# E C 

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R Incorporated Providing Environmental Technical Support Since 1989

501 Eastowne Drive, Suite 250 y Chapel Hill, North Carolina 27514 Telephone: (919)484-0222 y Fax: (919) 484-0122 MEMORANDUM

DATE: January 29, 2010

SUBJECT: Control Costs for Ex isting Stationary CI RICE

FROM: Bradley Nelson, EC/R, Inc.

TO: Melanie King, EPA OAQPS/SPPD/ESG

1.0 PURPOSE

The purpose of this memorandum is to pr esent information on the costs of control technology options for reducing hazardous air po llutants (HAP) emissions from stationary compression ignition (CI) reciprocating internal combustion engines (RICE). These estimates will be used for the above-the-floor maximum ac hievable control technology (MACT) analysis and generally available control technology (GACT) regulatory alternatives for RICE at major and area sources. This memorandum presents th e cost of retrofitti ng control technology on existing engines.

2.0 INTRODUCTION

EPA has determined that diesel oxidation ca talysts (DOC), catalyzed diesel particulate filters (CDPF), closed crankcase ventilation (CCV) and open crankcase ventilation (OCV) are applicable controls for HAP reduction from stati onary CI RICE. To determine the capital and
annual costs for these control tec hnologies, equipment cost inform ation was obtained from a cost study 1 performed by the California (CA) Air Resour ces Board (ARB) and cost data obtained from vendors. The annualized cost and capital co st equations were used to estimate the national impacts of controlling emissions from existing stationary CI engines.

1 Risk Reduction Plan to Reduce Particulate Matter Emissions from Diesel-Fueled Engines and Vehicles, California Environmental Protection Agency, Air Resources Board, Stationary Source Division, Mobile Source Control Division, October 2000. http://www.arb.ca.gov/diesel/documents/rrpapp.htm2 3.0 METHODOLOGY FOR DETERMINING COST EQUATIONS

The following section describes the methodology used to derive the capital and annual
costs for each of these control t echnologies. The capital and a nnual costs were determined using the costing methodology in the EPA Control Cost Manual. 2 A summary of the methodologies, equations, and assumptions used to estimate the capital and annual cost are described in the following sections.

3.1 Total Capital Costs

The total capital cost includes the direct a nd indirect costs of pur chasing and installing the control equipment. The direct cost incl udes the cost of purchasing the equipment and instrumentation, cost of shipping, and the cost of installing the control equipment. The indirect cost includes the costs for engineer ing, contractor fees, testing cost s, and also includes costs for contingencies, such as additional modifications, or delays in startup. The total capital cost equation can be summarized as follows;

Total Capital Cost (TCC) = Direct Costs (DC) + Indirect Costs (IC)

The direct costs include the costs of purchasing and installing the control equipment and can be summarized using the following equation;

DC = Purchased Equipment Cost (PEC) + Direct Installation Costs (DIC).

A summary of the cost assumptions for PEC includes the following:

- Control Device and Aux iliary Equipment (EC); - Instrumentation (10% of EC); - Sales Tax (3% of EC); - Freight (5% of EC);

and can be summarized as:

PEC = 118% EC.

A summary of the cost assumptions for DIC includes the following:

- Foundations and Supports (8% of PEC); - Handling and Erection (14% of PEC); - Electrical (4% of PEC); - Piping (2% of PEC); - Insulation for Ductwork (1% of PEC);

2 EPA Air Pollution Control Cost Manual, Sixth Edition, January 2002, EPA/452/B-02-001.3 - Painting (1% of PEC);

and can be summarized as:

DIC = 30% PEC = 0.3 PEC.

Therefore, the direct costs can be simplified using the following equation:

DC = PEC + 0.3 PEC = 1.3 PEC.

The indirect costs include the costs of engineerin g and contractor fees and contingencies and can be summarized using the following equation:

IC = Indirect Installation Co sts (ICC) + Contingencies (C).

A summary of the cost assumptions for ICC includes the following:

- Engineering (10% of PEC); - Construction and Field Expenses (5% of PEC); - Contractor Fees (10% of PEC); - Startup (2% of PEC); - Performance Test (1% of PEC);

and can be summarized as:

IIC = 28% PEC = 0.28 PEC.

