result in a TCI $98.2 million and a TAC of $616 million and would achieve additional VC

and total organic HAP (including VC) reductions of 1.4 tons per y ear and 1.4 tons per year

respectively beyond the MACT floor level of control. T he incremental cost effectiveness was

estimated to be $440 million per ton of total organic HAP reduc ed (including VC).

5.4 Other Emission Sources

8

# Based on the analysis, applying BTF control to reduce emi ssions from other emission

sources would result in a TCI $75,000 million and a TAC of $22,200 and would achieve

additional VC and total organic HAP 1 

# reductions of 22 tons per year and 22 tons per year

respectively beyond the MACT floor level of control. T he incremental cost effectiveness was

estimated to be $1,000 per ton of total organic HAP reduced (incl uding VC).

6.0 Results

Table 6-1 summarizes the results of the BTF analysis for all emission points for existing

PVC units. All emission reductions, costs, and cost effec tiveness values are incremental above

the MACT floor level of control.

1 

# Available emission estimates only included VC, therefo re, all total organic HAP was assumed to be VC.

9Table 6-1. Summary of Beyond-the-Floor Analysis Results forExisting PVCPUsEmission PointBTF OptionTCI(2010 $)TAC[1](2010 $)Incremental Emissions Reduction (tons/year) CostEffectiveness($/ton, TotalOrganic HAPBasis)VC HCl CDD/CDFTotalOrganicHAPProcessVentsPVC-Only New Source Limits 6,917,351 3,099,295 2.00E-02 2.19 8.90E-011 2.77E-01 11,187,904PVCCombinedNew Source Limits 3,640,439 1,452,660 1.17E-01 75.9 2.42E-08 1.26 1,156,532ResinsSuspensionThermal Oxidizerfor Dryer Vent[2](s)331,837,508 128,233,707 46.9 - - 674 190,397Dispersion 6,382,912 2,474,580 20.2 - - 18.8 131,550SuspensionBlending803,206 387,830 1.64 - - 1.37 283,478Copolymer 2,635,073 1,049,505 15.7 - - 16.2 64,780Equipment Leaks40 CFR Part 63,Subpart UU1,015,610 238,080 - - - 85.0 2,799Heat Exchange Systems None - - - - - - -Storage TanksHON capacity andVP cutoffs- - - - - - -WastewaterTreatment ofuncontrolledstreams98,237,246 615,889,097 1.4 - - 1.4 439,920,783Other Emission SourcesFloating objectsfor gasholders75,000 22,170 22.0 - - 22.0 1,010[1] – Calculated using a 7 percent discount factor.[2] – For facilities that produce more than 1 type of resin, dryer exhaust flow rates were not able to be allocated to the specific type of resin production; therefore, toapportion costs for facilities producing more than 1 type orresin, the total cost for the facility was divided by the number of resins types produced.BTF – Beyond-the-floorTCI – Total capital investment for the BTF optionTAC – Total annual cost for the BTF optionHON – Hazardous organic national emission standards for hazardous air pollutantsVP – Vapor pressureppmw – parts per million by weightppb – parts per billion$/ton – Dollars per tonVC – Vinyl ChlorideHCl – Hydrogen ChlorideCDD/CDF – Chlorinated dibenzodioxins and chlorinated dibenzofuransHAP – Hazardous air pollutant



# 10

# 7.0 References

1. “Revised Maximum Achievable Control Technology (MACT) Flo or Analysis for the

Polyvinyl Chloride and Copolymers (PVC) Production Source Category.” Memorandum

from Eastern Research Group, Inc. to Jodi Howard, U.S. Environmental Protection

Agency. February 2012.

2. “Revised Costs and Emissions Reductions for Major Sources in the Polyvinyl Chloride

and Copolymers (PVC) Production Source Category.” Memoran dum from Eastern

Research Group, Inc. to Jodi Howard, U.S. Environmental P rotection Agency. February

2012.

3. “Air Compliance Advisor.” U.S. EPA. 22 June, 2007. 24 Sept. , 2010.

http://www.epa.gov/ttnecas1/ACA.htm

4. “Revised Baseline Emissions Estimates for Major Sources in the Polyvinyl Chloride and

Copolymers (PVC) Production Source Category.” Memorandum from Eastern Research

Group, Inc. to Jodi Howard, U.S. Environmental Protection Agency. February 2012.

5. “Analysis of Emissions Reductions Techniques for Equipment Leaks.” Memorandum

from Cindy Hancy, RTI International to Jodi Howard, U.S . Environmental Protection

Agency. December 21, 2011.

6. 1995 Protocol for Equipment Leak Emission Estimates. U.S. E nvironmental Protection

Agency. November 1995. EPA-435/R-95-017.

7. US EPA Hazardous Air Pollutant Emissions from Process Units in the Synthetic Organic

Chemical Manufacturing Industry -- Background Information fo r Proposed Standards

Volume 1B: Control Technologies EPA-453/D-92-016b

8. Peters, Timmerhaus, and West. 2003. Plant Design and Economics for Chemical

Engineers . Fifth Edition. McGraw Hill, New York, NY.

11

# Attachments

Attachment A. Beyond-the-Floor Analysis for Process Ve nts

Attachment B. Beyond-the-Floor Analysis for Resins

Attachment C. Beyond-the-Floor Analysis Equipment Leaks

Attachment D. Beyond-the-Floor Analysis for Storage Ve ssels

Attachment E. Beyond-the-Floor Analysis for Wastewate r

Attachment F. Beyond-the-Floor Analysis for Other Emis sion Sources

12

# Attachment A

Beyond-the-Floor Analysis for Process Vents

13ATTACHMENT A: BEYOND THE FLOOR ANALYSIS FOR PROCESSVENTS02/08/2012BTF Reductions, CostsFacility ClassificationOutlet Max Flow Rate(DSCMM)Average O2(%)Avg. Temp(C)Vinyl Chloride(ppmvd @ 3%O2)HCl(ppmvd @ 3%O2)CDD/CDF(ng/dscm @ 3%O2)TotalHAP(ppmvd @ 3%O2)OVPA PVC - Only 1.55E+01 7.46E+00 2.48E+01 9.71E-01 3.60E+02 7.8E-03 1.8E+01CTLC Area Source 3.43E+01 1.69E+01 5.71E+01 5.24E+00 1.04E+02 3.1E-02 73.70SHTFP PVC - Only 1.10E+01 2.43E+00 2.29E+01 5.00E-03 1.20E-01 1.2E-02 2.2E-01FPC DE PVC - Only 1.57E+01 5.37E+00 6.17E+00 2.45E-01 1.21E+02 2.7E-03 2.8E+00GGA PVC - Only 1.07E+01 7.83E+00 2.09E+01 2.00E+00 1.57E+02 4.7E-03 6.9E+00POH PVC - Only 1.13E-01 1.53E+01 -6.37E+00 2.18E+00 5.30E-01 Not Reported 9.7E+03POP PVC - Only 4.36E-02 1.87E+01 -3.63E-01 2.66E+00 1.32E+00 Not Reported 2.5E+04SHTA PVC - Only 1.43E+01 7.59E+00 3.13E+01 2.43E-01 8.47E-02 1.7E-02 1.2E+01FPC BR PVC - Combined 4.10E+02 9.15E+00 4.87E+01 1.28E-01 9.23E+01 7.05E-02 2.02E+00FPC TX PVC - Combined 1.36E+02 9.10E+00 6.42E+01 4.40E-01 9.23E+01 3.10E-01 2.02E+00OVLADP PVC - Combined 1.05E+03 4.07E+00 5.50E+01 1.93E-01 9.23E+01 1.53E-02 2.02E+00GGP PVC - Combined 3.36E+02 1.08E+01 2.01E+01 2.35E-03 1.84E+02 4.69E-02 1.71E+00SHTP PVC - Combined 2.50E+02 6.72E+00 1.23E+02 1.28E-01 9.23E+01 1.95E-02 2.02E+00WLG PVC - Combined 6.50E+02 1.13E+01 2.50E+01 7.31E-04 4.06E-01 2.91E-02 4.02E+00WLCC PVC - Combined 4.10E+02 9.15E+00 4.87E+01 1.28E-01 9.23E+01 7.05E-02 2.02E+00DOWMI PVC - Combined 3.44E+01 1.29E+01 4.16E+00 4.51E-03Not Reported 1.68E-03 3.36E-01Color Code KeyAverage of PVC Combined FacilitiesBased on Average Factor (Inlet FlowRate/Outlet Flow Rate) of PVCCombined FacilitiesEstimated by calculating averageReduction Effy for VC for All PVCfacilties and applying to outletconcentrationAverage of All FacilitiesCalculated using Inlet flow, O2, andVC Concentration estimatesEstimated by calculating averagefactor of TOHAP (TPY)/Outlet FlowRateNew Source LimitsVCPVC - Only 0.56 ppmvd @ 3% O2VCPVC - Combined 0.56 ppmvd @ 3% O2HCl PVC - Only 0.17 ppmvd @ 3% O2HCl PVC - Combined 1.40 ppmvd @ 3% O2CDD/CDF PVC - Only 0.038 ng/dscm @ 3% O2CDD/CDF PVC - Combined 0.034 ng/dscm @ 3% O2TOHAP PVC - Only 5.500 ppmvd @ 3% O2TOHAP PVC - Combined 5.50 ppmvd @ 3% O2Outlet Conditions



# 14ATTACHMENT A: BEYOND THE FLOOR ANALYSIS FOR PROCESSVENTS02/08/2012Inlet Max FlowRate (DSCMM)Average O2(%)Avg. Temp(C)Vinyl Chloride(ppmvd @ 3%O2)CE Redux EffyVinyl Chloride(lbs/hr)VCBaseline(lbs/hr)HClBaseline(lbs/hr)CDD/CDFBaseline(lbs/hr)TOHAPBaseline(lbs/hr)VCBaseline(Tons/Yr)HClBaseline(Tons/Yr)CDD/CDF (TEQ)Baseline (Tons/Yr)TOHAPBaseline(Tons/Yr)1.51E+01 4.94E+00 1.89E+01 1.88E+05 9.999948E+01 8.82E+02 3.92E-03 8.46E-01 1.19E-11 6.72E-02 1.64E-02 3.55E+00 5.00E-11 2.82E-015.65E+00 3.33E-02 6.47E+01 9.59E+04 9.999453E+01 2.20E+02 1.39E-02 1.61E-01 3.14E-11 2.55E-01 5.84E-02 6.77E-01 1.32E-10 1.07E+005.47E-01 6.67E-01 1.56E+01 2.84E+02 9.999824E+01 6.09E-02 1.98E-05 2.77E-04 1.75E-11 8.96E-04 8.32E-05 1.16E-03 7.34E-11 3.76E-035.26E-01 8.15E+00 7.40E-01 6.33E+05 9.999996E+01 8.25E+01 1.16E-03 3.36E-01 4.88E-12 1.19E-02 4.88E-03 1.41E+00 2.05E-11 4.99E-021.12E-01 2.13E+00 1.63E+01 4.85E+05 9.999959E+01 1.98E+01 5.41E-03 2.47E-01 4.86E-12 1.81E-02 2.27E-02 1.04E+00 2.04E-11 7.60E-021.13E-01 6.03E+00 1.65E+01 7.39E+05 9.999971E+01 2.40E+01 2.66E-05 3.79E-06 No Data 2.18E-01 1.12E-04 1.59E-05 NoData 9.14E-019.01E-02 2.64E+00 -3.63E-01 5.08E+05 9.999948E+01 1.62E+01 4.89E-06 1.41E-06 No Data 8.45E-02 2.05E-05 5.94E-06 NoData 3.55E-019.97E+00 2.10E-01 1.89E+01 1.57E-01 -5.510638E+01 6.27E-04 8.98E-04 1.83E-04 2.43E-11 6.23E-02 3.77E-03 7.67E-04 1.02E-10 2.62E-019.08E+00 2.43E+00 1.89E+01 1.28E+04 9.999900E+01 4.16E+01 1.20E-02 5.04E+00 2.51E-09 1.13E-01 5.03E-02 2.11E+01 1.05E-08 4.76E-013.00E+00 2.43E+00 1.89E+01 4.39E+04 9.999900E+01 4.73E+01 1.37E-02 1.67E+00 3.67E-09 3.75E-02 5.74E-02 7.03E+00 1.54E-08 1.57E-012.33E+01 2.43E+00 1.89E+01 1.93E+04 9.999900E+01 1.61E+02 6.64E-02 1.85E+01 2.01E-09 2.91E-01 2.79E-01 7.78E+01 8.42E-09 1.22E+001.42E+00 1.90E+00 1.89E+01 5.18E+05 1.000000E+02 2.71E+02 1.55E-04 7.09E+00 1.18E-09 6.54E-02 6.52E-04 2.98E+01 4.95E-09 2.75E-015.54E+00 2.43E+00 1.89E+01 1.28E+04 9.999900E+01 2.54E+01 8.83E-03 3.71E+00 5.12E-10 6.92E-02 3.71E-02 1.56E+01 2.15E-09 2.90E-012.61E+01 2.97E+00 1.89E+01 1.26E+05 1.000000E+02 1.14E+03 8.82E-05 2.86E-02 1.34E-09 3.86E-01 3.71E-04 1.20E-01 5.62E-09 1.62E+009.08E+00 2.43E+00 1.89E+01 1.28E+04 9.999900E+01 4.16E+01 1.20E-02 5.04E+00 2.51E-09 1.13E-01 5.03E-02 2.11E+01 1.05E-08 4.76E-017.62E-01 2.43E+00 1.89E+01 4.51E+02 9.999900E+01 1.23E-01 2.41E-05 No Data 3.42E-12 1.42E-03 1.01E-04 No Data 1.44E-11 5.98E-03Inlet ConditionsBaseline Emissions Estimates



