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Attachment A 

Reasonably Achievable Control 

Technology (RA CT) analysis 
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REASONABLY ACHIEVABLE CONTROL 

TECHNOLOGY ANALYSIS 

PHILAD . LPHI 

E ERGY S LUTI 

Philadelphia Energy Solutions Refining and Marketing, LLC. 

(PES). 

Reasonably Achievable Control Technology Analysis for the 

Heater Firing Rate Increase 

August 31, 2012 (Submittal) 

September 6, 2012 (Completeness Determination) 

September 2013 (Supplement) 

Environmental Resources Management 

75 Valley Stream Parkway 

Suite 200 

Malvern, Pennsylvania 19355 
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REASONABLY ACHIEVABLE CONTROL TECHNOLOGY ANALYSIS 1 

1.0 REASONABLY ACHIEVABLE CONTROL TECHNOLOGY ANALYSIS 1 

1.1 RACT ANALYSIS REQUIREMENTS 1 

1.2 RACT PLAN APPROVAL CHANGES 3 

1.2.1 Presumptive RACT Revisions 3 

1.2.2 Modifications to Unit 231-B101 and Unit 865-11H1 3 

1.2.3 Cessation of Refinery Fuel Oil Firing 4 

1.3 RACT COST EFFECTIVENESS CALCULA TIONS 6 

1.4 RAeT ANALYSIS RESULTS 7 

2.0 RACT PLAN APPROVAL PROPOSED CONDITIONS 8 

2.1 RACT CONTROL EQUIPMENT REQUIREMENTS 8 

2.2 RACT IMPLEMENTATION SCHEDULE 8 

2.3 RACT TESTING REQUIREMENTS AND STACK EMISSION 

LIMITATIONS 8 

2.4 RACT RECORDKEEPING AND REPORTING REQUIREMENTS 9 

List of Tables 

Table 1-1 25 Pa Code §129.92(b) RACT Requirements 

Table 1-2 Proposed RACT Plan Approval Conditions for Unit 231-BI01 and 

Unit 865-11H1 

Table 1-3 

Table 1-4 

Table 2-1 

List of Appendix 

Appendix A 

ERM 

NOx Emissions Reductions from Cessation of Refinery Fuel Oil 

Firing 

Summary of RA CT Plan Approval Revisions 

RACT Plan Approval Existing and Proposed Limits 

RACT Cost Effectiveness Analysis 

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1.0 

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1.1 

REASONABLY ACHIEVABLE CONTROL TECHNOLOGY ANALYSIS 

The Sunoco, Inc. (R&M)l Girard Point Processing Area and Point Breeze 

Processing Area RACT Plan Approval amended on October 7, 2002 was 

established for nitrogen oxides (NOx) and volatile organic compounds 

(VOCs) and limits the firing rate on the heaters to comply with the RACT 

regulatory requirements codified in 25 Pa Code §129.91 through §129.95. 

This application addresses changes to certain NOx RACT conditions2

• No 

changes to VOC RACT conditions are requested. With this application, 

the Refinery proposes to remove the firing rate limits in the RACT Plan 

Approval for seven target heaters: 

• Unit 231-BIOI Heater; 

• Unit 865-11H1 Heater; 

• Unit 865-11H2 Heater; 

• Unit 21O-H101 Heater; 

• Unit 210-H2OI Heater; 

• Unit 866-12H1 Heater; and 

• Unit 868-8HIOI Heater. 

RACTANALYSffiREQUIREMENTS 

As described in 25 Pa Code §129.92(b), each RACT Analysis must include 

the requirements listed in Table 1-1 below. 

1 The Sunoco Philadelphia Refinery is now owned and operated by Philadelphia Energy Solutions 

Refining and Marketing, LLC (PES). 

2 The RACT Plan Approval revisions to the target heater firing rate or emission limits are not 

being requested by PES to comply with any requirements of Consent Decree No. 05-02866 

(Fourth Amendment, dated August 17, 2012). 

ERM 1 PES RAG ANALYSIS/SEPTEMBER 2013 

Table 1-1 25 Pa Code §129.92(b) RAeT Requirements 

25 Pa Code §129.92(b) 

Requirement 

A ranking of the available control 

options for the affected source in 

descending order of control 

effectiveness.1 

An evaluation of the technical 

feasibility of the available control 

options identified based on physical, 

chemical and engineering principles. 

A determination of technical 

infeasibility should identify technical 

difficulties restricting the successful 

use of the control option on the 

affected source. 

A ranking of the technically feasible 

control options in order of overall 

control effectiveness for NO, 

emissions. 

The baseline emissions of NO, before 

implementation of each control 

option ("pre-control emissions"). 

The estimated emission reduction 

potential or the estimated control 

efficiency of each control option. 

The estimated emissions after the 

application of each control option 

("post-control emissions"). 

An evaluation of cost effectiveness of 

each control option consistent with 

EPA's cost guidance manuals. The 

cost effectiveness shall be evaluated 

in terms of dollars per ton of NO, 

emissions reduction. 

Discussion 

• Ultra-low NO, burners (ULNB) and Selective Catalytic 

Reduction (SCR)-96% 

• Selective Catalytic Reduction - 85% 

• Ultra-low-NO, burners - 66 to 76% 

• Low-NO, burners and Selective Non-Catalytic Reduction 

(SNCR) -70% 

• Low-NO, burners (LNB) and FIue Gas Recirculation (FGR) 

- 55% 

• Selective Non-Catalytic Reduction - 40% 

• Unit 865-11 HI - The installation of SCR is not possible as 

there is not adequate plot space available; further, there is 

not adequate pressure to overcome the SCR pressure drop; 

therefore, SCR is infeasible. FGR installation would 

require the installation of mechanical draft burners, which 

is a major re-design of the unit; therefore FGR is infeasible. 

• Unit 21O-HI01 - FGR would not physically fit the plot 

space; therefore, it is infeasible. 

• Unit 210-H20I - The installation of SCR is not possible as 

there is not adequate plot space available; further, there is 

not adequate pressure to overcome the SCR pressure drop; 

therefore, SCR is infeasible. FGR installation would 

require the installation of mechanical draft burners, which 

is a maj()T re-design_ofthe unit; therefore FGR is infeasible. 

The RACT summary in Appendix A for each target heater 

ranks the technically feasible controls options by listing them 

from highest to lowest control effectiveness. 

The "pre-control emissions" are listed in the "Potential 

Emissions (fPY)" column for each target heater in the RACT 

summary for each heater in Appendix A. 

The estimated emission reduction potential for each control 

option for each target heater is listed in the "Potential NO, 

: Reduced (fPY)" column in the RACT summary for each 

heater in Appendix A. These values based on design firing 

for each heater. 

The "post-control emissions" are listed in the "Maximum 

Post Control Emissions @ Design Firing (fPY)" column for 

each target heater in the RACT summary for each heater in 

Appendix A. 

See Appendix A for the RACT Cost Effectiveness Analysis. 