A summary of the cost assumpti ons for C includes the following:

- Equipment Redesign and Modifications; - Cost Escalations; - Delays in Startup;

and is assumed to be:

C = 3% PEC = 0.03 PEC.

Therefore, the IC can be summari zed using the following equation:

IC = 0.28 PEC + 0.03 PEC = 0.31 PEC,

and the simplified TCC equa tion can be expressed as:4 TCC = 1.3 PEC + 0.31 PEC = 1.61 PEC = 1.61 (1.18 EC) = 1.9 EC

3.2 Total Annual Costs

The total annual cost includes the direct and indirect annual costs of operating and maintaining the control equipment. The direct annual cost includes the co st of the utilities, operating labor, and control device cleaning and maintenance. The indirect annual cost includes the overhead costs such as spare parts for the co ntrol equipment, administrative charges, and the capital recovery of the control technology. The total annual cost equation can be summarized as follows:

Total Annual Cost (TAC) = Direct Annual Co sts (DAC) + Indirect Annual Costs (IAC).

A summary of the cost assumptions for DAC includes the following:

- Utilities; - Operating Labor; - Maintenance; - Annual Compliance Test; - Catalyst Cleaning; - Catalyst Replacement; - Catalyst Disposal.

A summary of the cost assumptions for DAC includes the following:

- Overhead (60% of operating labor and maintenance costs); - Fuel Penalty; - Property Tax (1% of TCC); - Insurance (1% of TCC); - Administrative Charges (2% of TCC); - Capital Recovery = {I(1+I) n /((1+I) n -1)*TCC} where I is the interest rate, and n is the equipment life.

The DAC and fuel penalty costs will be estimated using inform ation obtained for each of the control technologies. The other an nual costs will be calculated using the assumed percentages.5 4.0 CONTROL COST EQUATIONS

4.1 Diesel Oxidation Catalysts

The cost of retrofitting a DOC to an existi ng CI engine was estimat ed using cost data obtained from a diesel engine control tec hnology study performed by the California ARB. 3 The study provided equipment cost ranges for 40, 100, 275, 400, and 1,400 horsepower (HP) diesel engines. The average cost in the cost range for each of the engine sizes was used to develop the capital and annual cost for each of the engines. The capital cost was calculated using the EPA Control Cost methodology and includes the direct, indirect, and contingenc y costs of installation of the DOC. The total annual cost was also ca lculated using the EPA Control Cost methodology
and includes the direct and indirect annual costs of opera ting and maintaining the DOC. Maintenance costs were estimated using the averag e of the cost range provided in the California ARB study. The study estimated the maintenance costs to range from $64 to $712 per year; $50 to $100 for thermal cleaning and 1 hour labor ($78) once every other year to 4 times a year. For estimating the annual maintenance cost, the ther mal cleaning was estimated to cost $153 ($75 for cleaning + $78 for 1 hour labor) and the thermal cleaning would occur twi ce a year for a total maintenance cost of $306 per year. An equipmen t life of 10 years and an interest rate of 7 percent were used to estimate th e indirect annual costs. The 10 y ear equipment life is consistent with the average life of control equipment. The fuel penalty associat ed with operating a DOC was assumed to be negligible. The capital and annual costs were adjusted to 2008 dollars using the Marshall & Swift Equipment Cost Index.

The calculated annual cost was plotted agai nst the engine HP and the resulting graph showed a straight line relationship between the annual cost and engine HP. Therefore a linear regression was performed using the calculated an nual cost and the engine HP to develop an equation that estimates annual costs when an engi ne HP is input into the equation. A summary of the calculated annual costs, gr aph, and linear regression analys is is presented in Appendix A of this memorandum. The annualized cost equa tion for retrofitting a DOC on a CI engine was
estimated to be:

DOC Annual Cost = $4.99*HP + $480 where;

HP = engine size in HP.

The linear equation has a correlation coefficient of 0.9938, whic h shows the data fit the equation very closely. Therefore, this equation was used to estimate annua lized cost for DOC for RICE at major and area sources.