# 15ATTACHMENT A: BEYOND THE FLOOR ANALYSIS FOR PROCESSVENTS02/08/2012VC -% Redux toMeetConc. LimitHCl- % Redux toMeet Conc. LimitCDD/CDF- %Redux to MeetTOHAP -% Redux toMeet Conc. LimitVC HCl CDD/CDF TOHAP42.3478 99.9527 0.0000 69.1029 78.31770.01290.0000 0.0000 0.0000 0.00000.0000 0.0000 0.0000 0.00000.00000.0000 99.8599 0.0000 0.0000 35.71430.001772.0305 99.8916 0.0000 19.9351 50.24790.011474.2645 67.9527 0.0000 99.943499.4241 0.000178.9700 87.1285 0.0000 99.978299.7775 0.00000.0000 0.0000 0.0000 53.75560.00000.0000 98.4837 51.7481 0.000027.62220.01390.0000 98.4837 89.0393 0.000083.55900.04800.0000 98.4837 0.0000 0.0000 0.0000 0.0000 0.0000 0.00000.0000 99.2402 27.5045 0.00000.00000.0000 98.4837 0.0000 0.00000.00000.0000 0.0000 0.0000 0.00000.00000.0000 98.4837 51.7481 0.000027.62220.01390.0000 0.0000 0.0000 0.00000.0000MACT Floor Reductions (Tons/yr)Percent Reductions Needed to Meet New Source Floors



# 16ATTACHMENT A: BEYOND THE FLOOR ANALYSIS FOR PROCESSVENTS02/08/2012Incremental TotalReductionsVC HCl CDD/CDF TOHAP Tons/yrCondenser TCI($)Condenser AnnualizedCapital Cost ($/yr)Condenser AnnualCosts ($/yr)Condenser TotalAnnualized Costs ($/yr)-7.83E+01 #VALUE! #VALUE! 2.69E-01 #VALUE! 2,454,057$ 231,646$ 1,224,928$ 1,456,573$#VALUE! #VALUE! #VALUE! 0.00E+00 #VALUE! -$ -$ -$ -$-3.57E+01 #VALUE! #VALUE! 4.81E-02 #VALUE! 491,037$ 46,350$ 68,420$ 114,771$-5.02E+01 #VALUE! #VALUE! 6.45E-02 #VALUE! 342,660$ 32,345$ 26,902$ 59,247$#VALUE! #VALUE! 9.94E+01 9.13E-01 #VALUE! 119,705$ 11,299$ 6,250$ 17,549$#VALUE! #VALUE! 9.98E+01 3.55E-01 #VALUE! 75,249$ 7,103$ 3,560$ 10,663$#VALUE! #VALUE! #VALUE! 1.41E-01 #VALUE! 3,434,645$ 324,206$ 1,116,285$ 1,440,492$#VALUE! -6.79E+00 #VALUE! 4.54E-01 -6.34E+00 801,567$ 75,662$ 255,462$ 331,125$#VALUE! -7.66E+01 #VALUE! 1.07E-01 -7.65E+01 345,080$ 32,573$ 65,734$ 98,307$#VALUE! #VALUE! #VALUE! 2.73E-01 #VALUE! 551,480$ 52,056$ 198,985$ 251,041$#VALUE! #VALUE! #VALUE! 2.86E-01 #VALUE! 1,140,745$ 107,678$ 333,385$ 441,063$#VALUE! #VALUE! #VALUE! 0.00E+00 #VALUE! -$ -$ -$ -$#VALUE! -6.79E+00 #VALUE! 4.54E-01 -6.34E+00 801,567$ 75,662$ 255,462$ 331,125$#VALUE! #VALUE! 0.00E+00 0.00E+00 -$ -$ -$ -$Incremental BTF Reductions (Tons/yr)Incremental Equipment Costing



# 17ATTACHMENT A: BEYOND THE FLOOR ANALYSIS FOR PROCESSVENTS02/08/2012Condenser Costing Algorithm, BTFOVPA CTLC SHTFP FPC DE GGA POH POP SHTA FPC BR FPC TX OVLADP GGP SHTP WLG WLCC DOWMI TotalsPVC - Only Area Source PVC - Only PVC - Only PVC - OnlyPVC - Only PVC - Only PVC - OnlyPVC - CombinedPVC - CombinedArea SourcePVC - CombinedPVC - CombinedPVC - CombinedPVC - CombinedPVC - Combined-- Inlet stream flowrate (DSCMM):1.51E+01 5.65E+00 5.47E-01 5.26E-01 1.12E-01 1.13E-01 4.36E-02 9.97E+00 9.08E+00 3.00E+00 2.33E+01 1.42E+00 5.54E+00 2.61E+01 9.08E+00 7.62E-01-- Inlet stream flowrate (scfm): (Qin)=DSCMM/35.31535 200 19 19 4 4 2 352 321 106 823 50 196 921 321 27-- Inlet stream temperature (oC):1.89E+01 6.47E+01 1.56E+01 7.40E-01 1.63E+01 -6.37E+00 -3.63E-01 1.89E+01 1.89E+01 1.89E+01 1.89E+01 1.89E+01 1.89E+01 1.89E+01 1.89E+01 1.89E+01-- Inlet stream temperature (oF): (Tin)=oC*1.8+3266 148 60 33 61 21 31 66 66 66 66 66 66 66 66 66-- VOC to be condensed:Vinyl chloride Vinyl chloride Vinyl chloride Vinyl chloride Vinyl chloride IsoOctance IsoOctance Vinyl chloride Vinyl chloride Vinyl chloride Vinyl chloride Vinyl chloride Vinyl chloride Acetaldehyde Vinyl chloride Vinyl chloride-- VOC inlet volume fraction:(Yvoc,in)=ppm/1E60.18791389 0.095862393 0.000283667 0.633376328 0.484980983 9.72E-03 2.52E-02 1.56667E-07 0.01278717 0.0439149590.0192627 0.518207166 0.012787174 3.35E-06 0.012787174 0.00045057-- Required VOC removal (fraction): (n)0.9995 0.0000 0.0000 0.9986 0.9989 0.999990 0.999990 0.5376 0.9848 0.9848 0.9848 0.9924 0.9848 0.0000 0.9848 0.0000-- Antoine equation constants for VOC: [4]A:6.497 6.497 6.497 6.497 6.497 6.812 6.812 6.497 6.497 6.497 6.497 6.497 6.497 8.006 6.497 6.497B:783.400 783.400 783.400 783.400 783.400 1257.840 1257.840783.400 783.400 783.400 783.400 783.400 783.400 1600.017 783.400 783.400C:230.010 230.010 230.010 230.010 230.010 220.735 220.735 230.010 230.010 230.010 230.010 230.010 230.010 291.809 230.010 230.010-- VOC heat of condensation (BTU/lb-mole): (****Hvoc,r)10080 10080 10080 10080 13260 13260 10080 10080 10080 10080 10080 10080 10080 11094 10080 10080-- VOC heat capacity (BTU/lb-mole-oF): (Cp,voc)11.655 11.655 11.655 11.655 11.655 45.080 45.080 11.655 11.655 11.655 11.655 11.655 11.655 13.100 11.655 11.655-- Coolant specific heat (BTU/lb-oF): Cp,cool0.650 0.650 0.650 0.650 0.650 0.650 0.650 0.650 0.650 0.650 0.650 0.650 0.650 0.650 0.650 0.650-- VOC boiling point (oF): (Tboil)7 7 7 7 7 211 211 7 7 7 7 7 7 68 7 7-- VOC critical temperature (oR): (Tc)773 773 773 773 773 979 979 773 773 773 773 773 773 830 773 773-- VOC molecular weight (lb/lb-mole): (MWvoc)63 63 63 63 63 114 114 63 63 63 63 63 63 44 63 63-- VOC condensate density (lb/gal):8.15 8.15 8.15 8.15 8.15 5.77 5.77 8.15 8.15 8.15 8.15 8.15 8.15 6.53 8.15 8.15-- Air heat capacity (BTU/lb-mole-oF): (Cp,air)6.95 6.95 6.95 6.95 6.95 6.95 6.95 6.95 6.95 6.95 6.95 6.95 6.95 6.95 6.95 6.95DESIGN PARAMETERS:-- Outlet VOC partial pressure (mm Hg): (Pvoc)=760*(Yvoc,in*(1-n)/(1-Yvoc,in*n))0.1 72.9 0.2 1.8 0.8 0.0 0.0 0.0 0.1 0.5 0.2 6.2 0.1 0.0 0.1 0.3-- Condensation temperature, Tc (oF): (Tcon)=(B/(A-log10(Pvoc))-C)*1.8+32-195.9 -77.8 -185.2 -155.8 -168.6 -158.4 -150.1 -250.9 -189.5 -173.8 -184.6 -135.0 -189.5 -221.5 -189.5 -179.5(oR): =Tcon+460264.1 382.2 274.8 304.2 291.4 301.6 309.9 209.1 270.5 286.2 275.4 325.0 270.5 238.5 270.5 280.5-- VOC flowrate in (lb-moles/hr): (Mvoc,in)=Qin*Yvoc,in*60/39215.39 2.93 0.00 1.80 0.29 0.01 0.01 0.00 0.63 0.71 2.43 3.97 0.38 0.00 0.63 0.00-- VOC flowrate out (lb-moles/hr): (Mvoc,out)=Mvoc,in*(1-n)0.007 2.930 0.001 0.003 0.000 0.000 0.000 0.000 0.010 0.011 0.037 0.030 0.006 0.000 0.010 0.002-- VOC condensed (lb-moles/hr): (Mvoc,con)=Mvoc,in-Mvoc,out15.381 0.000 0.000 1.798 0.293 0.006 0.006 0.000 0.618 0.7022.390 3.943 0.377 0.000 0.618 0.000(lb/hr): (Lb/hrvoc,con)=Mwvoc*Mvoc,con961.3 0.0 0.0 112.4 18.3 0.7 0.7 0.0 38.6 43.9 149.3 246.4 23.60.0 38.6 0.0-- VOC heat of condensation @ Tc (BTU/lb-mole): (****Hvoc)=(****Hvoc,r)*[(1-Tcon/Tc)/(1-Tboil/Tc)]^0.3812220 11054 12122 11845 15742 17888 13535 12706 12161 12016 12116 11642 12161 14331 12161 12069-- Enthalpy change, condensed VOC (BTU/hr): (****Hcon)=Mvoc,con[****Hvoc+Cp,voc(Tin-Tcon)234910 0 0 25257 5403 154 129 0 9355 10402 35932 55136 5714 0 9355 0-- Enthalpy change, uncondensed VOC (BTU/hr):(****Huncon)=Mvoc,out*Cp,voc*(Tin-Tcon)22 7722 2 6 1 0 0 0 28 30 107 71 17 2 28 5-- Enthalpy change, air (BTU/hr): (****Hnoncon)=Cp,air*(Tin-Tcon)*(Qin*60/392-Mvoc,in)121062 43432 5035 1370 498 749 290 118666 86012 25881 215161 5159 52535 281642 86012 7021-- Condenser heat load (BTU/hr): (Hload)=****Hcon+****huncon+****Hnoncon355994 51154 5038 26632 5902 903 419 118666 95395 36313 251200 60366 58266 281644 95395 7027-- Heat transfer coefficient, U (BTU/hr-ft2-oF):Estimate from OAQPS Manual20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20-- Log-mean temperature difference (oF): Tlm=(Tin-Tcon-25)/ln((Tin-Tcon-10)/15)84.0 75.4 80.0 66.2 76.3 63.6 64.2 96.7 82.5 78.7 81.3 69.2 82.5 90.0 82.5 80.1-- Condenser surface area (ft2): (Acon)=Hload/U*Tlm211.9 33.9 3.1 20.1 3.9 0.7 0.3 61.3 57.8 23.1 154.5 43.6 35.3 156.5 57.8 4.4-- Coolant flowrate (lb/hr):=Hload/(Cp,cool*(Tcon-15+25)-(Tcon-15))21907 3148 310 1639 363 56 26 7303 5870 2235 15458 3715 3586 17332 5870 432-- Refrigeration capacity (tons): (R)=Hload/120029.67 4.26 0.42 2.22 0.49 0.08 0.03 9.89 7.95 3.03 20.93 5.03 4.86 23.47 7.95 0.59-- Electricity requirement (kW/ton) [6]: (kW)=-9E-06(Tcon)^3 - 0.0004(Tcon)2 - 0.0331(Tcon) + 3.56062.38 0.00 0.00 33.04 40.91 34.51 29.95 128.87 56.68 44.51 52.65 22.86 56.68 0.00 56.68 0.00CAPITAL COSTSEquipment Costs ($):-- Refrigeration unit/single-stage (< 10 tons): (Rss<10)=exp(9.83-0.014Tcon+0.340lnR)0 90,367 184,842 215,828 154,706 70,778 48,553 1,358,594 533,574 308,744 0 212,908 451,229 0 533,574 191,161-- Refrigeration unit/single-stage (> 10 tons): (Rss>10)=exp(9.26-0.007Tcon+0.627lnR)346,977 0 0 0 0 0 0 0 0 0 257,573 0 0 358,416 0 0-- Multistage refrigeration unit: (Mru)exp(9.73-0.012Tcon+0.584lnR)1,278,08099,69793,445173,71384,02824,81914,3511,301,754548,129258,528910,031218,141411,0001,515,824548,129106,012Total equipment cost ($)--base: (ECp)=1.25*MAX(Rss<10,Rss>10,Mru)1,597,600 124,622 231,052 269,785 193,382 88,473 60,691 1,698,243 685,161 385,930 1,137,538 272,676 564,036 1,894,780 685,161 238,951Cost Indexa. 2010 CE Equip (Feb Final)CE Equipment index (Feb 2010 Final)641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1b. 1990 CE Equip (Oct Final)CE Equipment index (Oct 1990 Final)394 394 394 394 394 394 394 394 394 394 394 394 394 394 394 394' ' ' ' --escalated: (ECpe)=(ECp)*(FebFinal/OctFinal)2,601,527 202,934 376,245 439,317 314,903 144,069 98,830 2,765,414 1,115,714 628,448 1,852,364 444,025 918,474 3,085,455 1,115,714 389,107Purchased Equipment Cost ($): (PECp)=ECpe*1.082,809,650 219,169 406,344 474,462 340,095 155,594 106,7362,986,647 1,204,972 678,723 2,000,554 479,548 991,952 3,332,291 1,204,972 420,235Total Capital Investment ($): (TCI)=PECp*1.153,231,097 0 0 545,631 391,110 178,934 122,747 3,434,645 1,385,717 780,532 2,300,637 551,480 1,140,745 0 1,385,717 015,448,990ANNUAL COST INPUTS:Operating factor (hr/yr): (OF)8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400Operating labor rate ($/hr): (LR)34.60 34.60 34.60 34.60 34.60 34.60 34.60 34.60 34.60 34.60 34.60 34.60 34.60 34.60 34.60 34.60Maintenance labor rate ($/hr): (MR)38.06 38.06 38.06 38.06 38.06 38.06 38.06 38.06 38.06 38.06 38.06 38.06 38.06 38.06 38.06 38.06Operating labor factor (hr/sh): (OLF)1/2 hour per 8 hour shift0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50Maintenance labor factor (hr/sh): (MLF)1/2 hour per 8 hour shift0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50Electricity price ($/kWhr): (EP)0.0700 0.0700 0.0700 0.0700 0.0700 0.0700 0.0700 0.0700 0.0700 0.0700 0.0700 0.0700 0.0700 0.0700 0.0700 0.0700Recovered VOC value ($/lb)[5]: (Rvoc)0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00Annual interest rate (fraction): (Int)0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07Control system life (years): (EL)20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20Capital recovery factor: (CRF)=Int*(1+Int)^EL/((1+Int)^EL-1)0.0944 0.0944 0.0944 0.0944 0.0944 0.0944 0.0944 0.0944 0.0944 0.0944 0.0944 0.0944 0.0944 0.0944 0.0944 0.0944Taxes, insurance, admin. factor: (TaxF)0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04ANNUAL COSTS:ItemCost ($/yr) Cost ($/yr) Cost ($/yr) Cost ($/yr) Cost ($/yr) Cost ($/yr) Cost ($/yr) Cost ($/yr) Cost($/yr) Cost ($/yr) Cost ($/yr) Cost ($/yr) Cost ($/yr) Cost ($/yr) Cost ($/yr) Cost ($/yr)Operating labor=OF/8*OLF*LR18,165 18,165 18,165 18,165 18,165 18,165 18,165 18,165 18,165 18,165 18,165 18,165 18,165 18,165 18,165 18,165Supervisory labor=.15*Operating Labor2,725 2,725 2,725 2,725 2,725 2,725 2,725 2,725 2,725 2,725 2,725 2,725 2,725 2,725 2,725 2,725Maintenance labor=OF/8*MLF*MR19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982Maintenance materials100% of maintenance labor19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982Electricity=EP*OF*kW*R/0.851,280,160 0 0 50,732 13,919 1,796 723 881,535 311,715 93,176762,402 79,562 190,391 0 311,715 0Overhead=.60*(Operating Labor+Supervisory Labor+Maint Labor+Maint Materials) 36,512 36,512 36,512 36,512 36,512 36,512 36,512 36,512 36,512 36,512 36,512 36,512 36,512 36,512 36,512 36,512Taxes, insurance, administrative=TaxF*TCI129,244 0 0 21,825 15,644 7,157 4,910 137,386 55,429 31,221 92,025 22,059 45,630 0 55,429 0Capital recovery=CRF*TCI304,993 0 0 51,504 36,918 16,890 11,586 324,206 130,802 73,677 217,164 52,056 107,678 0 130,802 0Total Annual Cost (without credits) (TACwoc)=sum of all annual costs1,811,761 0 0 221,425 163,846 123,208 114,584 1,440,492 595,310 295,438 1,168,956 251,041 441,063 0 595,310 07,222,433Recovery credits (RC)=-Rvoc*OF*Lb/hrvoc,con0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0Total Annual Cost (with credits)=TACwoc+RC1,811,761 0 0 221,425 163,846 123,208 114,584 1,440,492 595,310 295,438 1,168,956 251,041 441,063 0 595,310 07,222,433NOTES:----------1. Base equipment costs reflect Third Quart 19902. Operating labor rate: Bureau of Labor Statistics,Occupational Employment Statistics, May 2008 National Industry-Specific Occupational Employment and Wage Estimates3. Electricity cost: Energy Information Administration.Average Industrial Retail Price of Electricity: October 2009.4. Antoine constants listed in OAQPS Manual5. ICIS, http://www.icis.com/v2/chemicals/9076567/vinyl-chloride/pricing.html, October 20, 2010. (Avg. $690/tonne= $0.313/lb)6. Polynomial of best fit based on Table 2.5 OAQPS Control Cost Manual Section 3.1 Chapter 2.INPUT PARAMETERS:Equation