1 NO, control effectiveness derived from Alternative Control Techniques Document NO, Emissions 

from Process Heaters (Revised) - EPA Emissions Standards Division - EP A-453JR-93-034 and 

Refinery process knowledge. 

ERM 2 PES RACT ANA L YSlS/SEPTEMBER 2013 
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1.2 

1.2.1 

1.2.2 

RACT PLAN APPROVAL CHANGES 

PES is requesting changes to the RACT Plan Approval including updates 

to presumptive RACT sources and updates to previous RACT 

determinations on select heaters. For this RACT analysis and future 

RACT analyses, PES is requesting that the RACT determinations focus on 

identifying specific NOx control technology requirements and pollutant 

emission rates (lb/MMBtu) as RACT. Previously the RACT 

determinations were identified as hourly firing rate limits (MMBtu/hr) 

and pollutant emission rates. The basis for the RACT analysis, provided 

here, now relies on design firing for all heaters. 

A summary of requested RACT Plan Approval revisions are found in 

Table 1-4 at the end of this section. 

Presumptive RACT Revisions 

Three of the target heaters, Unit 865-11H2, Unit 866-12H1, and Unit 

868-8H101, previously had firing rate limits less than 50 million British 

thermal units per hour (MMBtu/hr) and were therefore subject to 

presumptive RACT NOx controls established under 25 Pa Code §129.93. 

Presumptive RACT required the use of combustion tuning rather than 

physical controls. Because these three heaters are seeking annual 

equivalent firing rate limits over 50 MMBtu/hr, PES has provided a 

Case-by-Case RACT analysis in Appendix A for these heaters as a part of 

this plan approval application along with the other target heaters. 

Modifications to Unit 231-B101 and Unit 865-11Hl 

Ultra-low NOx burners (ULNBs) are planned to be installed on Unit 

231-B101 and Unit 865-11HF PES proposes that the RACT Plan Approval 

be revised to keep the current RACT limits for hourly firing limit 

(MMBtu/hr) and NOx emission rate (lb/MMBtu) in place until the 

installation of the ULNBs are complete. A new permit condition should 

be included in Section 2 of the RACT Plan Approval to only allow the 

removal of the hourly firing limits for the Unit 231-B101 and Unit 

865-11H1 heaters after the ULNBs have been successfully installed and 

stack test results show that the heaters meet the specified NOx emission 

rate (0.03Ib/MMBtu). See the proposed RACT limits in Table 1-2 below. 

3 As part of a settlement agreement with the Clean Air Council, PES agreed voluntarily to install 

ultra-low NO, burners on Unit 231-8101 Heater and Unit 865-11H1 Heater at the Refinery to 

further reduce emissions beyond the cuts achieved by the shut-down of the Marcus Hook 

Refinery. 

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Table 1-2 

1.2.3 

Proposed RACT Plan Approval Conditions for Unit 231-B101 and Unit 

865-11H1 

Heater : Hourly Firing Limit 

(MMBtujhr) 

NO. Emission Rate 

(lb/MMBtu) 

RACTNOx 

Control 

RACT Plan Approval Conditions Pending ULNB Installation ...... _ ............... _ .....................•..... 

Unit 23l-BIOI 91 0.122 (refinery fuel gas) Combustion Tuning ---.... ~.---.---- .-~ ............... -.. . ..... ~-............ -..•........ - .. --.. ---..... ---

Unit 865-l1Hl 

Unit 23l-BIOI 

Unit 865-UHl 

0.113 (refinerv fuel .. 

72.2_~ __ gaWO.~ (refinery fuel ~_ .. COrnb~s~on _Tu~g .. 

Proposed Conditions after ULNB Installation and Testing 

0.03 (refinery fuel gas) 

0.03 (refinery fuel gas) 

Combustion Tuning 

Combustion Tuning 

Cessation of Refinery Fuel Oil Firing 

As discussed under Section 110(1) of the Clean Air Act, while the changes 

to the RACT Plan Approval include removal of firing rates of seven 

heaters, the RACT Plan Approval will still provide reasonable further 

progress toward ozone attainment because PES is also requesting removal 

of the ability for fuel oil firing for five of the seven heaters. Typically 

refinery fuel oil firing NO. emission rates are higher than gaseous 

fuel-firing NO. emission rates. 

Table 1-3 below shows the change in NO. maximum emissions, based on 

the RACT limits for the target heaters based on the removal of the ability 

for fuel oil firing. The current oil firing NO. emissions rate limits and 

hourly firing limits (MMBtu/hr) as well as the proposed gaseous 

fuel-firing NO. emission rate limits and design firing (MMBtu/hr) for five 

of the target heaters were used to determine the total reduction in 

maximum NO. emissions associated with the proposed RACT limit 

changes. This reduction in emissions provides reasonable further 

progress toward ozone attainment. 

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C Table 1·3 NOx Emissions Reductions from Cessation of Refinery Fuel Oil Firing 

Existing Oil Firing Gas Firing 

Hourly Emission Current Design Proposed : Proposed: Change Firing RACf Firing Emission RACf Target Heater Limit Limit NOx (MMBtuj Limit NOx inNOx 

(MMBtuj (lbNOJ (TPY) hr) (lbNOJ (TPY) (TPY) 

hr~ MMBtu) MMBtul 

Unit 865-11Hl 72.2 0.400 126.5 87.3 0.030 11.5 -115.0 

Unit 865-11H21 49.9 0.113 24.7 64.2 0.113 31.8 7.1 

Unit 210-HI0l 183.0 0.400 320.6 192.0 0.089 74.8 -245.8 

Unit 21 ()"H201 242.0 0.400 254.0 0.030 33.4 -390.6 -""~,,---.,--.. - .. -.~.-"" ...... -.-... - 

__ __ "'''M'_'_'_'' __ '''''''''' ___ 

Unit 866-12Hl 1 43.0 0.113 21.3 61.2 0.113 30.3 9.0 

Total Target Heater NOx RACf Reduction (fFY) I -735.3 

1 Note that Unit 865-11H2 and Unit 866-12Hl are currently complying with the presumptive RACf limits and do not 

have oil firing NO. emission limits. Conservatively, the proposed gas firing NO, emission limit of 0.113 

Ib/MMBtu was assumed as the oil firing emission limit for this analysis. 

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Table 1-4 

1.3 

Summary of RACT Plan Approval Revisions 

Section 

Section 1.A(2) 

Section 1.A(l1) 

Section 1.A(15) 

Revisions Requested 

I Revise firing duty of Unit 231-B101 to 104.5 MMBtu/hr. I .. . .. 

Revise firing duty of Unit 210-HIOI to 192 MMBtu/hr. Revise firing duty of 

Unit 210-H201 to 254 MMBtu/hr. Revise the section to remove the firing of 

refinery fuel oil. 

Revise firing duty of Unit 865-11Hl to 87.3 MMBtu/hr. Revise firing duty 

of Unit 865-11H2 to 64.2 MMBtu/hr. Revise the section to remove the firing 

of refinery fuel oil. ----.··-·········· .• ··.-t·····························...... -............................. .. ........................................................ - ....... - .•••••........... -.......... . 