3 Appendix IX, Risk Reduction Plan to Reduce Particulate Matter Emissions from Diesel-Fueled Engines and Vehicles, California Environmental Prot ection Agency, Air Resources Board, St ationary Source Division, Mobile Source Control Division, October 2000. http://www.arb.ca.gov/diesel/documents/rrpapp9.PDF6 For capital cost, a graph of the calculate d capital cost and the engine HP showed a straight line relationship between the two variable s. Therefore a linear regression was performed using the calculated capital cost and the engine HP to develop an equation that estimates capital costs when an engine HP is input into the e quation. A summary of the calculated capital costs, graph, and linear regression analysis is presen ted in Appendix A of this memorandum. The capital cost equation for re trofitting a DOC on a CI engi ne was estimated to be:

DOC Capital Cost = $27.4*HP - $939 where;

HP = engine size in HP.

The linear equation has a correlation coefficient of 0.9938, whic h shows the data fit the equation very closely. Therefore, this equation was used to estimate capital cost for DOC for RICE at major and area sources.

4.2 Catalyzed Diesel Particulate Filters

The CDPF is a control technology that reduces the emissions of HAP from CI engines. However, it is primarily installed on engines for th e reduction of PM from the CI engine exhaust. The catalyst element in the CDPF is also effectiv e in reducing the emissions of CO and volatile organic compounds (VOC). The filt er system of the CDPF can be ei ther active or passive. The passive CDPF uses heat from the engine to regene rate the filter media, whereas the active filter
uses an electric heater or fuel burners to regenerate the filter media. The catalyzed coating in each of the two systems reduces emissi ons of CO, VOC, and HAP emissions.

The cost of retrofitting an active or passive CDPF to an existing CI engine was estimated using cost data obtained from a diesel e ngine control technology study performed by the California ARB. 4 The cost study did not distinguish equipment costs between the active and passive CDPF, therefore the equipment costs were assumed to be the same for both technologies. The study provided equipment cost ranges fo r 40, 100, 275, 400, and 1,400 HP diesel engines. The average cost in the cost range for each of these engine HPs and the EPA Control Cost methodology were used to develop the capital an d annual cost for each of the engines. An equipment life of 10 years and an interest rate of 7 pe rcent were used to estimate the indirect annual costs. The 10 year equipment life is consiste nt with the average life of control equipment. The fuel penalty associated with operating a CD PF was assumed to be negligible. The capital and annual costs were adjusted to 2008 dollars using the Marshall & Swift Equipment Cost
Index.

The calculated annual cost for the CDPF wa s plotted against the engine HP and the resulting graph showed a strai ght line relationship between the annual cost and engine HP.

4 Appendix IX, Risk Reduction Plan to Reduce Particulate Matter Emissions from Diesel-Fueled Engines and Vehicles, California Environmental Prot ection Agency, Air Resources Board, St ationary Source Division, Mobile Source Control Division, October 2000. http://www.arb.ca.gov/diesel/documents/rrpapp9.PDF7 Therefore a linear regression was performed using the calculated annual cost and the engine HP to develop an equation that estimates annual costs when an engine HP is input into the equation. A summary of the calculated annual costs, graph, and linear regres sion analysis is presented in Appendix A of this memorandum. The annualized cost equation for retrofitting a CDPF on a CI engine was estimated to be:

CDPF Annual Cost = $11.6*HP + 1414

where;

HP = engine size in HP.

The linear equation has a correlation coefficient of 0.9897, whic h shows the data fit the equation very closely. Therefore, this equation was used to estimate a nnualized cost for retrofitting CDPF for CI at major and area sources.

For capital cost, a graph of the calculate d capital cost and the engine HP showed a straight line relationship between the two variable s. Therefore a linear regression was performed using the calculated capital cost and the engine HP to develop an equation that estimates capital costs when an engine HP is input into the e quation. A summary of the calculated capital costs, graph, and linear regression analysis is presen ted in Appendix A of this memorandum. The capital cost equation for re trofitting a CDPF on a CI engi ne was estimated to be:

CDPF Capital Cost = $63.4*HP + $5699 where;

HP = engine size in HP.

The linear equation has a correlation coefficient of 0.9897, whic h shows the data fit the equation very closely. Therefore, this equation was used to estimate capital cost for CDPF for RICE at major and area sources.