# 18ATTACHMENT A: BEYOND THE FLOOR ANALYSIS FOR PROCESSVENTS02/08/2012PolyOne Isooctane Reduction Requirements for Condenser Cost Algorithm, BTFHAPHAPHAP_Cat_Name(All)Inlet_OutletOutletControl Device(All)Colocated with with EDC/VCM (0=No,1=Yes)(All)Compounds via Multiple Test Methods (0= Multiple Results Excluded)0Test Representative of Normal Op. Conditions (Yes=1, 0=No)(All)Test Included Streams Other Than PVC (0=No, 1=Yes)(All)Test Included Streams Other Than PVC/VCM/EDC (0=No,1=Yes)(All)Exclude Previous Test Data (1=data excluded)1DataStd FacilityCompound_StdAverage of MW Sum of Avg_Conc_ERG_UnitsTotal of Non-Iso Octane CompoundsTOH LimitMaximum ISO Conc (ppmvd @ 3%O2)% Redux of ISO Req.POHEthyl Chloride 6.45E+01 8.09E-014.19E+00 5.50 1.31E+00 99.99assume99.99%Isooctane 1.14E+02 9.72E+03Methyl Chloride 5.05E+01 1.21E+00Vinyl Chloride 6.25E+01 2.18E+00POPEthyl Chloride 6.45E+01 1.19E+00 6.49E+005.50-9.88E-01100.00assume99.99%Isooctane 1.14E+02 2.52E+04Methyl Chloride 5.05E+01 2.64E+00Vinyl Chloride6.25E+012.66E+00



# 19

# Attachment B

Beyond-the-Floor Analysis for Resins

20ATTACHMENT B. BEYOND THE FLOOR ANALYSIS FOR RESINS02/08/2012BEYOND THE FLOOR CALCULATIONS AND SUMMARYMoisture TemperatureSupp Fuel ElectricityVinyl Chloride Total Non-VC HAP (fraction) Vinyl Chloride Total Organic HAP DSCFM Vinyl Chloride Total Non-VCHAP % oF2010 2010Ft^3/yr kWh/yrFormosa - Delaware City Dispersion, Copolymer32.1 33.0 0.98 31.4 32.4 101,8827.634 7.863 8.9 130.6 $3,917,879 $369,820 $1,099,642 122,680,8586,770,114PolyOne - Henry Suspension, Dispersion, Suspension Blending 5.0 4.2 0.98 4.9 4.1 89,3431.198 0.997 8.9 130.6 $2,409,618 $227,451 $936,040 107,847,5255,936,871PolyOne - Pedricktown Dispersion2.9 1.3 0.98 2.8 1.3 92,4770.684 0.307 8.9 130.6 $3,620,766 $341,775 $1,010,244 111,536,3046,145,171Dow - Midland Copolymer0.0 0.0 0.98 0.004 0.02 15,3570.001 0.005 8.9 130.6 $676,134 $63,822 $250,951 18,210,0001,020,481Formosa - Baton Rouge Suspension0.2 18.2 0.98 0.242 17.88 652,0450.059 4.345 8.9 130.6 $21,998,070 $2,076,462 $6,394,439 786,867,98743,328,714Formosa - Point Comfort Suspension1.3 14.9 0.98 1.286 14.64 1,112,8650.312 3.556 8.9 130.6 $37,255,660 $3,516,670 $10,839,013 1,344,871,28773,950,429Georgia Gulf - Aberdeen Suspension9.3 113.1 0.98 9.108 110.81 711,6062.213 26.921 8.9 130.6 $23,879,753 $2,254,079 $6,966,456 859,376,23847,286,571Georgia Gulf - Plaquemine Suspension2.2 141.2 0.98 2.154 138.39 852,6740.523 33.622 8.9 130.6 $28,336,452 $2,674,760 $8,307,374 1,026,528,05356,660,571OxyVinyls - Pasadena Suspension5.8 81.1 0.98 5.672 79.50 1,493,7471.378 19.314 8.9 130.6 $49,987,856$4,718,499 $14,504,200 1,801,709,57199,260,286OxyVinyls - Pedricktown Suspension1.2 6.9 0.98 1.183 6.80 249,2190.287 1.652 8.9 130.6 $8,572,627 $809,195 $2,511,001 300,841,58416,560,714Shintech - Addis Suspension1.9 21.3 0.98 1.869 20.89 443,5780.454 5.074 8.9 130.6 $14,712,950 $1,388,798 $4,368,024 534,287,12929,476,000Shintech - Freeport Suspension5.8 108.3 0.98 5.701 106.13 2,272,7521.385 25.784 8.9 130.6 $75,297,743$7,107,572 $22,002,896 2,746,501,650151,025,714Shintech - Plaquemine Suspension2.2 44.2 0.98 2.152 43.32 924,7750.523 10.525 8.9 130.6 $31,313,481 $2,955,770 $9,035,925 1,116,996,70061,451,714Westlake - Calvert City Suspension7.5 136.3 0.98 7.305 133.54 782,0651.775 32.444 8.9 130.6 $26,105,744 $2,464,197 $7,640,876 944,408,58151,968,571Westlake - Geismar Suspension8.8 0.3 0.98 8.6 0.26 407,5282.089 0.063 8.9 130.6 $13,573,966 $1,281,286 $4,028,385 492,574,25727,080,429Totals84.44 709.89$341,658,699 $32,250,155 $99,895,466FacilityStream ParametersEstimated Dryer FlowRatePollutant Mass Flow Rate - ACA Inputlb/hrTO Total AnnualizedCapital Cost ($/yr)Part 63Floor Emissions, tons/yrTO Annual CostSecondary ImpactsBTF Reductions, tons/yrTO TCI ($)TO ReduxPart 63



# 21

# ATTACHMENT B. BEYOND THE FLOOR ANALYSIS FOR RESINS

02/08/2012

RTO Cost Summary

TCI (2008 Dollars) $413,923,096 In-Cell Calculation

Total Ann. Costs (2008 Dollars) $143,507,188

Note: use "x" in include in summation line to select whi ch facilities are included in the industry total cost estima te

TCI (2010 Dollars) $348,707,092

Total Ann. Costs (2010 Dollars) $134,742,473

Include in Summation (x=yes) x x x x x x x x x x x x x x

Dow

Baton Rouge Delaware Point Comfort Aberdeen Plaquemine Deer Park Pasadena Pedricktown Henry Pedricktown Addis Freeport Plaquemine Midland Calvert City Geismar

Formosa - Baton Rouge Formosa - Delaware City Formosa - Point Comfort Georgia Gulf - Aberdeen Georgia Gulf - Plaquemine

OxyVinyls - Deer Park OxyVinyls - Pasadena OxyVinyls - Pedricktown PolyOne - Henry PolyOne - Pedricktown Shintech - Addis Shintech - Freeport Shintech - Plaquemine Dow - Midland Westlake - Calvert City Westlake - Geismar 1

Program Inputs 2

Hours of Operation (per year) 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 840 0 8400 8400 8400 3

Total Dryer Exhaust Flow Rate (SCFM) 715,746.09 111,835.33 1,221,585.88

781,126.75 935,975.66 #REF! 1,639,677.95 273,566.42 98,070.98

101,512.07

486,913.81

2,494,788.06

1,015,120.66 16,857.21

858,468.96

447,341.31 4

Total Dryer Exhaust Flow Rate (DSCFM) 652,045 101,882 1,112,865 711,606 852,674 #REF! 1,493,747 249,219 89,343 92,477 443,578 2,272,752 924,775 15,357 782 ,065 407,528 5