Section 1.A(16) Revise firing duty of Unit 866-12H1 to 61.2 MMBtu/hr. Revise the section 

I to remove the firing of refinery fuel oil. 

Section 1.A(19) I Revise firing duty of Unit 868-8HI01 to 60.0 MMBtu/hr . • ____ """"_"_ •• 

___ O>_ 

Section 1.B(l) Add control technology for Unit 21O-H201 (ultra-low NO, burners). 

Section2.A 

Section 2.B 

Section 2.C 

New paragraph 

in Section 2 

Add description that ultra-low NO, burners are planned to be installed on 

Unit 231-BI01 and Unit 865-11H1. Installation will be completed after 

issuance of plan approval. 

. Include combustion tuning as RAG for Unit 865-11H2 and Unit 868-8HIOI. 

I Removal of the heat input caps (MMBtu/hr) for Unit 231-BI01 and Unit 

I 21O-H201. 

Add control technologies for Unit 21O-H101 (low NO, burners) and Unit 

I 210-H201 (ultra-low NO, burners). 

New paragraph . Add description that original RAG limits apply until the installation of 

in Section 3 ultra-low NO, burners on Unit 231-BI01 and Unit 865-11Hl. 

Section 4.B 

Section4.C 

Add description that NO, RACT emissions limit for Unit 21O-H201 has been 

established using CEMS. 

Removal of Unit 231-B101 and Unit 865-11Hl Heaters from the table as 

compliance will be demonstrated through performance testing. _____ .. ~"_"~~.mm_·· ___ ............. ,,,"' .. _ .... ,, __ 

Section4.C 

Section4.C 

Updates to add NO, emission rate for Unit 865-11H2, Unit 866-12Hl, and 

Unit 868-8H101. 

Updates to NO, emission rate for Unit 21O-H201 Heater and removing 

refinery fuel oil firing NO, emission limitations for Unit 210-H101 and Unit 

210-H201. 

RACT COST EFFECTIVENESS CALCULATIONS 

In this application, the cost effectiveness calculations for the RACT 

analyses were based on the EPA guidance document entitled AlternatilJe 

Control Techniques Document· NOx Emissions from Process Heaters (Revised) -

EPA-453/R-93-034. PES also used cost information from past Refinery 

ULNB installations on two heaters (Unit 1332 H-400/H-401 Heater and 

Unit 137 F-3 Heater). These costs - capital and operation and maintenance 

(O&M) - were scaled up to 2012 dollar amounts using Chemical 

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1.4 

Engineering cost indices. PES has also conducted the analysis at the 

current cost of borrowing capital. 

As PES is a recently established company under new ownership in a 

private equity structure, the cost of borrowing capital (the minimum 

return that investors expect for providing capital to the company) is 

considered at a higher risk than many established companies. The cost 

effectiveness analysis reflects the current cost of capital for PES, which is 

21.83%. 

RAeT ANALYSIS RESULTS 

The RACT cost effectiveness for the subject heaters are calculated at 

approximately $6,700 to $163,000 per ton of NOx emissions reductions for 

additional controls beyond those considered part of current heater design 

and operation. The RACT analysis leads to the following conclusions: 

• The Unit 210-H101 Heater already has LNB installed4

; however, the 

installation of current generation UNLB is not cost effective. 

• Unit 210-H201 has NOx control today at a permit limit of 0.03 

lb / MMBtu, and no further control is deemed to be cost effective as 

indicated by the RACT analysis. 

• With the planned installations of ULNBs on Unit 231-B101 and Unit 

865-11H1, as indicated by the RACT analysis, no other control 

technologies are found to be cost effective. 

• As illustrated in Appendix A, for the remaining heaters, additional 

retrofit NOx control options beyond combustion tuning are not cost 

effective. Therefore, combustion tuning is RACT for these heaters. 

4 Burners were considered UNLB when installed, but referred to here as LNB to avoid confusion. 

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2.0 RACT PLAN APPROVAL PROPOSED CONDITIONS 

Based on this RACT analysis, including the RACT cost effectiveness 

analysis completed in Appendix A, PES is proposing RACT for the seven 

target heaters as described below. Table 2-1 at the end of this section 

shows the existing and proposed RACT Plan Approval limits. 

2.1 RACT CONTROL EQUIPMENT REQUIREMENTS 

Combustion tuning will be RACT for the following heaters: Unit 231-BI01 

Heater, Unit 865-11Hl Heater, Unit 865-11H2 Heater; Unit 210-HI0l 

Heater; Unit 210 H-201 Heater; Unit 866-12Hl Heater; and Unit 868-8HI0l 

Heater as well as compliance with the RACT NOx emission rate limit for 

each heater listed in Table 2-1. 

2.2 RACT IMPLEMENTATION SCHEDULE 

Sources in Table 2-1 below proposing combustion tuning to comply with 

RACT requirements of 25 PA Code 129.91(f) shall perform quarterly 

combustion tuning. 

2.3 RACT TESTING REQUIREMENTS AND STACK EMISSION 

LIMITATIONS 

After installation of the ULNB on the Unit 231-B101 and Unit 865-11Hl 

Heaters, PES shall conduct a one-time performance tests for NOx• The 

results of these tests will be submitted to AMS. 

The final NOx RACT emission limits for the Unit 210-H201 Heater shall be 

established through the use of the Department-approved Continuous 

Emission Monitoring System (CEMS) currently installed. Compliance 

with the limitation listed in Table 2-1 below for Unit 210-H201 will be on a 

365-day rolling average based on hourly averages of CEM data. 

Compliance with emission limits for the Unit 210-H101, Unit 865-11H2, 

Unit 866-12H1, and Unit 868-8HI01 Heaters shall be determined by 

quarterly stack sampling with a portable NOx analyzer. After one year 

sampling, PES may petition AMS for semi-annual monitoring . 

ERM 8 PES RACT ANALYSIS/SEPTEMBER 2013 
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All annual combustion tuning shall at a minimum meet the requirements 

set forth in 25 PA Code 129.93 (b)(2) through (5). 

At least thirty (30) days prior to a performance NOx test, PES shall inform 

AMS of the date and time of the scheduled test. 

RACT RECORDKEEPING AND REPORTING REQUIREMENTS 

PES shall maintain a file containing all the records and other data that are 

required to be collected to demonstrate compliance with NOx RACT 

requirements of 25 PA Code 129.91-129.94. 

The records shall provide sufficient data and calculations to clearly 

demonstrate that the requirements of §129.91-129.94 are met. 

Data or information required to determine compliance shall be recorded 

and maintained in a time frame consistent with the averaging period of 

the requirement. 

Records shall be retained for a t least two years and shall be made 

available to the Department on request. 