4.3 Open and Closed Crankcase Ventilation

In diesel engines, the crankcase exhaust is either exhausted to the atmosphere (open crankcase) or routed to the air intake to be used as combustion air (closed crankcase). Crankcase ventilation systems use filtration or centrifugal force to remove oil mist and particulates from the crankcase exhaust stream in both open and closed crankcase diesel engines. The OCV system is installed on diesel engines with open crankcases, whereas the CCV system is installed on diesel engines with closed crankcases. The filtrati on or separator units used for both OCV and CCV are the same and have essentially the same cost. Therefore for this analysis, it is assumed that the capital and annual cost of OCV and CCV are the same.8 The cost of retrofitting an OCV on an existing CI engine was estimated based on
information obtained from a distributor of the OCV technology (see Appendix B). The
distributor sells and installs th ree different models of the OCV system and provided information
on the installation costs and mainte nance required. These models we re applied to en gine sizes of 100, 150, 200, 300, 500, 750, 1,000, 1,250, and 1,500 HP to estimate capital and annual costs using the EPA Control Cost methodology. An equipment life of 10 years and an interest rate of 7 percent were used to estimat e the indirect annual costs. The 10 year equi pment life is consistent with the average life of control equipment. The calculat ed annual cost and engine size were graphed and a straight line relationship was observed. A linear regression analysis was
done on the data set and the linear equation for annualized cost was;

OCV Annual Cost = $0.065*HP + $254

where;

HP = engine size in HP.

The linear equation has a correlation coefficient of 0.8154, which is due to the same annual cost being calculated for several differe nt sized CI engines. This is due to the fact that the same model OCV can be retrofit on several different engine sizes, because the OCV are based on the flow rate of the crankcase exhaust. However, it is believed that the equation represents a representative averag e annual cost of retrofitting an OCV on a CI engine.

For capital cost, a graph of the calculate d capital cost and the engine HP showed a straight line relationship between the two variable s. Therefore a linear regression was performed using the calculated capital cost and the engine HP to develop an equation that estimates capital costs when an engine HP is input into the e quation. A summary of the calculated capital costs, graph, and linear regression analysis is presen ted in Appendix A of this memorandum. The capital cost equation for re trofitting a OCV on a CI engi ne was estimated to be:

OCV Capital Cost = $0.26*HP + $997 where;

HP = engine size in HP.

The linear equation has a correlation coefficient of 0.7920, wh ere again the capital cost was calculated to be the same for seve ral different sized CI engines. However, it is believed that the cost equation provides a representa tive estimate of the average capital cost of retrofitting an OCV on a CI engine.9 5.0 SUMMARY

The following table presents a summary of th e costs for control devices to reduce HAP emissions from stationary CI engines.

Table 1. Summary of Annual and Capital Costs Equations for CI HAP Controls

HAP Control Device Annual Cost ($) Capital Cost ($)

DOC $4.99*HP + $480 $27.4*HP - $939

CDPF $11.6*HP + $1414 $63.4*HP + $5699

OCV $0.065*HP + $254 $0.26*HP + $99710 Appendix A

Control Cost Summary and Linear Regression Statistics11 Diesel Oxidation Catalyst Cost Data obtained from CARB Appendix IX, Diesel PM Control Technologies Capital and Annual Cost Equations are from EPA Air Pollution Control Cost Manual, Sixth Edition (EPA/452/B-02-001)

Direct Costs Indirect Costs

Engine Size (HP) Equipment
Cost ($2000) Equipment
Cost ($2008) PEC DIC IIC C Total Capital
Cost Regression Capital
Cost Direct
Annual
Cost Indirect
Annual
Cost Total
Annual
Cost Regression
Annual
Cost Annual Cost/Hp 40 $500 $665 $785 $236 $220 $24 $1,264 $156 $407 $475 $882 680 $22.05 100 $1,018 $1,355 $1,599 $480 $448 $48 $2,574 $1,798 $407 $714 $1,121 979 $11.21 275 $2,350 $3,128 $3,690 $1,107 $1,033 $111 $5,942 $6,587 $407 $1,328 $1,735 1,853 $6.31 400 $3,250 $4,325 $5,104 $1,531 $1,429 $153 $8,217 $10,008 $407 $1,743 $2,150 2,477 $5.38 1400 $15,000 $19,963 $23,556 $7,067 $6,596 $707 $37,925 $37,374 $407 $7,161 $7,568 7,468 $5.41