Stream Temperature (F) 130.6 130.6 130.6 130.6 130.6 130.6 130.6 130.6 130.6 130.6 1 30.6 130.6 130.6 130.6 130.6 130.6 6

VC Flow Rate (lb/hr) (Assumed ALL TOH) 4 8 4 27 34 #REF! 19 2 1 0 5 26 11 0 32 0 7

Op. Labor Cost 34.6 34.6 34.6 34.6 34.6 34.6 34.6 34.6 34.6 34.6 34.6 34.6 34. 6 34.6 34.6 34.6 8

Electricity Cost ($/kWh) 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.0 7 0.07 0.07 0.07 9

Interest Rate 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.0 7 0.07 0.07 0.07 10

Equipment Life 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 11

Program Outputs 12

Min % O2 Required 19.8 13

Op. Temp (R) 2660 14

Auxiliary Air Req (CFM) 0 15

Min Fuel Req (CFM) 1534 16

Auxiliary Fuel Req (CFM) 1561 243 2668 1705 2037 939 3575 597 214 221 1060 5449 2216 36 18 74 977 17

Auxiliary Fule Req (Ft^3 per year) 786867987 122680858 1344871287 859376238 1026528053 4734 85149 1801709571 300841584 107847525 111536304 534287129 2746501650 1116996700 18210000 944408581 492574257 18

Electricity Requirments (kWh/yr) 43328714 6770114 73950429 47286571 56660571 26038857 9926 0286 16560714 5936871 6145171 29476000 151025714 61451714 1020481 51968571 27080429 19

Auxiliary Fuel Cost ($/yr) $2,384,210 20

Equipment Cost* 1.37E+07 21

Auxilary Equipment Cost 0 22

Total Equipment Cost 1.37E+07 23

Instrumentation Cost 1.37E+06 24

Sales Tax $412,341 25

Freight Cost $687,235 26

Purchased Equipment Cost 1.62E+07 27

Foundation Cost 1.30E+06 28

Equipment Erection Cost 2.27E+06 29

Electrical Cost $648,750 30

Piping Cost $324,375 31

Insulation Cost $162,188 32

Painting Cost $162,188 33

Direct Installation Cost 4.87E+06 34

Total Direct Capital Cost 2.11E+07 35

Engineering Cost 1.62E+06 36

Field Cost $810,938 37

Contractor Cost 1.62E+06 38

Start Up Cost $324,375 39

Performance Test Cost $162,188 40

Contingencies Cost $486,562 41

Total Indirect Capital Cost 5.03E+06 42

Total Capital Investment (2008 Dollars) 2.61E+07 4.65E+06 4.42E+07 2.83E+07 3.36E+07 1.55E+07 5.93E+07 1.02E+07 2.86E+06 4.30E+06 1.75E+07 8.94E+07 3.72E+07 $802,586 3.10E+07 1.61E+07 43

Total Capital Investment (2010 Dollars) $21,998,070.20 $3,917,879.20 $37,255,660.49 $23,879,75 3.46 $28,336,451.51 $13,078,776.98 $49,987,855.94 $8,57 2,627.45 $2,409,617.74 $3,620,766.00 $14,712,950.14 $75 ,297,742.59 $31,313,480.66 $676,133.88 $26,105,743.64 $ 13,573,965.65 44

Operating Labor $18,152 $18,152 $18,152 $18,152 $18,152 $18,152 $18 ,152 $18,152 $18,152 $18,152 $18,152 $18,152 $18,15 2 $18,152 $18,152 $18,152 45

Supervisory Labor $2,723 $2,723 $2,723 $2,723 $2,723 $2,723 $2,723 $2 ,723 $2,723 $2,723 $2,723 $2,723 $2,723 $2,723 $2,7 23 $2,723 46

Maintenance Labor $19,968 $19,968 $19,968 $19,968 $19,968 $19,968 $19 ,968 $19,968 $19,968 $19,968 $19,968 $19,968 $19,96 8 $19,968 $19,968 $19,968 47

Maintenance Materials $19,968 $19,968 $19,968 $19,968 $19,968 $19,968 $19 ,968 $19,968 $19,968 $19,968 $19,968 $19,968 $19,96 8 $19,968 $19,968 $19,968 48

Replacement Parts $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 49

Utilities 5.42E+06 $845,631 9.25E+06 5.91E+06 7.08E+06 3.26E+06 1. 24E+07 2.07E+06 $742,359 $768,117 3.68E+06 1.89E+07 7.6 9E+06 $126,610 6.50E+06 3.39E+06 50

Electricity** 3.03E+06 $473,908 5.18E+06 3.31E+06 3.97E+06 1.82E+06 6. 95E+06 1.16E+06 $415,581 $430,162 2.06E+06 1.06E+07 4.3 0E+06 $71,434 3.64E+06 1.90E+06 51

Total Direct Annual Cost 5.48E+06 $906,441 9.31E+06 5.97E+06 7.14E+06 3.32E+06 1. 25E+07 2.13E+06 $803,169 $828,927 3.74E+06 1.90E+07 7.7 5E+06 $187,420 6.56E+06 3.45E+06 52

Overhead $36,486 $36,486 $36,486 $36,486 $36,486 $36,486 $36 ,486 $36,486 $36,486 $36,486 $36,486 $36,486 $36,48 6 $36,486 $36,486 $36,486 53

Administrative Charges $522,244 $93,012 $884,466 $566,916 $672,719 $310,49 7 1.19E+06 $203,518 $57,206 $85,959 $349,291 1.79E+0 6 $743,395 $16,052 $619,761 $322,252 54

Property Taxes $261,122 $46,506 $442,233 $283,458 $336,360 $155,24 8 $593,367 $101,759 $28,603 $42,979 $174,646 $893,8 01 $371,698 $8,026 $309,881 $161,126 55

Insurance $261,122 $46,506 $442,233 $283,458 $336,360 $155,24 8 $593,367 $101,759 $28,603 $42,979 $174,646 $893,8 01 $371,698 $8,026 $309,881 $161,126 56

Capital Recovery Factor 0.0943929 0.0943929 0.0943929 0.0943929 0.0943929 0.0943 929 0.0943929 0.0943929 0.0943929 0.0943929 0.0943929 0.0 943929 0.0943929 0.0943929 0.0943929 0.0943929 57

Capital Recovery 2.46E+06 $438,984 4.17E+06 2.68E+06 3.18E+06 1.47E+06 5. 60E+06 $960,532 $269,990 $405,694 1.65E+06 8.44E+06 3. 51E+06 $75,758 2.93E+06 1.52E+06 58

Total Indirect Annual Cost 3.55E+06 $661,495 5.98E+06 3.85E+06 4.56E+06 2.12E+06 8. 01E+06 1.40E+06 $420,887 $614,098 2.38E+06 1.20E+07 5.0 3E+06 $144,348 4.20E+06 2.20E+06 59

Recovery Credit $0 $0 $0 $0 $0 60

Total Annualized Cost (2008 Dollars) 9.02E+06 1.57E+06 1.53E+07 9.82E+06 1.17E+07 5.44E+06 2.05E+07 3.54E+06 1.22E+06 1.44E+06 6.13E+06 3.10E+07 1.28E+07 $331,768 1.08E+07 5.65E+06 61

62

2010 Cost Calculations 63

Overhead (2010 Dollars) $36,486.1 $36,486.1 $36,486.1 $36,486.1 $36,486.1 $36,48 6.1 $36,486.1 $36,486.1 $36,486.1 $36,486.1 $36,486.1 $36 ,486.1 $36,486.1 $36,486.1 $36,486.1 $36,486.1 64

Administrative Charges (2010 Dollars) $439,961.40 $78,357.58 $745,113.21 $477,595.07 $566,729 .03 $261,575.54 $999,757.12 $171,452.55 $48,192.35 $72,4 15.32 $294,259.00 $1,505,954.85 $626,269.61 $13,522.68 $ 522,114.87 $271,479.31 65

Property Taxes (2010 Dollars) $219,980.70 $39,178.79 $372,556.60 $238,797.53 $283,364 .52 $130,787.77 $499,878.56 $85,726.27 $24,096.18 $36,20 7.66 $147,129.50 $752,977.43 $313,134.81 $6,761.34 $261, 057.44 $135,739.66 66

Insurance (2010 Dollars) $219,980.70 $39,178.79 $372,556.60 $238,797.53 $283,364 .52 $130,787.77 $499,878.56 $85,726.27 $24,096.18 $36,20 7.66 $147,129.50 $752,977.43 $313,134.81 $6,761.34 $261, 057.44 $135,739.66 67

Capital Recovery Factor 0.0943929 0.0943929 0.0943929 0.0943929 0.0943929 0.0943 929 0.0943929 0.0943929 0.0943929 0.0943929 0.0943929 0.0 943929 0.0943929 0.0943929 0.0943929 0.0943929 68

Capital Recovery (2010 Dollars) $2,076,461.64 $369,819.98 $3,516,669.83 $2,254,079.18 $ 2,674,759.83 $1,234,543.69 $4,718,498.69 $809,195.17 $2 27,450.81 $341,774.60 $1,388,798.03 $7,107,572.29 $2,95 5,770.25 $63,822.24 $2,464,196.85 $1,281,285.98 69

Total Indirect Annual Cost (2010 Dollars) $2,992,871 $563,021 $5,043,382 $3,245,755 $3,844,704 $1, 794,181 $6,754,499 $1,188,586 $360,322 $523,091 $2,013,8 02 $10,155,968 $4,244,796 $127,354 $3,544,913 $1,860,731 70

Recovery Credit 71

Total Annualized Cost (2010 Dollars) $8,470,901 $1,469,462 $14,355,682 $9,220,535 $10,982,13 4 $5,112,361 $19,222,699 $3,320,196 $1,163,491 $1,352,01 8 $5,756,822 $29,110,468 $11,991,696 $314,774 $10,105,07 3 $5,309,671 72

* - Does not include auxialiary equipment

** - Represented as subpart of Utilities Shintech Westlake Formosa Georgia Gulf OxyVinyls PolyOne



# 22ATTACHMENT B. BEYOND THE FLOOR ANALYSIS FOR RESINS02/08/2012DRYER DATA SUMMARYMin Max AvgFormosa - Baton Rouge9 323,496 240,226917,121,920 652,045Formosa - Delaware City2143,300,300 101,882Formosa - Point Comfort11,565,280,200 1,112,865Georgia Gulf - Aberdeen71,000,897,480 711,606Georgia Gulf - Plaquemine161,199,313,280 852,674OxyVinyls - Deer Park2551,155,000 391,854OxyVinyls - Pasadena7325,4682,101,002,860 1,493,747OxyVinyls - Pedricktown3 81,055350,534,580 249,219PolyOne - Henry 7 154,826 96,576 76,007,292 145 668 125,663,340 89,343PolyOne - Pedricktown239,809,584130,072,580 92,477Shintech - Addis 1623,907,460 443,578Shintech - Freeport13,196,699,000 2,272,752Shintech - Plaquemine11,300,725,800 924,775Dow - Midland 121,600,000 4115,357 1Westlake - Calvert City51,100,000,000 2,093800,277,060 782,065 2Westlake - Geismar1 33,000 76,000 44,250 476,390,000 906 49 573,201,200 407,528*Estimate from Survey Submission358DSCF/Lb of Dry Resin Produced1 No Capacity Info - Based on Non-CBI Survey Response2 Survey Response > Capacity Info - Based on Non-CBI Survey ResponseAverage of Avg Dry Flow Rate per LbProductionSum of Dryer Flow Rates (DSCFM)Number of Dryers*CompanyNote2006 ProductionCapacity (lbs)Dryer Flow Rate Based on Capacity &Avg Flow Per Production (DSCFM)AnnualProduction (Lbs)Annual Production(lbs/min)Avg Dryer Flow Rate perProduction (DSCF/LB)



# 23

# Attachment C

Beyond-the-Floor Analysis for Equipment Leaks

24ATTACHMENT C: BEYOND THE FLOOR ANALYSIS FOR EQUIPMENT LEAKS02/08/2012BTF Equipment Leaks Options Cost SummaryPumps - Option 15,9489722091,181Valves - Option 16,2168834161,299Connectors - Option 165,6339,3206,40515,725Total77,79811,1757,03018,205Cost Summary for Equipment LeaksCompanyLDAR Program[1](A) Capital Cost Increase ofLDAR ($)(B) AnnualizedCapital Cost Increaseof LDAR(C) Annual Increase inLDAR Cost(D) TAC ($)D=B+CBaseline Emission[2](Tons/yr)EstimatedEmissionReductions(Tons/yr)Formosa - Baton Rouge 40CFR61 V 77,79811,1757,03018,20514.64 6.54Formosa - Delaware City 40CFR63 UU-8.10 -Formosa - Point Comfort 40CFR61 V 77,79811,1757,03018,20514.64 6.54Georgia Gulf - Aberdeen 40CFR61 V 77,79811,1757,03018,20514.64 6.54Georgia Gulf - Plaquemine 40CFR63 UU-8.10 -OxyVinyls - Pasadena 40CFR61 V 77,79811,1757,03018,20514.64 6.54OxyVinyls - Pedricktown 40CFR61 V 77,79811,1757,03018,20514.64 6.54PolyOne - Henry 40CFR61 V 77,79811,1757,03018,20514.64 6.54PolyOne - Pedricktown 40CFR61 V 77,79811,1757,03018,20514.64 6.54Shintech - Addis 40CFR61 V 77,79811,1757,03018,20514.64 6.54Shintech - Freeport 40CFR61 V 77,79811,1757,03018,20514.64 6.54Shintech - Plaquemine 40CFR61 V 77,79811,1757,03018,20514.64 6.54Dow - Midland 40CFR61 V 77,79811,1757,03018,20514.64 6.54Westlake - Calvert City 40CFR61 V 77,79811,1757,03018,20514.64 6.54Westlake - Geismar 40CFR61 V 77,79811,1757,03018,20514.64 6.54Totals1,011,368145,27391,392236,66620785[1] - LDAR program type reported by facility in August 12, 2009 information collection request.[2] - VOC assumed to equal total HAP.Component Capital CostsAnnualized CapitalCostsAnnual Costs Total Annualized Costs