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Table 2-1 

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RACT Plan Approval Existing and Proposed Limits 

Existing Emission Rate Limit (lb NOJMMBtu) RACT Control 

Unit Hourly Firing Design Firing Exist!!,g3_ . P!()posed 4 Limit (MMBtu/hr) Existing' Proposed (MMBtu/hr) 2 Gas Oil Gas Oil 

Unit 231-B101 91 104.5 0.122 ! 0.03 1 Tuning j Tuning 5 ) 

runing 

Tuning 

183 192.0 0.089 0.400 0.089 Tuning Tuning 6 

Unit 210-H201 242 254.0 0.173 OAOO 0.03 Tuning Tuning 6 

Unit 866-12Hll 43 61.2 0.113 Tuning 

Unit 868-8HI01 1 I 49.5 60.0 0.113 Tuning ! 

1 Units are currently subject to PADEP's presumptive RACT and not subject to specific requirements in the RACT Plan Approval. 

2 Compliance with limitation is based on the daily average heat input. 

3 Compliance with limitation is based on quarterly stack sampling using a portable NO, analyzer. 

4 The Refinery is only proposing limits for firing natural gas at the target heaters. The Refinery no longer uses refinery fuel oil as a fuel 

for the Unit 865-11 HI, Unit 21 O-H 101 , and Unit 210-H201 heaters and proposes to remove the capability to use refinery fuel oil as a 

fuel from the RACT Plan Approval. For Unit 210-H201, compliance with the emission rate limit will be through the use of 

Department-approved CEMS currently installed. For heaters other than Unit 210-H201, compliance with limitation is based on 

quarterly stack sampling using a portable NO, analyzer. 

5 PES is proposing that the current RACT Plan Approval conditions remain in place and the hourly firing rate limits can only be 

removed after the installation and testing of the ULNBs at Unit 231-BIOI and Unit 865-11H1. 

6 Control equipment is currently installed; however only combustion tuning is currently required as RACT control for these units in 

the RACT Plan Approval. The proposed emission rate limits also reflect the presence of control equipment. 

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CITY OF PHILADELPHIA 

DEPARTMENT OF PUBLIC HEALTH 

AIR MANAGEMENT SERVICES 

RACT PLAN APPROVAL 

Effective Date: August 1, 2000 

Amended Date: October 7, 2002 

Expiration Date: None 

r These amendments will update RACT requirements for 

J£ sources affected in the Heater Firing Rate Increase Plan 

Approval. 

Replaces Permit No. None 

In accordance with provisions of the Air Pollution Control Act, the Act of January 8, 1960, 

P.L. 2119, as amended, and after due consideration of a Reasonably Available Control 

Technology (RACT) proposal received under the Pennsylvania Code, Title 25, Chapter 

129.91 thru 129.95, of the rules and regulations of the Pennsylvania Department of 

Environmental Protection (PADEP), Air Management Services (AMS) amended the RACT 

Plan Approval of the Facility below for the source(s) listed in section 1.A. Emission Sources 

of the attached RACT Plan Approval. 

Facility: 

Owner: 

Location: 

Mailing Address: 

SIC Code(s): 

Plant 10: 

Facility Contact: 

Phone: 

Permit Contact: 

Phone: 

Responsible Official: 

Title: 

Sunece, InG. (R & fiAl. 

Sunece, Incl.. 

Girard Point Processing Area located at 3001 Penrose Ave 

Point Breeze Processing Area located at 3144 Passyunk Ave 

3144 Passyunk Ave., Philadelphia, PA 19145 

2911 

1501 and 1517 

Vincent J. Kelley..4-

Refinery ManageFi. 

Edward Braun, c'hief of Sou-;:ce Registration 

/tblc~ Dat~ 
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RACT PLAN APPROVAL Stlftoee, lae. (R&M1. Page 2 

C The RACT plan approval is subject to the following conditions: 

I. The purpose of this Plan Approval is to establish Nitrogen Oxides (NOx)Nolatile Organic Compound (YOC) Reasonably 

Available Control Technology (RACT) for StiReea, IRe. (R&M) ... Girard Point Processing Area and Point Breeze Processing 

Area. This includes the following emission sources and control equipment: 

A. Emission Sources 

(I) Process Heaters: Unit 137: FI heater (415 MMBTUlhr) 

F2 heater (155 MMBTUlhr) 

F3 heater (60 MMBTUlhr) 

Process heaters FI and F2 bum refinery fuel gas or refinery fuel oiL Heater F3 bums refinery fuel oil. 

(2) Process Heater: Un it 231: B-1 0 I heater (%. MMBTUlhr) Heater fires refinery fuel gas. 

(3) Process Heater: Unit 433: H-l heater (243 MMBTUlhr) Heater fires refinery fuel gas. 

(4) Process Heaters: Unit 1332: H-400 heater (186 MMBTUlhr) 

H-401 heater (233 MMBTUlhr) 

H-600 heater (21.3 MMBTUlhr) 

H-60 I heater (48 MMBTu/hr) 

H-602 heater (49 MMBTUlhr) 

H-I heater (45 MMBTUlhr) 

H-2 heater (60 MMBTUlhr) 

H-3 heater (43 MMBTUlhr) 

These heaters bum refmery fuel gas. 

C (5) Process Heater: Unit 1232: B- I 04 heater (70 MMBTUlhr) Heater fires refinery fuel gas. 

c 

(6) Boiler House #3: Boiler #37 (495 MMBTUlhr) 

Boiler #38 (495 MMBTUlhr) 

Boiler #39 (495 MMBTUlhr) 

Boiler #40 (660 MMBTUlhr) 

These boilers fire refinery fuel gas or refinery fuel oiL 

(7) Sludge Incinerator 8832: Unit was 44 MMBTUlhr and burned refinery fuel gas or refinery fuel oiL 

(8) Sulfur Recovery Unit 532: S02 incinerator was 16 MMBTUlhr. Unit burned refinery fuel gas. 

(9) 1232 FCCU CO Boiler: CO waste gas combustion unit (580 MMBTUIhr) bums process waste gas, refinery fuel 

gas and refinery fuel oil. 

(10) Asphalt Heater: HI (12.8 MMBTUlhr) 

H2 (12.8 MMBTUlhr) 

H3 (12.8 MMBTUlhr) 

H5 (12.8 MMBTUlhr) 

These heaters burned fire refinery fuel gas. 

(I I) Crude Unit 210: Section A HTR HIOI (+8iMMBTU/hr) 

Section B HTR H201 (~MMBTu/hr) 

Section C HTR 13H I (135.4 MMBTUihr) 

These heaters above fire refinery fuel gas aHa refiRe!,), fuel oil. 
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RACT PLAN APPROVAL Stlft6e6, hie. (R&Ml. 

(12) Hydrocracker Unit 859: HTR I H I (76 MMBTUlhr) Unit fires refinery fuel gas and refinery fuel oil. 

(13) Reformer Unit 864: 

HTR I H2 (70 MMBTUlhr) Unit fires refinery fuel gas and refinery fuel oil. 