$10.07 Assumptions: PEC = 118% of purchased equipment cost (PEC). DIC = 30% of purchased equipment cost (PEC) and includes cost of installation. IIC = 28% of purchased equipment cost (PEC). C = 3% of purchased equipment cost (PEC). Direct Annual Cost = 0, equipment certified by engine manufacturer. Indirect Annual Cost = 60% of direct annual cost + 4% of total capital cost + capital recovery. Capital Recovery assumes equipment life of 10 years and 7% interest rate. 0.1423775

SUMMARY OUTPUT - Annual Cost

Regression Statistics Multiple R 0.99687955 R Square 0.99376884 Adjusted R S 0.99169179
Standard Er r 252.645997
Observation s 5

ANOVA
df SS MS F S ignificance F Regression 1 30539570.1 30539570.1 478.45167 0.00020915
Residual 3 191490 63830
Total 4 30731060.1

Coefficients S tandard Erro t Stat P-value Lower 95% Upper 95% L ower 95.0%Upper 95.0% Intercept 480.351703 151.603431 3.16847514 0.05053998 -2.1180765 962.821482 -2.1180765 962.821482 Engine Size 4.99102525 0.2281764 21.8735381 0.00020915 4.2648661 5.7171844 4.2648661 5.7171844

SUMMARY OUTPUT - Capital Cost

Regression Statistics Multiple R 0.99687955 R Square 0.99376884 Adjusted R S 0.99169179
Standard Er r 1385.29146
Observation s 5

ANOVA
df SS MS F S ignificance F Regression 1 918164273 918164273 478.45167 0.00020915
Residual 3 5757097.3 1919032.43
Total 4 923921370

Coefficients S tandard Erro t Stat P-value Lower 95% Upper 95% L ower 95.0%Upper 95.0% Intercept -938.90096 831.26169 -1.129489 0.34084422 -3584.3467 1706.54473 -3584.3467 1706.54473 Engine Size 27.3664524 1.25112143 21.8735381 0.00020915 23.3848256 31.3480792 23.3848256 31.3480792 $0 $1,000 $2,000 $3,000 $4,000 $5,000 $6,000 $7,000 $8,000

0 200 400 600 800 1000 1200 1400 1600 A n n u a l i z e d C o s t ( $ / y r )

Engine Size (HP) Annual Cost for Retrofit of a Diesel Oxidation Catalyst

Total Annual Cost Regression Annual Cost

$0 $5,000 $10,000 $15,000 $20,000 $25,000 $30,000 $35,000 $40,000

0 200 400 600 800 1000 1200 1400 1600 C a p i t a l C o s t ( $ )

Engine Size (HP) Capital Cost for Retrofit of a Diesel Oxidation Catalyst

Total Capital Cost Regression Capital Cost12 Catalyzed Diesel Particulate Filter Cost Data obtained from CARB Appendix IX, Diesel PM Control Technologies Capital and Annual Cost Equations are from EPA Air Pollution Control Cost Manual, Sixth Edition (EPA/452/B-02-001)

Direct Costs Indirect Costs

Engine Size (HP) Equipment
Cost ($2000) Equipment
Cost ($2008) PEC DIC IIC C Total Capital
Cost Regression Capital
Cost Direct
Annual
Cost Indirect
Annual
Cost Total
Annual
Cost Regression
Annual
Cost Annual Cost/Hp 40 $4,150 $5,523 $6,517 $1,955 $1,825 $196 $10,493 $8,237 $234 $2,054 $2,288 1,877 $57.20 100 $6,250 $8,318 $9,815 $2,945 $2,748 $294 $15,802 $12,043 $234 $3,022 $3,256 2,571 $32.56 275 $7,950 $10,580 $12,485 $3,745 $3,496 $375 $20,100 $23,146 $234 $3,806 $4,040 4,596 $14.69 400 $10,500 $13,974 $16,489 $4,947 $4,617 $495 $26,548 $31,076 $234 $4,982 $5,216 6,042 $13.04 1400 $38,000 $50,572 $59,675 $17,903 $16,709 $1,790 $96,078 $94,518 $234 $17,663 $17,897 17,612 $12.78