# 25ATTACHMENT C: BEYOND THE FLOOR ANALYSIS FOR EQUIPMENT LEAKS02/08/2012Major Source Equipment Leaks Baseline and EmissionReduction Analysis[1]Type of ComponentNumber ofComponents1SubpartV EmissionFactor(kg/hr/equipment)Subpart UU EmissionFactor(kr/hr/equipment)Subpart VEmissions(Tons/yr)Subpart UUEmissions(Tons/yr)EmissionReduction(Tons/yr)Model 2Pump Seals* Light-liquid service 40 2.51E-03 6.95E-04 0.93 0.26 0.67* Heavy-liquid service 5Valves* Gas/vapor service 414 3.52E-04 2.03E-04 1.35 0.78 0.57* Light-liquid service 1,179 3.90E-04 2.32E-04 4.26 2.53 1.72* Heavy-liquid service 71Connectors* Flanges - gas/vapor 0 3.07E-04 3.07E-04 0.00 0.00 0.00* Flanges - light liquid 2,662 3.07E-04 1.62E-04 7.57 3.99 3.57* Flanges -heavy liquid 0Agitators* Light-liquid service 3 2.51E-03 2.51E-03 0.07 0.07 0.00* Heavy-liquid service 3Pressure Relief Devices* Disks 45 0.00E+00 0.00E+00 0.00 0.00 0.00* Disk holders, valves,etc. 45 NA NAOpen-ended Valves141 3.33E-05 3.33E-05 0.04 0.04 0.00Sampling Connections35 0.00E+00 0.00E+00 0.00 0.00 0.00Compressor Vent2 2.28E-02 2.28E-02 0.42 0.42 0.00Totals14.648.106.54[1] - Emissions estimated based on 8,400 operatinghours per year



# 26ATTACHMENT C: BEYOND THE FLOOR ANALYSIS FOR EQUIPMENT LEAKS02/08/2012Major Source Equipment Leaks - Subpart V CostType of ComponentNumber ofComponentsInitialMonitoringFee or UnitCost($/comp)Initial LDARCosts ($/yr)(Capital)InitialLDARAdmin.CostsFrequencyofMonitoring(times/yr)SubsequentMonitoring Fee($/comp) orCharge (%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumber ofLeaksSubsequentLeakFrequency (%)AnnualNumberof LeaksPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)Annual OnLineLeak RepairCost ($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoring toVerify Repair($)AnnualAdmin. Cost($/yr)Annual Misc.Charges ($/yr)Model 2Pump Seals* Light-liquid service4023.80121.501547.01310.22.420.970.231.09710016.0066.241162.87080.0066.240.001.65248.15* Heavy-liquid service 5 1.10 5.52Valves* Gas/vapor service41423.8021.501242.000.331.380.332.77750.1766.2422.95254.0066.24183.224.15* Light-liquid service1,17923.80
21.503537.000.333.940.337.88750.1766.2465.35254.0066.24521.7811.82* Heavy-liquid service 71 1.10 78.38Connectors* Flanges - gas/vapor 0 1.10 0.00* Flanges - light liquid 2,662 1.10 2938.85* Flanges -heavy liquid 0 1.10 0.00Agitators* Light-liquid service 3 23.80 71.41 12 1.50 140.11 0.00 2.42 0.07 0.23 0.08 100.00 16.00 66.24 87.22 0 80.00 66.24 0.000.12 0.00* Heavy-liquid service 3 1.10 3.31Pressure Relief Devices* Disks 45 122.11 5494.78 0 2.00 0.00 109.90219.79* Disk holders, valves,etc. 45 6,374.29 286842.955.00 14342.1511473.72Open-ended Valves141 140.92 19870.035.00 993.50794.80Sampling Connections35 687.86 24075.015.00 1203.75963.00Compressor Vent2 10526.21 21052.425.00 1052.62842.10Replacement Pump Seals40282.71273.72Monitoring Instrument110,80010,800Data Collection System114,50014,500hr/activity $/hrAdministrative and Reports250 92.7223180.00Planning and Training320 92.72 29670.40TOTALS426311.44 29670.406466.12 18012.111338.39705.00 17.73 23180.00 14541.56Capital Costs 455,982Capital Rec. Fac for Pump Seals and Rupture Disks 0.244Capital Rec. Fac for All other Equipment 0.142Annualized Capital Costs65,338Annual Expenses 64,261Annual Fixed Costs ($/yr) 103,049 129,599Annual Variable Costs ($/yr) 26,861



# 27ATTACHMENT C: BEYOND THE FLOOR ANALYSIS FOR EQUIPMENT LEAKS02/08/2012Equipment Leaks - Pumps Option 1 Incremental CostType of ComponentNumber ofComponentsInitialMonitoringFee or UnitCost($/comp)Initial LDARCosts ($/yr)(Capital)InitialLDARAdmin.CostsFrequencyofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin. Cost($/yr)AnnualMisc.Charges($/yr)Model 2Pump Seals* Light-liquid service400.00121.501547.01347.913.485.390.261.23110016.0066.241304.21080.0066.240.001.85278.32* Heavy-liquid service 5 0.00 0.00Replacement Pump Seals40282.711524.88hr/activity $/hrAdministrative and Reports0 92.720.00Planning and Training0 92.72 0.00TOTALS7249.53 0.001547.01 347.901304.210.00 1.85 0.00 278.32Capital Costs 7,250Capital Rec. Fac for Pump Seals and Rupture Disks 0.244Capital Rec. Fac for All other Equipment 0.142Annualized Capital Costs 1,185Annual Expenses 3,479Baseline MonitoringType of ComponentNumber ofComponentsInitialMonitoringFee or UnitCost($/comp)Initial LDARCosts ($/yr)(Capital)InitialLDARAdmin.CostsFrequencyofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin. Cost($/yr)AnnualMisc.Charges($/yr)Model 2Pump Seals* Light-liquid service400.00121.501547.01310.22.420.970.231.09710016.0066.241162.87080.0066.240.001.65248.15* Heavy-liquid service 5 0.00 0.00Replacement Pump Seals40282.71273.72hr/activity $/hrAdministrative and Reports0 92.720.00Planning and Training0 92.72 0.00TOTALS1301.32 0.001547.01 310.191162.870.00 1.85 0.00 248.15Monitoring RepairCapital Costs 1,301 1,301.32Capital Rec. Fac for Pump Seals and Rupture Disks 0.244Capital Rec. Fac for All other Equipment 0.142Annualized Capital Costs 213212.71Annual Expenses 3,270 1,548.86 1,473.07Incremental Capital Costs 5948.21Incremental Annual Costs 1181.47



# 28ATTACHMENT C: BEYOND THE FLOOR ANALYSIS FOR EQUIPMENT LEAKS02/08/2012Equipment Leaks - Valves Option 1 Cost AnalysisType of ComponentNumber ofComponentsInitialMonitoringFee or UnitCost($/comp)Initial LDARCosts ($/yr)(Capital)InitialLDARAdmin.CostsFrequencyofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin. Cost($/yr)AnnualMisc.Charges($/yr)Model 2Valves* Gas/vapor service4140.0021.501242.007.2429.980.514.19750.1766.2434.75254.0066.24277.416.28* Light-liquid service1,1790.0021.503537.004.8457.090.5111.93750.1766.2498.95254.0066.24790.0117.89* Heavy-liquid service 71 0.00 0.00hr/activity $/hrAdministrative and Reports0 92.720.00Planning and Training0 92.72 0.00TOTALS6620.56 0.004779.00 0.00133.691067.42 24.17 0.00 0.00Capital Costs 6,620.56Capital Rec. Fac for Pump Seals and Rupture Disks 0.244Capital Rec. Fac for All other Equipment 0.142Annualized Capital Costs 940Annual Expenses 6,004Baseline MonitoringType of ComponentNumber ofComponentsInitialMonitoringFee or UnitCost($/comp)Initial LDARCosts ($/yr)(Capital)InitialLDARAdmin.CostsFrequencyofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin. Cost($/yr)AnnualMisc.Charges($/yr)Model 2Valves* Gas/vapor service4140.00
21.501242.000.331.380.332.77750.1766.2422.95254.0066.24183.224.15* Light-liquid service1,1790.0021.503537.000.333.940.337.88750.1766.2465.35254.0066.24521.7811.82* Heavy-liquid service 71 0.00 0.00hr/activity $/hrAdministrative and Reports0 92.720.00Planning and Training0 92.72 0.00TOTALS404.63 0.004779.00 0.0088.30705.00 15.96 0.00 0.00Capital Costs 405Capital Rec. Fac for Pump Seals and Rupture Disks 0.244Capital Rec. Fac for All other Equipment 0.142Annualized Capital Costs 57Annual Expenses 5,588Incremental Capital Costs 6215.93Incremental Annual Costs 1298.68V Option 1 - MCI-1



# 29ATTACHMENT C: BEYOND THE FLOOR ANALYSIS FOR EQUIPMENT LEAKS02/08/2012Equipment Leaks - Connectors Option 1 Cost AnalysisType of ComponentNumber ofComponentsInitialMonitoringFee or UnitCost ($/comp)Initial LDARCosts ($/yr)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoring Fee($/comp) orCharge (%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency (%)AnnualNumberof LeaksPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoring to VerifyRepair ($)AnnualAdmin. Cost($/yr)AnnualMisc.Charges($/yr)Model 2Connectors* Flanges - gas/vapor 0 23.80 0.00 0.20 2.50 0.00 0.36 0.00 0.36 0.00 75 0.17 66.24 0.00 25 2.00 66.24 0.00 0.00* Flanges - light liquid 2,662 23.80 63778.96 0.25 2.501663.75 0.36 9.58 0.36 2.40 75 0.17 66.24 19.88 25 2.00 66.24 79.35 5.99* Flanges -heavy liquid 0 0.00 0.00hr/activity $/hrAdministrative and Reports50 92.724636.00Planning and Training20 92.72 1854.401663.75 0.0019.8879.35 5.99 0.00 0.00TOTALS63778.96 1854.401663.75 0.0019.8879.35 5.99 4636.00 0.00Capital Costs65,633Capital Rec. Fac for Pump Seals and Rupture Disks 0.244Capital Rec. Fac for All other Equipment 0.142Annualized Capital Costs9,320Annual Expenses6,405C Option 1 - MCI-1



# 30

# Attachment D

Beyond-the-Floor Analysis for Storage Vessels

31ATTACHMENT D: BEYOND THE FLOOR ANALYSIS FOR STORAGEVESSELS02/08/2012Emissions, lb/yr*20,000 gal40,000 galMTVP, 1 TO 5 TO 1 TO 5 TOVP, mm Hg LowestHAP psi S_Loss W_Loss Total W_Loss Total S_Loss W_Loss TotalW_Loss Total25 C emissions 10.78992 120.069692Methanol 1.85557 49 606 243 80020 C TrendMethylene chloride 6.78 3,693 246 3,939 1,229 4,922 6,006 4916,498 2,457 8,464 79 1,176 972Hexane 2.351,763 171 1,933 853 2,616 92 571 1,113 y=10.79*VP+120.1Acetaldehyde** 14.5115 1,482 1,361Propylene oxide 8.48 3,724 211 3,935 1,054 4,778 6,015 422 6,437 2,109 8,124 125 606 1,469Vinylidene chloride 9.64 8,028 400 8,428 1,998 10,026 12,922799 13,721 3,995 16,917 151 1,933 1,749Vinyl acetate 1.741,357 125 1,482 627 1,983 194 3,484 2,213Ethyl benzene 0.14250 3,366 2,818Phenol 0.004429 3,939 4,749Methyl isobutyl ketone 0.28533 3,935 5,871Acetonitrile 1.41523 48 571 241 764 601 8,428 6,605Chloroform 3.003,183 301 3,484 1,507 4,690Methyl tert-butyl ether 2.133,071 294 3,366 1,472 4,543Ethylene dichloride 1.201,079 98 1,176 488 1,567> 4 psi ----->> 0.75 psi ----->* Emissions = breathing losses (S_Loss) + working losses (W_Loss). Default values for Atlanta, Georgia.** Unable to model acetaldehyde tank emissions due to vapor pressure.Estimated S and WmmHg psia emissions, lb/yrtriethylamine 57 1.1 735trichloroethylene 69 1.3 745benzene 95 1.8 1,025acrylonitrile 109 2.1 1,176carbon tetrachloride 115 2.2 1,241methyl chloroform 124 2.4 1,338MTBE 250 4.8 2,697acrolein 274 5.3 2,956carbon disulfide 359 6.9 3,874allyl chloride 368 7.1 3,971Vapor pressure (25C)y = 10.79x + 120.07R2 = 101,0002,0003,0004,0005,0006,0007,0008,0009,0000 100 200 300 400 500 600 700