HTR I H3 (21 I MMBTUlhr) Unit fires refinery fuel gas and refinery fuel oiL 

HTR I H4 (19 MMBTUlhr) Unit fires refinery fuel gas. 

HTR PH3 (80 MMBTUlhr) 

HTR PH5 (90 MMBTUlhr) 

HTR PH I (80 MMBTUlhr) 

HTR PH2 (45 MMBTUlhr) 

HTR PH4 (57 MMBTUlhr) 

HTR PH7 (45.5 MMBTUlhr) 

HTR PH 11 (74 MMBTUlhr) 

HTR PHI2 (85.1 MMBTUihr) 

These heaters fire refrnery fuel gas and refinery fuel oil. 

(14) Hydrogen Plant 861: HTR 3HIS (123 MMBTWhr) 

HTR 3HIN (125 MMBTUlhr) 

These heaters burned refinery fuel gas. 

(I 5) Distillate HDS Unit 865: HTR IIHI (72.2,..MMBTUlhr) 

HTR IIH2 (~MMBTUlhr) 

These heaters fire refinery fuel gas !tAd refinery fuel oil. 

(16) Gas Oil HDS Unit 866: HTR 12H I (4lMMBTUlhr) Heater fires refinery fuel gas aAa refiAery fuel oil. 

(17) 22 Boiler House: Boiler # I (169 MMBTUlhr) 

Boiler #2 ( 169 MMBTUlhr) 

Boiler #3 (203 MMBTUlhr) 

Page 3 

These three boilers bum only refrnery fuel gas or natural gas and are equipped with Ultra Low NOx 

Burners. 

(18) Reformer Unit 860: HTR 2H3 (174.67 MMBTUlhr) Unit fires refinery fuel gas and refinery fuel oil. 

HTR 2H5 (155 MMBTWhr) Unit fires refinery fuel gas and refinery fuel oil. 

HTR 2H I (49 MMBTUlhr) Unit fires refinery fuel gas and refinery fuel oil. 

HTR 2H2 (69.78 MMBTUlhr) Unit fires refinery fuel gas and refrnery fuel oil. 

HTR 2H4 (99.44 MMBTUlhr) Unit fires refinery fuel gas and refinery fuel oil. 

HTR 2H6 (36.7 MMBTUlhr) Unit fires refinery fuel gas and refrnery fuel oil. 

HTR 2H7 (59 MMBTUlhr) Unit fires refinery fuel gas and refinery fuel oiL 

HTR 2H8 (49.6 MMBTUlhr) Unit fires refinery fuel gas and refinery fuel oiL 

Boiler 2H9 (165 MMBTUlhr) Unit fires refinery fuel gas or natural gas. 

(19) 868 FCCU HTR SHIOI (~MMBTUlhr) Unit fires refinery fuel gas. 

(20) 868 FCCU Catalyst Regenerator 

(21) 867 Sulfur Recovery Unit Incinerator 

(22) Emergency Flares 

(23) Cooling towers 

(24) Fugitive leaks: valves. flanges. compressors. pumps, pipes. 

B. Control Equipment 
J 
MCT PLAN APPROVAL Sl:IB6ee. lac. (R&Mi Page 4 

(I) Ultra-low NOx burner (ULNB) systems are installed on the following sources to control NOx emissions: 

Unit 433 H-I heater 

Un it 1::!3 2 B- 104 heater 

#3 Boiler House boilers #37. #38. #39. and #40. 

-E: IUnit 21 0-H201 

2. This approval requires and authorizes: 

A. The installation of the Ultra Low NOx Burners on 433 H-I heater. l::!32 B-104 heater. and #3 Boiler House boilers 

#37, #38. #39, and #40 to comply with RACT requirements. The installation of the burners has been completed. 

B. 1rtr.~l.l!ml!.lIbustion tuning to comply with RACT requirements for the following heaters: 

Unit 137: FI heater, F2 heater, F3 nea-I:'ef--_ 

Unit 231: B-1 0 I heater 

Unit 1332: H-400 heater, H-40 I heater, H·2 heater 

r.-~~--~~~~~--~~~~----~ Add description that ultra-low NOx burners 

are planned to be installed on Unit 231-

-- '8101 and Unit 865-11H1. Installation will 

Crude Unit: 2 lOA HTR HlOI, 210B HTR H201, 210C HTR 13HI be completed after issuance of plan 

Hydrocracker Unit 859: HTR IHI, HTR IH2, HTR IH3 approval. 

Reformer Unit 864: HTR PH3, HTR PH5, HTR PH I, HTR PH2, H"".:.m:l'lI""""t:l'T1T""I:rc:n.,..-;t:rr1T"C0l'fT..,------------I 

Hydrogen Plant 861: HTR 3 HI S, HTR 3 HI N 

Distillate HDS Unit 865: HTR II H I 

Reformer Unit 860: HTR 2H3, HTR 2H5, HTR 2H4, HTR 2H2, HTR 2H7 

Gas Oil HDS Un it 866: H~~:,-P ... H~J(.::t4 ... 3 ~M~M~Bu.T:'-I!~Ih'_':'r..L) =-=--:-:-:=--:--:-:--:-=-_...,....,-:-=--:::--:-:-~_:___=_:::___:_:_:=__:_,....,...,_:::_~ 

< {DIstillate HDS Unit 865: HTR 11 H2 and HDS Unit 868: HTR 8H101 

c. All fuel burning sources will be capped at the heat input specified in the table below. If ~ desires to raise the 

cap, a RACT evaluation will have to .be performed at that new heat input. The economic evaluation will be made 

using cost of living increases. Changes will require a resubmission as revision to the PA State Implementation Plan. 

The applicant shari bear the cost of public hearing and notification required for EPA approval as stipulated in 25 PA 

Code §129.9(h). Modifications or changes may require additional controls or more strict emission limits depending 

on the appl icable regulation triggered as a result of the modification or change. 

I 

Heat Input 

Cap 

Process Unit Source (MMBTUlhr) 

Unit 137: FI heater 415 

F2 heater 155 

Yflit i!31: B IQI J:te,*ef 9-l 

Unit 433: H-I heater 243 

Unit 1332: H-400 heater 186 I 

Unit 1232: B-\ 04 heater 70 

Boiler House #3: Boilers #37, #38. #39 495 

Boiler #40 660 

bfl:lae Idflit i! I QB: H:t=R: Hi!Q I ~ 

I 

Hydrocracker Unit 859: HTR IHI 76 

HTR IH2 70 

I Reformer Unit 864: HTR PH3 80 

I HTR PHS 90 

. HTR PH2 45 

I HTR PH4 57 ! 