$26.06 Assumptions: PEC = 118% of purchased equipment cost (PEC). DIC = 30% of purchased equipment cost (PEC) and includes cost of installation. IIC = 28% of purchased equipment cost (PEC). C = 3% of purchased equipment cost (PEC). Direct Annual Cost = 0, equipment certified by engine manufacturer. Indirect Annual Cost = 60% of direct annual cost + 4% of total capital cost + capital recovery. Capital Recovery assumes equipment life of 10 years and 7% interest rate. 0.1423775

SUMMARY OUTPUT - Annual Cost

Regression Statistics Multiple R 0.99482924 R Square 0.98968521 Adjusted R S 0.98624695
Standard Er r 755.115259
Observation s 5

ANOVA
df SS MS F S ignificance F Regression 1 164128740 164128740 287.844638 0.00044599
Residual 3 1710597.16 570199.054
Total 4 165839337

Coefficients S tandard Erro t Stat P-value Lower 95% Upper 95% Intercept 1413.79818 453.116477 3.12016501 0.0524648 -28.22068 2855.81703 Engine Size 11.57046 0.68197987 16.9659847 0.00044599 9.40009569 13.7408243

SUMMARY OUTPUT - Capital Cost

Regression Statistics Multiple R 0.99482924 R Square 0.98968521 Adjusted R S 0.98624695
Standard Er r 4140.39697
Observation s 5

ANOVA
df SS MS F S ignificance F Regression 1 4934488108 4934488108 287.844638 0.00044599
Residual 3 51428661.1 17142887
Total 4 4985916769

Coefficients S tandard Erro t Stat P-value Lower 95% Upper 95% Intercept 5699.15785 2484.49765 2.2938874 0.10557881 -2207.6225 13605.9382 Engine Size 63.4423645 3.73938592 16.9659847 0.00044599 51.5419696 75.3427594 $0 $2,000 $4,000 $6,000 $8,000 $10,000 $12,000 $14,000 $16,000 $18,000 $20,000

0 200 400 600 800 1000 1200 1400 1600 A n n u a l i z e d C o s t ( $ / y r )

Engine Size (HP) Annual Cost for Retrofit of a Catalyzed Diesel Particulate Filter

Total Annual Cost Regression Annual Cost

$0 $20,000 $40,000 $60,000 $80,000 $100,000 $120,000

0 200 400 600 800 1000 1200 1400 1600 C a p i t a l C o s t ( $ )

Engine Size (HP) Capital Cost for Retrofit of a Catalyzed Diesel Particulate Filter

Total Capital Cost Regression Capital Cost13 Crankcase Filtration Cost Equations Data obtained from Telephone Communications with Mid-Atlantic Engine Supply Corporation Capital and Annual Cost Equations are from EPA Air Pollution Control Cost Manual, Sixth Edition (EPA/452/B-02-001)

Direct Costs Indirect Costs

Engine Size (HP) Equipment
Cost ($2008) PEC DIC IIC C Total Capital
Cost Regression Capital
Cost Direct
Annual
Cost Indirect
Annual
Cost Total
Annual
Cost Regression
Annual
Cost Annual Cost/Hp 100 $500 $590 $177 $165 $18 $950 $1,022 $45 $200 $245 260 $2.45 150 $500 $590 $177 $165 $18 $950 $1,035 $45 $200 $245 264 $1.63 200 $600 $708 $212 $198 $21 $1,140 $1,048 $50 $238 $288 267 $1.44 300 $600 $708 $212 $198 $21 $1,140 $1,074 $50 $238 $288 273 $0.96 500 $600 $708 $212 $198 $21 $1,140 $1,125 $50 $238 $288 286 $0.58 750 $600 $708 $212 $198 $21 $1,140 $1,190 $50 $238 $288 302 $0.38 1000 $700 $826 $248 $231 $25 $1,330 $1,254 $60 $279 $339 319 $0.34 1250 $700 $826 $248 $231 $25 $1,330 $1,318 $60 $279 $339 335 $0.27 1500 $700 $826 $248 $231 $25 $1,330 $1,382 $60 $279 $339 351 $0.23