Emissions, lb/yrVapor pressure, mm HgEmissions vs Vapor Pressure



# 32ATTACHMENT D: BEYOND THE FLOOR ANALYSIS FOR STORAGEVESSELS02/08/2012Emissions Needed to Achieve Cost Effectiveness of $3,500/tonVolumeDegas(1989)FlRoof(1989)CostEscal* TCI (2010) O&MEmissions, lb/yrEmiss Red,lb/yr TAC** Rec. Cr.*** $/tonVolume20,000$1,227 $8,817 1.80 $18,087 $1,809 1,997 1,897 $3,795 $949 $3,500Volume 20,000 gal 75.7 m3 30,000$1,510 $9,925 1.80 $20,593 $2,059 2,599 2,469 $4,320 $3,500Tank diameter 15.0 ft 4.6 m 40,000$1,750 $10,807 1.80 $22,614 $2,261 2,497 2,372 $4,744 $1,186 $3,500Height15.0 ft 4.6 m 50,000$1,963 $11,552 1.80 $24,338 $2,434 3,071 2,918 $5,106 $3,50060,000$2,155 $12,203 1.80 $25,858 $2,586 3,263 3,100 $5,425 $3,500Volume 30,000 gal 113.6 m3* Cost escalation conducted from 7/89 to 6/06.Tank diameter 17.2 ft 5.2 m** TAC (annualized capital cost plus O&M, w/o recovery credit).Height17.2 ft 5.2 m***Based on $500/ton (approx average of methylene chloride and ethylene dichloride from Platts)Equation: Emissions = 0.0191 x volume + 1442.7 (R2=0.99)Volume 40,000 gal 151.4 m3Tank diameter 18.953 ft 5.777 mHeight 18.953 ft 5.777 mVolume 50,000 gal 189.3 m3Tank diameter 20.4 ft 6.2 mHeight20.4 ft 6.2 mVolume 60,000 gal 227.1 m3Tank diameter 21.7 ft 6.6 mHeight21.7 ft 6.6 mbEmissions estimated for model tank in Atlanta, Georgia using TANKS4.



# 33ATTACHMENT D: BEYOND THE FLOOR ANALYSIS FOR STORAGEVESSELS02/08/2012Turnovers: 1mm Hg mm Hg mm Hg mm Hg mm Hg mm Hg mm Hg mm Hg mm Hg mm Hg mm Hg mm Hg39 52 78 103 129 155 39 52 78 103 129 155psia psia psia psia psia psia psia psia psia psia psia psiaVolume TAC** 0.75 1 1.5 2 2.5 3 0.75 1 1.5 2 2.5 320,000$3,795 539 678 957 1236 1515 179413616 10717 7455 5665 4534 375530,000$4,32040,000$4,7446061518850,000$5,10660,000$5,425Turnovers: 5mm Hg mm Hg mm Hg mm Hg mm Hg mm Hg mm Hg mm Hg mm Hg mm Hg mm Hg mm Hg39 52 78 103 129 155 39 52 78 103 129 155psia psia psia psia psia psia psia psia psia psia psia psiaVolume TAC** 0.75 1 1.5 2 2.5 3 0.75 1 1.5 2 2.5 320,000$3,795 2213 2910 4305 5700 7095 84902955 2133 1288 856 595 41930,000$4,32040,000$4,7448001137950,000$5,10660,000$5,425Turnovers: 10# of TO's $/Tonmm Hg mm Hg mm Hg mm Hg mm Hg mm Hg mm Hg mm Hg mm Hg mm Hg mm Hg mm Hg 1 15,188$39 52 78 103 129 155 39 52 78 103 129 155 5 11,379$psia psia psia psia psia psia psia psia psia psia psia psia 10 8,616$Volume TAC** 0.75 1 1.5 2 2.5 3 0.75 1 1.5 2 2.5 3 20 $ 5,72520,000$3,795 4305 5700 8490 11280 14070 168601288 856 419 198 64 -2540 3,315$30,000$4,32080 1,657$40,000$4,74410448616160 662$50,000$5,10660,000$5,425Using methanol TANKS value in CMAS table, VP = 1.85lb/yr Emissions$/ton including recovery creditslb/yr Emissions$/ton including recovery creditslb/yr Emissions$/ton including recovery credits



# 34

# Attachment E

Beyond the Floor Analysis for Wastewater

35ATTACHMENT E: BEYOND THE FLOOR ANLYSIS FOR WASTEWATER02/08/2012Baseline Emissions Analysis for Maintenance and Process WastewaterPollutant Existing Source (ppmw) New Source (ppmw)VC6.80 0.28Total Non_VC HAP 110.00 0.018CONTROLLED WW STREAMS - Stripper Outlet Data - VC concentrations replaced with VI data where suppliedCompany & Facility Originating Equipment Total WW (GAL) Acetaldehyde EDC MeOH MIBK VC Total Non-VC HAP VI DataName LookupCertain Teed Lake Charles Waste Water Stripper 3,6000.4000Dow MidlandFormosa Baton RougeWastewater Stripping Columns13,703,0400.30.1400 0.3Formosa DelawareFormosa Point Comfort1.6212 FPCTXOxyVinyls Deer Park Waste Water Stripper0.0180.3761 0.018 OXYDPOxyVinyls PasadenaWaste Water Preheater E-42264,000,0000.0245 OXYPAOxyVinyls PedricktownPolyOne HenryWaste Water Stripper Column4,953,6001.4832 POHPolyOne PedricktownWaste Water Stripping Column247,1011.8752 POPShintech Addis Waste Water Stripper 14,839,20040 0.26 0.0060 40.26Shintech Freeport HEAT EXCHANGER 27,000,00039 0.259 0.1186 39.259 SHTFShintech Plaquemine Waste Water Stripper 3,801,60040 0.3 0.0100 40.3Westlake Calvert CityWater Stripper Col Feed Heat Exch28,908,0002.261.0146 2.26 WLCCWestlake GeismarPVC Plant Waste Water Stripper13,225,1381.1870 WLGGeorgia Gulf Aberdeen Waste Water strippers 10,584,0000.8678 GGAGeorgia Gulf Plaquemine Waste Water Stripper1.0000Avg Conc (PPMW)0.72 20.40VI Supplied DataStripper Outlet Wastewater Baseline EstimationCompany & Facility Resin Type2008 lbs ofResin2008 lb of Resin CBI? 2006 Capacity 2008 Stripper WW(Gal)2008 Stripper Outlet(Gals)/Lb of Resin2008 Stripper Outlet(Gals/YR)VC Conc W/ Avgfor Non-Report(PPMW)% Reduction of VCConc Needed tomeet MACT floorlimitTotal Non-VCHAP Conc W/Avg for Non-Report(PMW)% Reduction ofTotal Non-VCHAP ConcNeeded tomeet MACTfloor limitBaseline VC(Tons/YR)Baseline Total Non-VCHAP (Tons/YR)VCReduction(Tons PerYear)Total Non-VCHAPReduction(Tons/yr)Certain Teed Lake Charles Bulk 447,348,640No 480,607,1603600.00 8.05E-06 3,6000.40- 20.40- 6.01E-06 3.06E-04 0.00E+00 0.00E+00Dow Midland Other 21,600,000No677,2730.72- 20.40- 2.04E-03 5.77E-02 0.00E+00 0.00E+00Formosa Baton Rouge OtherYes 917,121,92013703040.00 13,703,0400.14- 0.30- 8.01E-03 1.72E-02 0.00E+00 0.00E+00Formosa Delaware Dispersion Yes 143,300,3004,493,2140.72- 20.40- 1.36E-02 3.82E-01 0.00E+00 0.00E+00Formosa Point Comfort OtherYes 1,565,280,20049,079,7231.62- 20.40- 3.32E-01 4.18E+00 0.00E+00 0.00E+00OxyVinyls Deer Park OtherYes 551,155,00017,281,5930.38- 0.02- 2.71E-02 1.30E-03 0.00E+00 0.00E+00OxyVinyls Pasadena OtherYes 2,101,002,86064000000.00 64,000,0000.02- 20.40- 6.53E-03 5.45E+00 0.00E+00 0.00E+00OxyVinyls Pedricktown Other350,534,58010,991,0930.72- 20.40- 3.32E-02 9.36E-01 0.00E+00 0.00E+00PolyOne Henry Other/Dispersion 76,007,292No 125,663,3404953600.00 6.52E-02 4,953,6001.48- 20.40- 3.07E-02 4.22E-01 0.00E+00 0.00E+00PolyOne Pedricktown Dispersion 39,809,584No 130,072,580247101.00 6.21E-03 247,1011.88- 20.40- 1.93E-03 2.10E-02 0.00E+00 0.00E+00Shintech Addis OtherYes 623,907,46014839200.00 14,839,2000.01- 40.26- 3.72E-04 2.49E+00 0.00E+00 0.00E+00Shintech Freeport OtherYes 3,196,699,00027000000.00 27,000,0000.12- 39.26- 1.34E-02 4.42E+00 0.00E+00 0.00E+00Shintech Plaquemine OtherYes 1,300,725,8003801600.00 3,801,6000.01- 40.30- 1.59E-04 6.39E-01 0.00E+00 0.00E+00Westlake Calvert City Other 1,100,000,000No 800,277,06028908000.00 2.63E-02 28,908,0001.01- 2.26- 1.22E-01 2.73E-01 0.00E+00 0.00E+00Westlake Geismar Other 476,390,000No 573,201,20013225138.43 2.78E-02 13,225,1381.19- 20.40- 6.55E-02 1.13E+00 0.00E+00 0.00E+00Georgia Gulf Aberdeen Other1,000,897,48010584000.00 10,584,0000.87- 20.40- 3.83E-02 9.01E-01 0.00E+00 0.00E+00Georgia Gulf Plaquemine Other1,199,313,28037,604,7461.00- 20.40- 1.57E-01 3.20E+00 0.00E+00 0.00E+00Average*3.14E-02Totals8.52E-01 2.45E+01 0.00E+00 0.00E+00*Average does not include CTLC due to absence of H20UNCONTROLLED WASTEWATER STREAMSin Bulk processAverage of Avg Conc (ppmw)Wastewater Stripper Outlet Concentration Limits (Monthly Basis)



# 36ATTACHMENT E: BEYOND THE FLOOR ANLYSIS FOR WASTEWATER02/08/2012Pollutant Existing Source (ppmw) New Source (ppmw)VC6.80 0.28Wastewater Stripper Outlet Concentration Limits (Monthly Basis)UnControlled DataDataFacilityName Sum of Total WW (GAL) Sum of VC2 Sum of Total Non-VC HAP2Formosa Plastics Corporation Baton Rouge 342048960 0.14273188Georgia Gulf Chemicals Aberdeen Facility 27720000 0Lake Charles Polymer Plant 59616000 0.000621921OxyVinyls Deer Park0OxyVinyls Pasadena462061144.2 0 1.439935448PolyOne Henry41253800 0.34429179Shintech Addis51112800 0.007939744 2.492969532Shintech Freeport27000000 0.000676002 4.423191163Shintech Plaquemine10022400 0.002797745 0.61992652Westlake Calvert City64648800 0 0.609679537Westlake Geismar110527230.7 0.006666394Company & Facility Total WW (GAL) Tons VC Tons TotalNon-VC HAP VC Conc (PPMW) Total Non-VC HAP Conc (PPMW)Formosa Baton Rouge342048960 0.142731880.1Georgia Gulf Aberdeen27720000 00Certain Teed Lake Charles 59616000 0.0006219210.0025OxyVinyls Deer Park0OxyVinyls Pasadena462061144.2 0 1.439935448 0 0.746811268PolyOne Henry41253800 0.344291792Shintech Addis51112800 0.007939744 2.492969532 0.037225806 11.6883871Shintech Freeport27000000 0.000676002 4.423191163 0.006 39.259Shintech Plaquemine10022400 0.002797745 0.61992652 0.066896552 14.82298851Westlake Calvert City64648800 0 0.609679537 0 2.26Westlake Geismar110527230.7 0.0066663940.01445403Average0.22 13.76Company & Facility Resin Type2008 lbs ofResin2008 lb of Resin CBI? 2006 Capacity 2008 UncontrolledWW (Gal)2008 UncontrolledFlow (Gals/Lb ofResin2008 UncontrolledFlow (Gals/YR)VC Conc W/ Avgfor Non-Report(PPMW)Total Non-VC HAPConc W/ Avg for Non-Report (PMW)Baseline VC(Tons/YR)Baseline TotalNon-VC HAP(Tons/YR) 	
 	