Hydrogen Plant 861 : HTR 3HlS p" _:> 

HTR 3HIN 125 

D. ~shall monitor all fuel input to all heaters and boilers with BTU limitations on a daily basis to insure capacity 

limits are not exceeded or Stlftshall install fuel limiting devices on the heaters or boilers to keep capacities below 

allowable. The compliance method must be in place by June 30'h 2000. 
J 

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J 
RACT PLAN APPROVAL S\ffi6e9, Iae. (R&Ml. Page 5 

E. All fuel combustion sources with heat input equal to or greater than 20 MMBTUlhr and less than 50 MMBTUlhr shall 

comply with applicable presumptive RACT requirements of 25 PA Code 1 29.93(b)(2)-(5). All fuel combustion 

sources with heat input less than 20 MMBTUihr shall comply with presumptive RACT requirements of 15 PA Code 

129.93(c). 

F. RACT for 22 Boiler House: Boiler # I. Boiler #2, and Boiler #3 is combustion tuning. 

G. RACT for Reformer Unit 860 HTR 2H9 is combus£ion tuning. 

H. The 868 FCCU NOx emissions shall be limited to 569 tons per year calculated on a 365 day rolling average basis. 

Smt shall follow good combustion practices controlling the level of excess oxygen and CO promoter in the 

regenerator to minimize NOx emissions from the regenerator. 

J. ~ shall utilize an inspection and maintenance/monitoring program for VOC fugitive emissions from cooling 

towers. 

K. ~ shall utilize a fugitive emissions leak detection and repair program (LDAR) for all valves, pumps, flanges, 

and compressors in VOC service. All applicable equipment shall be tagged by May 31, 1995. Monitoring of 

components shall begin by July 31, 1995 and shall be conducted on a quarterly basis (gaseous service) and an annual 

basis (liquid service) for all sources not covered under an existing LDAR program. 

L. The 1232 FCCU CO Boiler: CO waste gas combustion unit (580 MMBTUlhr) shall comply with the presumptive 

RACT requirements of15 PA Code 129.93(c)(4). which is installation, maintenance and operation of the source in 

accordance with manufacturers specifications. ( ~A~d~d-c-o-n-tr-o~lt-e-c~hn-o~lo-g~i-es~fu-r~U~n~it-2~1~0~-~H~1~0~1~(I-ow~N~O~x-----' 

3. RACT Implementation Schedule burners) and Unit 21 0-H201 (ultra-low NOx burners ). 

A. Upon issuance of this approval, StlReee, hIe. (R&M), IR9, shall begin immediate implementation of the measures 

necessary to comply with the approved RACT proposal. 

B. s proposing combustion tuning to comply with RACT requirements of25 PA Code 129.91(f) shall perform the 

annual c ustion tuning by December 31 st of each year not to exceed 12 months between tunings. 

C. Sources applicable resumptive RACT requirements of 25 PA Code 129.93(b)(2) shall complete the annual 

adjustment or tune-up by ember 31" of each year not to exceed 12 months between tunings. 

D. Sources proposing installing Ultra Lo Ox Burners to comply with RACT requirements of 25 PA Code 129.9l(f) 

shall perform combustion tuning annually I:) ecem Add description that original RACT limits apply until the 

4. Testing Requirements and Stack Emission Limitations 

installation of ultra-low NOx burners on Unit 231-8101 

and Unit 865-11H1. 

A. For units installing ULNB. ~shall conduct performance tests for NOx. The results of these tests have been 

submitted to AMS. 

B. The final NOx RACT emission limits for the #3 Boiler House boilers. 137 Unit FI heater, #22 Boiler House boilers: 

#1,2, & 3 and the 860 unit Boiler 2H9 have been established through the use of Department approved Continuous 

Emission Monitoring System (CEMS). Compliance with the limitation listed below will be on a 30 day rolling 

average ba se d h on our I y averages 0 fCEM d a t a. 

Source I Limitation 

Boiler House #3 - boilers #37, #38, #39, and #40 I 0.330 Ibs. NOxlMMBTU 

137 Unit FI heater 

Reformer Unit 860 Boiler 2H9 

#22 Boiler House boilers # I, #2. and # 

C. Complia nce with emission limi£s for combustion so 

with a p 

AMS m 

separate 

ortable NOx analyzer. After one year sa 

ay. at any time. require three one-hour s 

Iy. AMS may. at any time. require three 0 

! 0.230 Ibs. NOxiMMBTU 

I 0.20 Ibs. NOxlMMBTU 

• 0.20 Ibs. NOx/MMBTU 

rces listed below shall be determined by quarterly stack sampling 

flpling, ~may pe£ition AMS for semi-annual monitoring. 

llck tests per fuel type for each unit where fuels can be fired 

e-hour stack tests for dual-fuel type combustion sources where 

Add description that !\lOx RACT emission limit for Unit 

L 210-H201 has been established based on a rolling 

365-day average using CEMS. 
J 

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J 
RACT PLAN APPROVAL Sl:Ifleee. IRC. (R:&Ml. Page 6 

both fuels must be fired at the same time and compliance with emission limits will be through the use of one set of 

three one-hour stack tests. 

Limitation (lbs. NOxlMMBTU) 

Source ~ Gas Oil 

Process Heater Unit 433 n-l ~ 0.060 N/A 

Add NOx emission Process Heater Unit 1332 H-400 heater 

--...Q..156 N/A 

Process Heater Unit 1332 H-401 heater 0.156 -- ~ rate for Unit 

Crude Unit 2IOA HTR HIOI 0.089 G4 - 865-11 H2, Unit 

Crude Unit nOB HTR H20 I ~ G,4 866-12H1, and Unit 

Crude Unit ZIOC HTR 13HI 0.104 OA 868-8H101 

Hydrocracker Unit 859 HTR 1 H3 0.134 0.4 

Hydrogen Plant 861 HTRJ HIS 0.133 N/A 

Hydrogen Plant 861 HTR3H 1 N 0.133 N/A 

F-2 @ 137 Unit 0.257 OA 

F-3 @ 137 Unit N/A OA 

8 HH@231 YRit ~ Nf.A 

H-Z @ 1332 Unit 0.300 N/A 

B·I04@ 1232 Unit 0.177 N/A 

IH-I @ 859 Unit 0.123 OA 

I H-2 @ 859 Unit 0.123 0.4 

PH-3 @ 864 Unit 0.284 0.4 

PH-5 @ 864 Unit 0.283 OA 

PH-I @ 864 Unit 0.167 0.4 

PH-4 @ 864 Unit 0.102 OA 

PH-II @ 864 Unit 0.145 0.4 

PH-12 @ 864 Unit 0.119 0.4 

II W I @ Sa§ YRi~ G:-J:..J.:; G,4 

2H-3 @ 860 Unit 0.163 0.4 

2H-5 @ 860 Unit 0.163 0.4 

2H-2 @ 860 Unit 0.350 0.4 

2H-4 @ 860 Unit 0.270 OA 

2H-7 @ 860 Unit 0.157 0.4 . . D. All annual combustIOn tunmg shall at a minimum meet the reqUirements set forth In 129.93 (b)(2) through (5) . 

E. At least thirty (30) days prior to a perfonnance NOx test, ~shall infonn AMS of the date and time of the 

scheduled test. 