$0.92 Assumptions: PEC = 118% of purchased equipment cost (PEC). DIC = 30% of purchased equipment cost (PEC) and includes cost of installation. IIC = 28% of purchased equipment cost (PEC). C = 3% of purchased equipment cost (PEC). Direct Annual Cost = 0, equipment certified by engine manufacturer. Indirect Annual Cost = 60% of direct annual cost + 4% of total capital cost + capital recovery. Capital Recovery assumes equipment life of 10 years and 7% interest rate. 0.1423775

SUMMARY OUTPUT - Annual Cost

Regression Statistics Multiple R 0.90297617 R Square 0.81536597 Adjusted R S 0.78898968
Standard Er r 16.909021
Observation s 9

ANOVA
df SS MS F S ignificance F Regression 1 8838.44377 8838.44377 30.9128379 0.00085098
Residual 7 2001.40494 285.914991
Total 8 10839.8487

Coefficients S tandard Erro t Stat P-value Lower 95% Upper 95% Intercept 253.982196 9.3261336 27.233386 2.3087E-08 231.929395 276.034998 Engine Size 0.06466166 0.01162994 5.55993147 0.00085098 0.03716122 0.09216209

SUMMARY OUTPUT - Capital Cost

Regression Statistics Multiple R 0.88999704 R Square 0.79209473 Adjusted R S 0.76239398
Standard Er r 72.3930199
Observation s 9

ANOVA
df SS MS F S ignificance F Regression 1 139766.49 139766.49 26.6691805 0.00130337
Residual 7 36685.2453 5240.74934
Total 8 176451.735

Coefficients S tandard Erro t Stat P-value Lower 95% Upper 95% Intercept 996.708476 39.928212 24.9625121 4.2234E-08 902.293257 1091.12369 Engine Size 0.25713456 0.04979155 5.16422119 0.00130337 0.13939626 0.37487286 $0 $50 $100 $150 $200 $250 $300 $350 $400

0 200 400 600 800 1000 1200 1400 1600 A n n u a l i z e d C o s t ( $ / y r )

Engine Size (HP) Annual Cost for Retrofit of Open Crankcase Ventilation

Total Annual Cost Regression Annual Cost

$0 $200 $400 $600 $800 $1,000 $1,200 $1,400 $1,600

0 200 400 600 800 1000 1200 1400 1600 C a p i t a l C o s t ( $ )

Engine Size (HP) Capital Cost for Retrofit of Open Crankcase Ventilation

Total Capital Cost Regression Capital Cost14 Appendix B

Contact Report15 

## CONTACT REPORT

Date/Time Project Name Project Number

November 20, 2009 10:00pm RICE NESHAP MME-304

EC/R Originator Contact Phone Number

Bradley Nelson Chuck Cook – Mid-Atlantic Engine Supply (800) 257-8133

General Subject

The purpose of the telephone call was to disc uss the feasibility of retrofitting existing stationary diesel engines with an open or cl osed crankcase ventilation system, and obtain equipment and installation costs for the retr ofit. I spoke with General Manager of the company who stated that their company had installed numerous open and closed crankcase ventilation systems on both stationary and no nroad engines. He stated that the OCV and CCV systems are the same products with the only difference being the installation kit needed to retrofit the unit. The OCV system is installed in the open crankcase ventilation port, whereas the CCV is installed somewhere along the crankcase exhaust line before it
reaches the intake manifold. He noted that en gines that are enclosed in a housing or other
shelter emit an oil mist from the crankcase that accumulates on the radiator and reduces the radiators effectiveness in cooling the engi ne. He noted that the Racor systems they sell reduce oil mist emissions by 95% using a filt ration system. The equipment costs for the
systems are;

CCV4500 Series – Maximum Flow 10 CFM (< 160 HP diesel engines) $500

CCV6000 Series – Maximum Flow 20 CFM (160- 800 HP diesel engines) $600

CCV8000 Series – Maximum Flow 40 CFM (> 800 HP diesel engines) $700

The filter needs to be replaced every 750 ho urs and the replacement cost is $45 for the 4500, $50 for the 6000, and $60 for the 8000. The contact also stated it takes roughly 1-2 hours for installation, therefore at $80 per ho ur, installation would cost roughly $160.

http://www.maesco.com/products/rac or/r_ccv_intro/r_ccv_intro.html