%Reductionof HAPVCReductions(tpy)%Reductionof Non-VCHAPNon-VC HAPReductions(tpy)Certain Teed Lake Charles Bulk 447,348,640No 480,607,16059616000.00 1.33E-01 59,616,0000.0025 13.75543737 6.22E-04 3.42E+00 4,312,495.51$ 195,687.80$ 407,063.77$ 99 0.000615702 2.10688E-05 7.20959E-07Dow Midland Other 21,600,000No6,001,5070.222707639 13.75543737 5.58E-03 3.44E-01 1,170,206.76$ 263,169.23$ 110,458.54$ 99 0.00552158 1.90209E-05 6.55237E-08Formosa Baton Rouge OtherYes 917,121,920342048960.00 342,048,9600.1 13.75543737 1.43E-01 1.96E+01 12,497,714.15$ 27,555,245.71$ 1,179,678.11$ 99 0.141304561 0.027742882 0.005446869Formosa Delaware Dispersion Yes 143,300,30039,815,6390.222707639 13.75543737 3.70E-02 2.29E+00 3,607,537.41$ 4,760,376.15$ 340,522.10$ 99 0.03663167 0.000837177 1.91328E-05Formosa Point Comfort OtherYes 1,565,280,200434,909,2900.222707639 13.75543737 4.04E-01 2.50E+01 15,004,502.40$ 68,716,040.93$ 1,416,298.20$ 99 0.400130544 0.099886663 0.024935226OxyVinyls Deer Park OtherYes 551,155,000153,137,0740.222707639 13.75543737 1.42E-01 8.79E+00 8,050,612.18$ 30,134,452.20$ 759,910.49$ 99 0.140891037 0.012384282 0.001088575OxyVinyls Pasadena OtherYes 2,101,002,860462061144.24 462,061,1440 0.746811268 0.00E+00 1.44E+00 15,765,447.36$ 108,791,861.15$ 1,488,125.20$ 99 0 0 0OxyVinyls Pedricktown Other350,534,58097,395,1790.222707639 13.75543737 9.05E-02 5.59E+00 6,147,011.88$ 26,713,314.84$ 580,226.88$ 99 0.089606699 0.005009392 0.000280046PolyOne Henry Other/Dispersion 76,007,292No 125,663,34041253800.00 5.43E-01 41,253,8002 13.75543737 3.44E-01 2.37E+00 3,698,428.98$ 12,919,660.71$ 349,101.51$ 99 0.340848872 0.008071104 0.000191119PolyOne Pedricktown Dispersion 39,809,584No 130,072,58011,060,9960.222707639 13.75543737 1.03E-02 6.35E-01 1,603,065.92$ 3,901,367.75$ 151,316.76$ 99 0.010176472 6.46098E-05 4.10204E-07Shintech Addis OtherYes 623,907,46051112800.00 51,112,8000.037225806 11.6883871 7.94E-03 2.49E+00 4,561,891.33$ 19,963,003.73$ 430,605.54$ 99 0.007860347 0.000195956 4.88512E-06Shintech Freeport OtherYes 3,196,699,00027000000.00 27,000,0000.006 39.259 6.76E-04 4.42E+00 4,025,728.22$ 11,596,709.31$ 379,997.39$ 99 0.000669242 2.96018E-05 1.30935E-06Shintech Plaquemine OtherYes 1,300,725,80010022400.00 10,022,4000.066896552 14.82298851 2.80E-03 6.20E-01 1,796,626.93$ 4,700,549.55$ 169,587.67$ 99 0.002769768 1.71705E-05 1.06445E-07Westlake Calvert City Other 1,100,000,000No 800,277,06064648800.00 5.88E-02 64,648,8000 2.26 0.00E+00 6.10E-01 5,610,422.62$ 32,757,050.10$ 529,578.58$ 99 0 0 0Westlake Geismar Other 476,390,000No 573,201,200110527230.71 2.32E-01 110,527,2310.01445403 13.75543737 6.67E-03 6.34E+00 6,651,912.71$ 60,274,694.99$ 627,885.24$ 99 0.00659973 0.0004187 2.65631E-05Georgia Gulf Aberdeen Other1,000,897,48027720000.00 27,720,0000 13.75543737 0.00E+00 1.59E+00 3,296,630.76$ 16,199,462.93$ 311,175.68$ 99 0 0 0Georgia Gulf Plaquemine Other1,199,313,280333,226,2730.222707639 13.75543737 3.10E-01 1.91E+01 12,800,118.20$ 207,503,809.01$ 1,208,223.21$ 99 0.306578896 0.058639277 0.011215921Average*2.78E-011.51 104.68110,600,353.33$ 636,946,456.09$ 10,439,754.89$ 1.490205119 0.213336905 0.04321095*Average does not include CTLC due to absence of H20CE ($/ton) 370,622,647in Bulk processTotals W/O CTLC or OVDP 98,237,245.63$ 606,616,316.10$ 9,272,780.63$1.350.210.04(see "BTF Costing" sheet)BTF Costing



# 37ATTACHMENT E: BEYOND THE FLOOR ANLYSIS FOR WASTEWATER02/08/2012Pollutant Existing Source (ppmw) New Source (ppmw)VC6.80 0.28Wastewater Stripper Outlet Concentration Limits (Monthly Basis)MAINTENANCE WW STREAMSCompany & Facility Total WW (GAL)VC Conc(PPMW)Total Non-VC HAP Conc(PPMW)PolyOne Henry22,243,957.002Shintech Freeport430,000.000.077Westlake Calvert City1,206,000.00Westlake Geismar852,000.002.252.1250 0.077Company & Facility Resin Type2008 lbs ofResin2008 lb of Resin CBI? 2006 Capacity 2008 Main WW (Gal)2008 Maint Flow(Gals/Lb of Resin2008 Maint Flow(Gals/YR)VC Conc W/ Avgfor Non-Report(PPMW)TOHAP Conc W/ Avgfor Non-Report(PMW)Baseline VC(Tons/YR)BaselineTOHAP(Tons/YR)Certain Teed Lake Charles Bulk 447,348,640No 480,607,16044,069,8622.13 0.077 3.91E-01 1.42E-02Dow Midland Other 21,600,000No2,127,8912.13 0.077 1.89E-02 6.84E-04Formosa Baton Rouge OtherYes 917,121,92090,348,8542.13 0.077 8.01E-01 2.90E-02Formosa Delaware Dispersion Yes 143,300,30014,117,0082.13 0.077 1.25E-01 4.54E-03Formosa Point Comfort OtherYes 1,565,280,200154,201,1682.13 0.077 1.37E+00 4.95E-02OxyVinyls Deer Park OtherYes 551,155,00054,296,1862.13 0.077 4.81E-01 1.74E-02OxyVinyls Pasadena OtherYes 2,101,002,860206,977,0612.13 0.077 1.84E+00 6.65E-02OxyVinyls Pedricktown Other350,534,58034,532,3742.13 0.077 3.06E-01 1.11E-02PolyOne Henry Other/Dispersion 76,007,292No 125,663,34022,243,957.002.93E-01 22,243,9572.000.077 1.86E-01 7.15E-03PolyOne Pedricktown Dispersion 39,809,584No 130,072,5803,921,7802.13 0.077 3.48E-02 1.26E-03Shintech Addis OtherYes 623,907,46061,463,2832.13 0.077 5.45E-01 1.97E-02Shintech Freeport OtherYes 3,196,699,000430,000.00430,0002.13 0.077 3.81E-03 1.38E-04Shintech Plaquemine OtherYes 1,300,725,800128,138,9992.13 0.077 1.14E+00 4.12E-02Westlake Calvert City Other 1,100,000,000No 800,277,0601,206,000.001.10E-03 1,206,0002.13 0.077 1.07E-02 3.87E-04Westlake Geismar Other 476,390,000No 573,201,200852,000.001.79E-03 852,0002.25 0.077 8.00E-03 2.74E-04Georgia Gulf Aberdeen Other1,000,897,48098,601,8742.13 0.077 8.74E-01 3.17E-02Georgia Gulf Plaquemine Other1,199,313,280118,148,5012.13 0.077 1.05E+00 3.80E-02Average*9.85E-029.17E+00 3.33E-01*Average does not include CTLC due to absence of H20in Bulk processStripper Outlet, Uncontrolled, and Maint. Wastewater CombinedCompany & Facility Resin TypeBaseline VC(Tons/YR)Baseline Total Non-VCHAP (Tons/YR)VC Reduction(Tons Per Year)Total Non-VC HAP Reduction(Tons Per Year)Certain Teed - Lake Charles Bulk 3.91E-01 3.44 0.00E+000.00E+00Dow - Midland Other 2.65E-02 4.03E-01 0.00E+00 0.00E+00Formosa - Baton Rouge Other 9.52E-01 19.7 0.00E+00 0.00E+00Formosa - Delaware City Dispersion 1.76E-01 2.67 0.00E+00 0.00E+00Formosa - Point Comfort Other 2.10 29.2 0.00E+00 0.00E+00OxyVinyls - Deer Park Other 6.51E-01 8.81 0.00E+00 0.00E+00OxyVinyls - Pasadena Other 1.84 6.95 0.00E+00 0.00E+00OxyVinyls - Pedricktown Other 4.30E-01 6.54 0.00E+00 0.00E+00PolyOne - Henry Other/Dispersion 5.61E-01 2.80 0.00E+000.00E+00PolyOne - Pedricktown Dispersion 4.70E-02 6.57E-01 0.00E+00 0.00E+00Shintech - Addis Other 5.53E-01 5.01 0.00E+00 0.00E+00Shintech - Freeport Other 1.79E-02 8.85 0.00E+00 0.00E+00Shintech - Plaquemine Other 1.14 1.30 0.00E+00 0.00E+00Westlake - Calvert City Other 1.33E-01 8.83E-01 0.00E+00 0.00E+00Westlake - Geismar Other 8.02E-02 7.47 0.00E+00 0.00E+00Georgia Gulf - Aberdeen Other 9.13E-01 2.52 0.00E+00 0.00E+00Georgia Gulf - Plaquemine Other 1.51 22.4 0.00E+00 0.00E+00Total11.5 130 0.00 0.00Totals w/o area sources 10.49 117.29



# 38ATTACHMENT E: BEYOND THE FLOOR ANALYSIS FOR WASTEWATER02/08/2012Cost of Piping Additional Streams to Wastewater Stripper Feed TankAssumptionsWastewater Flow (GPM)50Assume Hard pipe wastewater flow to Stripper Feed TankWastewater Flow (m^3/sec)0.003154534Assume all piped flow is turbulentFluid Density (kg/m^3)983.24Assume water temperature of 140FOptimum Pipe Diameter (m)0.066599847Optimum Pipe Diameter Calculation Eq. (12-15) Peters, Timmerhaus, &West pg. 501Optimum Pipe Diameter (inches)2.622035973Caluclated (Rounded) Pipe Diameter (inches)3Estimated Pipe Cost (304 Stainless)* (Jan. 2002 Dollars) $/linear foot50<-----Estimated Pipe Cost (Carbon Steel)* (Jan. 2002 Dollars) $/linear foot3.3Where:Pump and Pumping CostDi,opt=optimum pipe diameter in metersPump cost (w/o motor)†$3,0001000 gpm, 20 ft, general purpose centrifugalmv=volumetric flow rate (m^3/sec)Power Output (kW) (brake power)11.25p=fluid density kg/m^3Pump motor cost§2,000$Alternating Current, Explosion proof (~13 kW)Motor Efficiency‡87% ~11.25 bkWAssumed 20 ft of headPower requirement † (kW)12.9Operating hours per year (Hrs)8400Electricity Cost ($/kWh)0.07Electricity Cost per year ($/yr)7603Total Capital InvestmentAssumed length of pipe run (ft)500GPM TCI TAC CRPurchased cost of pipe (Stainless Steel)25,000$10 47300 13960 4465 18425Purchased cost of pump3,000$50 105111 11808 9922 21730Purchased cost of motor2,000$100 140148 13209 13229 26438Equipment Cost30,000$500 297813 19516 28111 47627Installation Factor** (Ratio of total cost for fittings and installation to the purchase cost for thenew pipe)1.41000 420443 24421 39687 64108Installation Cost (includes pump and moto)42,000$Tax and Freight Factor††0.08Tax and Freight Cost2,400$Total Capital Investment (Jan. 2002)74,400$CE - July 02 (Pipes, Valves, and Fittings)563.5$CE - Feb 2010 (Pipes, Valves, and Fittings)796.1$Total Capital Investment (Feb. 2010)105,111$Annual CostAnnual interest rate (fraction):0.07System life (years):20Capital recovery factor:0.0944Taxes, Insurance, Admin Factor0.04Electricity7,603$Taxes Insurance, Administrative4,204$Capital Recovery9,922$Total Annual Cost ($/yr)11,808$does not incl. capital recovery* From Figure 12-4 Peters, Timmerhaus, & West. Plant Design and Economics for Chemical Engineers** pg. 404 Peters, Timmerhaus, & West. Plant Designand Economics for Chemical Engineers† Estimated from Figure 12-19 Peters, Timmerhaus, &West. Plant Design and Economics for Chemical Engineers§ Estimated from Figure 12-24 Peters, Timmerhaus, &West. Plant Design and Economics for Chemical Engineers‡ Estimated from Figure 12-18 Peters, Timmerhaus, &West. Plant Design and Economics for Chemical Engineers†† - Eqn. 10.39 pg. 10-49 OAQPS Control Cost ManualFifth Edition Feb. 1996pg. 10-51 OAQPS Cost Control Manual (Ductwork)Pipe Cost $/Linear FootDiameter304/L. Stainless (Sch 40) Carbon Steel (Sch 40)117 0.9231 2.1350 3.3470 5.8590 7.56120 107160 138190 179210 1910230 20* From Figure 12-4 Peters, Timmerhaus, & West. Plant Design and Economics for Chemical Engineers



	



      

* From Figure 12-4 Peters, Timmerhaus, & West. Plant Design and Economics for Chemical Engineers