5. Recordkeeping and Reporting Requirements 

A. The pennittee shall maintain a file containing all the records and other data that are required to be collected to 

demonstrate compliance with NOxlVOC RACT requirements of25 PA Code 129.91 • 129.94. 

8. The records shall provide sufficient data and calculations to clearly demonstrate that the requirements of §129.91-

129.94 are met. 

C. Data or infonnation required to detennine compliance shall be recorded and maintained in a time frame consistent 

with the averaging period of the requirement. 

D. Records shall be retained for at least two years and shall be made available to the Department on request. 

6. The operation of the aforementioned sources shall not at any time result in the emission of visible air contaminants in 

excess of the limitations specified in Section 123 AI. particulate matter in excess of the limitations specified in Section 

123.11 or sulfur oxides in excess of the limitations specified in Section 123.22, all Sections or Chapter 113 of Article III 

of the Rules and Regulations of the Department of Environmental Resources. or in the emission of any of these or any 
J 

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c 

I • 

RACT PLAN APPROVAL StUlf'lee, IRe. (R&Mt Page 7 

other type of air contaminant in excess of the limitations specified in, or established pursuant to. any other applicable rule 

or regulation contained in Article III. 

7. The company shall not impose conditions upon or otherwise restrict the Department's access to the aforementioned 

source(s) and/or any associated air cleaning device(s) and shall allow the Department to have access at any time to said 

source(s) and associated air cleaning device(s) with such measuring and recording equipment, including equipment 

recording visual observations, as the Department deems necessary and proper for performing its duties and for the 

effective enforcement of the Air Pollution Control Act. 

8. Revisions to any emission limitations incorporated in this RACT Approval will require resubmission as revision to the 

PA State Implementation Plan. The applicant shall bear the cost of public hearing and notification required for EPA 

approval as stipulated in 25 PA Code §129.9(h). 
J 

J 
c 

Appendix A 

RACT Cost Effectiveness 

Analysis 

NOx RACT Control Cost Effectiveness 

Cost Effectiveness Summary 

~~'"- Unit 231-BlIn 

NA 

102.243 

NA 

ILNB&SNCR NA 

ILNB& FGR NA 

ISNCR 39,924 

Unit 865-11Hl 

NA 

NA 

I\A 

I\A 

NA 

42,874 

Cost Effectiveness (!(fon) 