# 39ATTACHMENT E: BEYOND THE FLOOR ANALYSIS FOR WASTEWATER02/08/2012Wastewater - Steam Stripper CostingWastewater Strippe - Current Operation Cost EstimateCompanyWestlake ChemicalCorporation -MODELCertain TeedLake Charles Dow MidlandFormosa BatonRougeFormosaDelawareFormosa PointComfortOxyVinyls DeerParkOxyVinylsPasadenaOxyVinylsPedricktown PolyOne HenryPolyOnePedricktown Shintech AddisShintechFreeportShintechPlaquemineWestlakeCalvert CityWestlakeGeismarGeorgia GulfAberdeenGeorgia GulfPlaquemineFacilityWestlake GeismarProcess TypeSuspensionProcess Type StdSuspensionProcess Unit IDP-1Stripped Resin Stream IDS-1Stripping TypeContinuous ContinuousInlet Stream Flow, liters/min1930 0.02704 5.08686 102.92076 33.74762 368.62788 129.79855 480.69107 82.55188 37.20549 1.85593 111.45423 202.79154 28.55305 217.12215 99.33134 79.49429 282.44165A. Parameters(Inputs and ExampleCalculation)1. Stripper inlet flow rate,pm (Q)5001930 0 5 103 34 369 130 481 83 37 2 111 203 29 217 99 79 2822. Annual operating hours, hr/yr (H)84008400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 84003. Steam to Feed Ratio, kg /(S)0.0960.060 0.060 1.060 2.060 3.060 4.060 5.060 6.060 7.060 8.060 9.060 10.060 11.060 12.060 13.060 14.060 15.060 16.0604. Electricity use, kWhr/day (EU)260260 260 260 260 260 260 260 260 260 260 260 260 260 260 260 260 2602605. Operating labor rate, $/hr (LR) [2]$34.60$34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60$34.606. Electricity cost, $/kWh (EC) [3]$0.07$0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.077. Water cost, $/1,000 gal (WC) [4]$0.20$0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.208. Steam cost, $/1,000 lb (SC) [4]$4.65$4.65 $4.65 $4.65 $4.65 $4.65 $4.65 $4.65 $4.65 $4.65 $4.65 $4.65 $4.65 $4.65 $4.65 $4.65 $4.65 $4.65 $4.659. Capital recovery factor= [i x (1 + i)a] / [(1 + i)a- 1], where i = interest rate, a = equipment lifea. Equipment CRF, 20-yr life, 7%interest0.094390.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.0943910. Cost indexa. 2010641.1641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1b. 1989356.0356.0 356.0 356.0 356.0 356.0 356.0 356.0 356.0 356.0 356.0 356.0 356.0 356.0 356.0 356.0 356.0 356.0 356.0B. Total Capital Investment1. $= 0.3731 x Q^0.267 x 10^6$02. $ /pm = $ / Q$0C. Direct Annual Operating Costs, $/yr1. Electricity = EU / (24 hr/day) x H x EC$6,079$6,079 $6,079 $6,079 $6,079 $6,079 $6,079 $6,079 $6,079 $6,079 $6,079 $6,079 $6,079 $6,079 $6,079 $6,079 $6,079 $6,079$6,0792. Steam = Q x S x (2.2 lb/kg) x (60 min/hr) x H xSC / 1000$247,484$596,994 $8 $27,801 $1,093,142 $532,440 $7,716,500$3,386,309 $15,019,132 $3,004,954 $1,546,138 $86,695 $5,780,970 $11,564,081 $1,775,440 $14,620,205 $7,200,751 $6,172,585$23,387,3193. Water = Q x (5220 liters water-min / liters feed-day) x (1 day / 24 hr) x H x (0.264 gal/liter) xWC / 1000$0$186,159 $3 $491 $9,928 $3,255 $35,560 $12,521 $46,370 $7,963 $3,589 $179 $10,751 $19,562 $2,754 $20,945 $9,582 $7,668$27,2464. Operating labor = (1 hr/shift) x (1 shift/8 hr)x H x LR$36,330$0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0$05. Supervisory labor = 0.15 x (operating labor)$5,450$0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0$06. Maintenance labor = (0.5 hr/shift) x (1 shift/8hr) x H x (LR x 1.1)$19,982$0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0$07. Maintenance materials = 0.02 x TCI$0$0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0$0D. Indirect Annual Costs, $/yr1. Overhead = 0.6 x (labor + maintenance materials)$37,057$0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0$02. Property taxes, insurance, andadministration= 0.04 x TCI$0$0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0$03. Capital recovery = Equipment CRF x TCI$0$0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0$0F. Include in Annual Cost?yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yesyesF. Total Annual Cost1. $/yr = Direct Annual Costs + Indirect Annual Costs - Recovery Credit$352,381$789,232$6,090$34,371$1,109,149$541,774$7,758,139$3,404,908$15,071,581$3,018,996$1,555,806$92,953$5,797,800$11,589,723$1,784,273$14,647,229$7,216,412$6,186,332$23,420,644Sources:1. Cost equations: HON BID, Vol 1-b and 1-c, Nov 1992 (EPA-453/D-92-016c)2. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2008 National Industry-Specific Occupational Employment andWage Estimates3. Electricity cost: Energy Information Administration. Average Industrial Retail Price of Electricity: October 2009.4. Water cost and steam cost: Air Compliance Advisor,version 7.5.5. ICIS, http://www.icis.com/v2/chemicals/9076567/vinyl-chloride/pricing.html, October 20, 2010. (Avg. $690/tonne = $0.313/lb)Parameters/CostsEquation



# 40ATTACHMENT E: BEYOND THE FLOOR ANALYSIS FOR WASTEWATER02/08/2012Wastewater - Steam Stripper CostingWastewater stripper - incremental cost of controlling previously uncontrolled streamsCompanyWestlake ChemicalCorporation -MODELCertain Teed LakeCharles Dow MidlandFormosa BatonRouge Formosa DelawareFormosa PointComfort OxyVinyls Deer Park OxyVinyls PasadenaOxyVinylsPedricktown PolyOne HenryPolyOnePedricktown Shintech Addis Shintech Freeport ShintechPlaquemineWestlake CalvertCity Westlake GeismarGeorgia GulfAberdeenGeorgia GulfPlaquemineFacilityWestlake GeismarProcess TypeSuspensionProcess Type StdSuspensionProcess Unit IDP-1Stripped Resin Stream IDS-1Stripping TypeContinuousInlet Stream Flow, liters/min1930 448 50 2672 333 3635 1280 3951 814 347 85 495 406 104 703 929288 2785A. Parameters(Inputs and ExampleCalculation)1. Stripper inlet flow rate,pm (Q)5001930 448 50 2672 333 3635 1280 3951 814 347 85 495 406 104 703 929288 27852. Annual operating hours, hr/yr (H)84008400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 84003. Steam to Feed Ratio, kg /(S)0.0960.060 0.060 1.060 2.060 3.060 4.060 5.060 6.060 7.060 8.060 9.060 10.060 11.060 12.060 13.060 14.060 15.060 16.0604. Electricity use, kWhr/day (EU)260260 260 260 260 260 260 260 260 260 260 260 260 260 260 260 260 2602605. Operating labor rate, $/hr (LR) [2]$34.60$34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60$34.606. Electricity cost, $/kWh (EC) [3]$0.07$0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.077. Water cost, $/1,000 gal (WC) [4]$0.20$0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.208. Steam cost, $/1,000 lb (SC) [4]$4.65$4.65 $4.65 $4.65 $4.65 $4.65 $4.65 $4.65 $4.65 $4.65 $4.65 $4.65 $4.65 $4.65 $4.65 $4.65 $4.65 $4.65 $4.659. Capital recovery factor= [i x (1 + i)a] / [(1 + i)a- 1], where i = interest rate, a = equipment lifea. Equipment CRF, 20-yr life, 7%interest0.094390.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.0943910. Cost indexa. 2010641.1641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1b. 1989356.0356.0 356.0 356.0 356.0 356.0 356.0 356.0 356.0 356.0 356.0 356.0 356.0 356.0 356.0 356.0 356.0 356.0 356.0B. Total Capital Investment1. $= 0.3731 x Q^0.267 x 10^6$0$10,000,000$4,162,340$1,119,238$12,156,052$3,483,361$14,621,955$7,816,538$15,371,841$5,957,838$3,572,161$1,535,104$4,422,226$3,922,296$1,731,747$5,454,430$6,451,137$3,191,910$12,462,6322. $ /pm = $ / Q$0$5,182 $9,295 $22,312 $4,549 $10,467 $4,022 $6,107$3,890 $7,319 $10,293 $18,074 $8,927 $9,671 $16,679$7,762 $6,941 $11,095$4,475C. Direct Annual Operating Costs, $/yr1. Electricity = EU / (24 hr/day) x H x EC$6,079$0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0$02. Steam = Q x S x (2.2 lb/kg) x (60 min/hr) x H xSC / 1000$247,484$0 $138,518 $246,353 $27,286,494 $4,718,102 $68,378,090 $30,007,037 $108,433,711 $26,627,746 $12,876,305 $3,880,741 $19,912,230 $11,564,081 $4,680,705 $32,696,095 $60,179,262 $16,166,293$207,241,6423. Water = Q x (5220 liters water-min / liters feed-day) x (1 day / 24 hr) x H x (0.264 gal/liter) xWC / 1000$0$0 $43,194 $4,348 $247,826 $28,848 $315,106 $110,953 $334,779 $70,566 $29,890 $8,014 $37,033 $19,562 $7,262 $46,840 $80,081 $20,084$241,4344. Operating labor = (1 hr/shift) x (1 shift/8 hr)x H x LR$36,330$0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0$05. Supervisory labor = 0.15 x (operating labor)$5,450$0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0$06. Maintenance labor = (0.5 hr/shift) x (1 shift/8hr) x H x (LR x 1.1)$19,982$0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0$07. Maintenance materials = 0.02 x TCI$0$0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0$0D. Indirect Annual Costs, $/yr1. Overhead = 0.6 x (labor + maintenance materials)$37,057$0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0$02. Property taxes, insurance, andadministration= 0.04 x TCI$0$0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0$03. Capital recovery = Equipment CRF x TCI$0$943,929 $392,895 $105,648 $1,147,445 $328,805 $1,380,209 $737,826 $1,450,993 $562,378 $337,187 $144,903 $417,427 $370,237 $163,465 $514,860 $608,942 $301,294$1,176,384F. Include in Annual Cost?yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yesyesF. Total Annual Cost1. $/yr = Direct Annual Costs + Indirect Annual Costs - Recovery Credit$352,381$943,929$574,607$356,350$28,681,766$5,075,755$70,073,406$30,855,815$110,219,483$27,260,690$13,243,381$4,033,658$20,366,690$11,953,881$4,851,431$33,257,795$60,868,284$16,487,671$208,659,460Sources:1. Cost equations: HON BID, Vol 1-b and 1-c, Nov 1992 (EPA-453/D-92-016c)2. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2008 National Industry-Specific Occupational Employment andWage Estimates3. Electricity cost: Energy Information Administration. Average Industrial Retail Price of Electricity: October 2009.4. Water cost and steam cost: Air Compliance Advisor,version 7.5.5. ICIS, http://www.icis.com/v2/chemicals/9076567/vinyl-chloride/pricing.html, October 20, 2010. (Avg. $690/tonne = $0.313/lb)Parameters/CostsEquation



# 41

# Attachment F

Beyond the Floor Analysis for Other Emission Sources

42	

	

	

	










 !"#$%#&'#''()(&#&*!!+&&'+ !",!#&+#! )(&#&*!!+&&'"!--".&+#!/0#'-!"/!"123&!"!" !"%( !+鷕*!"!60789#&'
:;!%#&'#! #<2-!" !"#&+#! !+&&'"! (%#&')"+)#&':;!%#$=>!#?!!&+"%#)+#5 !'#&'%( !&'##&'9<42Table B.2 Total Capital Investment and Total Annualized Cost Estimate: Flow Indicator - Gas PhaseComponentEquation Cost ($)Capital and Other Initial CostsTotal Capital Investment ($2011)TCI5,000Annualized CostsMaintenance and repairs3O&M=.07*TCI350Taxes, Insurance3TI=0.04*TCI200Interest Rate3i0.07Equipment Life3(years)n7Capital Recovery Factor4CRF=(i*(1+i)n)/((1+i)n-1)0.19Capital Recovery4CR=CFR*TCI928Total Annualized Costs ($/yr) ($2011)TAC=O&M+TI+CR1,478LOWHIGH AveraegTotal VCM Emission (ton/yr)(tons per gas holder)*(gas holders)13.20 49.50 31.35Total VCM Removed (ton/yr)(ton per gas holder) * (gas holders) * (% reduction)9.24 34.7 21.9Removal Effectiveness ($/ton VCM)(Total VCM Removed) / ((Total Costs)* (gas holders))2,399 640 1,010References1 - Comments Of The Vinyl Institute, Inc., PVC MactWorking Group. Docket ID No. EPA-HQ-OAR-2002-00372 - Krock, Richard P. Memorandum to Ms. Jodi Howard. "Vinyl Institute Response to EPA Request for Additional Information on Work Practices for Gasholders at PVC Resin Manufacturing Facilities." September22, 20113 - Peters, Timmerhaus, and West. "Plant Design andEconomics for Chemical Engineers." Fifth Edition.McGraw Hill. New York, NY. 2003. pg. 2684 - U.S. EPA. "Air Pollution Control Cost Manual."Sixth Edition (EPA/452/B-02-001). January 2002 pg 2-21Assumed emission ReduxEquationComponent



# 43