Unit865-11H2 Uni~ Unit 21O-H201 Unil86b-12Hl Unit &68-8HIOl 

34,287 30,796 !'JA 34,831 35,060 

32,909 27,397 !'JA 33,524 33,782 

6,737 9,477 NA 6,737 6,737 

11,045 57,667 162,271 11,331 14,513 

8,704 I\A NA 8,960 12,965 

13,132 10,825 28,098 13,379 13,482 

~~~~~~!t~=::::::===t==1!:g[=:::1Based on 90% equity cost of the average Carlyle energv funds and 10% after tax debt cost 

ACF = ;(1 + i)R 

(1 + /)"-1 

EPA Air Pollution Control Cost Manual, Sixth Edition, EPA! 452/8-02-001 - Equation 2.8a 

Chemical 

Year Engineering Cost 

Index 

1986 318.4 

1991 361 

2012 582.2 

Cost Escalation Factor for SCR1 1,83 

Cost Escalation Factor for LNB, SNCR, 1.61 and feR' 

I Cost data from Allenuztillf! Control Techmques Document· 

NOs Emissions from Process Hetll:ers (Revised)· EPA-453!R93-034 scaled from 1986 102012 cosl5 using the Cost 

Escalation factor. 

'Cost data from Altertlalive Control Techniques DommentNO, EmissifJ1ls from Process Heaters (R.emsed) - EPA-453!R93-034 scaled from 1991 10 2012 cosl5 using the Cost 

Escalation Factor. 

Soun:. 

Ultra low-NO, burner.; and Selective ULNB&SCR Catalytic Reduction 

Selective Catalytic Red uction SCR 

Ultra low-NO, burner.; UL"IB 

Low-NO, burner.; and Selective Non- L"IB& SNCR Catalytic Reduction 

Low-NO, burners and Flue Gas LNB&FGR Rffirculation 

Selective !'Jon-Catalylic Reduction SNCR 

Design Capacity Soun:e N;un. (MMBtWhr) 

Unit 231·B101 104,5 

Unit 865-11Hl 87.3 

Unit 865-11H2 I 64.2 

Unit 210-HI01 192.0 

Unit 210-H201 254.0 

Unit 86b-12Hl 61.2 

Unit 86S-llHl01 60,0 

Control 

Efficiency Comment 

96% Combmmg both removal efficiencies of Ul.NB and SCR 

85% Based on Unit 1332 perfonuance, 

66 to 87% Based on vendor experience at 0,03 Ib!MMBtu. 

Combining buth removal efficiencies. Assumes 50% control efficiency for LNB and 40% control efficiency 

70% for SNCR. Altenmtive CotltrO/ Techlliqlles Documenl- NO, £misswlls from Proc£ss Healers (Re,,;sed) - EPA453/R-93-034, 

55% Irol Techlliqlles DOCIIment - NO, Emissions from Proc£ss Heaters (Rel'ised) . EPA-453/R·93-034, 

40% Heat"r stack temperatun> below 700"F results in low NO, removal efficiency, EPA Air Pollution Control 

Technology Fact Sheet - EPA452/F-024l31. 

NO. Emission Number of Rate Summary of T eclmkallnfeasibilitles for NO, Control 

(lbjMMBtu) Burners 

0,030 None. 

SCR would not physically fit the plot space and there is not adequate pressure to 

0,030 8 overcome the SCR pressure drop; therefore, SCR is infeasible. FGR installation would 

require the installatmn of mechanical draft bumer.;, which is a major re-design of the 

unit therefore FGR is infeasible. 

0,113 8 None. 

0.089 6 FGR would not physically fit the plot space; therefore, it is infeasible, 

SCR would not physically fit the plot space and there is not adequate pressure to 

0.030 8 overcome the SCR pressure drop; lhefPfore, SCR is infeasible. FGR installation would 

require the installation of mechanical draft burners, which is a major re-design of the 

unit therefore FGR is infeasible. 

0.113 6 None. 

0.113 4 None. 

I 

App A RACT Cost Effectiveness 9-6-2013.xlsx RACT Cost Summary lof66 
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PES Refinery 

Heater firing Rate Increase Plan Approval 

NO. RACT Control Cost Effectiveness 

Costs derived from Alternalive Conlrol Techniques Document NOx Emissionsfrom Procl!5s Heaters (Rn>ised) - EPA-453/R-93-034 

AU costs are scaled from 2012 1.1.5. dollar.; using the appropriate Cost Escalation Factor. 

Capita! Cost of Low NO Burners lpage 6-4 and 6-51: 

Tel = 30,000 + HQ[5,230 - (622 )( BQ) + (26.1 )( BQ')] 

Where: 

TO ~ Total Capital Investment 

HQ ~ heater eapadty (GJjhr) 

BQ ~ burner heat release rate (GJ/hr) 

BQ ~ HQ/NB x (1.158 + 8/HQ) 

NB ~ number of burners 

Capital Cost of Ultra-low NO, Burners: 

See the 'Refinery ULt..'1l Control Costs" tab for capital cost details for ultra-low NO. Burners 

Capital Cost of Selectiv e Non-Catalvtic Reduction (page 6-7): 

Tel = 31,850(HQ)o.6 

HQ ~ heater capacily (GJ/hr) 

Overatins Cost of Selective Non,catalytic Reduction (page b-Il): 

(

1 mole NOr) (17 lb NH3) (1 mole NH3) ($0.125) ( hOUrS) NH3 cost =Q x (lbIMMBtu) x 46lbNOz )( 1moleNH3 x 1 mole NOr x IbNH3 )( 8,760 year 

Where: 

Q~ heater capacity. MMBIu/hr 

(

0.3 kWh) (ton NH3) ($0.06) Electricty cost = ---H- x --- x -k h tonN 3 year W 

Where: 

---= Q x Ib NO MMBtu) x )( )( x --- x 8,760-- tonNH3 (1 mole NOr) (17 Ib NH3) (1 mole Nfl3) ( ton ) ( hOUrS) 

year (rl 46 Ib NOr 1moieNfl3 1moieNOz 20001b year 

Capita! Cost of Selective Catalytic Reduction (page b-Ill: 

( Q)O'6 (Q) Tel 1,373,000 x 48.5 + 49,000)( 485 

Where: 

Q ~ heater capacity, MMBIu/hr 

Operating Cost of Selectivp Catalytic Reduction (page 6-91: 

_ (1 mole NOr) (17 Ib Nfl,) (1 mole Nfl3) ($0.125) (8,760 hOUrs) Nfl3 cost - Q )( (lbIMMBtu)( 46lb NOr X 1 mole Nfl3 )( 1 mole NOr X lb Nfl3 X year 

Where: 

Q ~ heater eapacily, MMBIu/hr 

Note the capacity factor has been assumed to be equat to 1; theretoT(', the capacily factor term has been omitted 

Catalyst Replacement east = 49,000 x years 

Electricty cost = (~~~~~:) X CO;e~:3) x (~~:) 

Where: 

ton NII3 _ (1 mole NOr) (17IbNII,) (1 mole Nil,) ( ton \ ( hourS) year - Q x (lb NOrIMMBtu) X 46lb NOr X 1 mole Nfl3 x 1 mole NOr X 2000 lb) X 8,760 year 

Capital Cost of Fine Gas RPcirculation /page 6-9): 

Tel = 12,800(HQ)O.6 

Where: 

HQ ~ heatereapacily (GJ/hr) 

Operating Cost of F1"" Gas Recirculation /page 6-10): 

(

0.75 kW) (8,760 hOurs) ($0.06) Electrictycost = (motor hp) x ----;:;:;;- X year x kWh 

Where: 

motor hp ~ FGR fan motor horsepower, (1/5) x (Q) 

Q ~ heater capacity, MMBIu/hr 

App A - RACT Cost Effectiveness 9-6-2013.xlsx Refinery Control Costs 2 of 66 
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PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

r 

Ultra Low NO. Burner Costs - from PES Refinerv Proiect Experience 

Economic Data 

1332 H-400/H-401 Heater 

137 F-3 Heater 

Source Name 

Unit 2.."I1-BI0l 

Unit 865-11 HI 

Unit 865-11H2 

Unit 210-H101 

Unit 210-H201 

Unit 866-12Hl 

Unit 868-8HI01 

Heater Fired Duty 

(MMBtu/hr) 

Design Capacity 

(MMBtufhr) 

104.5 

87.3 

64.2 

192.0 

254.0 

61.2 

60.0 

App A - RACT Cost Effectiveness 9-6-2013.xlsx 

Number of 

Burners 

ULNB Capital 

Cost Using 

($jMMBtufhr) 

$617,103 

$515,532 

$379,120 

$1,133,816 

$1,499,944 

$361,404 

$,:154,317 

Burner Heat Release 

(MMBtufhrfbumer) 

7.8 

15 

ULNB Total Capital 

Investment 

NA 

NA 

$559,581 

$1,673,512 

NA 

$533,432 

$522,973 

Base Year ULNB 

Cost ($fburner) 

Refinery Burner Control Costs 

Normalized Cost 

($jMMBtufhr) 

$6,444 

$5,367 

$5,905 

r 

3 of 66 
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PES Refinery 

Heater Firing Rate Increase Plan Approval 

Unit 231-BIOl RACT Cost Effectiveness Summary 

A B C D E F G H 

Control Option 

Current , Design Firing IE' , R t Potential EmissIOns miSSion a e (MMBtu/hr) 1 (TrY) (lb/MMBtu) 

Maximum Post 

Control I Control Emissions 

Efficiency @ Design Firing 

(%) 'TPY 

2012 Total I 2012 O&M Cost 

Capital Cost ($) 

($) 

13.7 

104.5 

104.5 

104.5 6.2 

104.5 8.2 

104.5 13.7 

Calculation =C*O-D 

Notes: 

11.7 

9.6 

7.6 

5.5 

0.0 

= C-E 

NA 

4,118,447 

NA 

NA 

773,123 

NA 

1 ULNB are planned to be installed on the Unit 231-B101 heater and the current emission rate is assumed to be O.03lb/MMBtu. 

2 See "RACT Cost Summary" tab for details on the Annualized Cost Factor (ACF). 

App A - RACT Cost Effectiveness 9-6-2013.)(ls)( 231-B101 RACT 

NA 

7 

2012 Annualized 

Cost2 

($) 

(' 

2012 Cost 

Effectiveness 

($/Ton) 

NA 

4of66 
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PES Refinery 

Heater Firing Rate Increase Plan Approval 

NO); RACT Control Cost Effectiveness 

Source Unit 23]·B]0] 

Control SCR 

Rated Heat Input ]04.5 

Number of Burners 26.0 

Baseline Actual Emissions 13.73 

Current Emission Rate 0.030 

Control Efficiency 85% 

Heater Capacity 110.3 

Burner Heat Release Rate 5.2 

Evaluated at New Firing Limit at 2012 Cost and Efficiencies 

MMBtu/hr 

Burners 

tpy 

IblMMBtu 

G.Jlhr 

GJ/hr 

Costs derived from Alternative Control Techniques Document- NOx Emissions/rom Process Heaters (Revised) - EPA-453/R-93-034 

DIRECT COSTS 

COST COMPONENT: 

Purchased Equipment Costs 

Equipment Cost (EC) 

Instrumentation (Included in above costs) 

Sales taxes (Included in above costs) 

Freight (Included in above costs) 

Subtotal- Purchased Equipment Costs (PEC) 

Direct Installalion Costs 

Foundations & supports; handling & erection; electrical; piping; 

etc. 

Site Preparation I Buildings- Included above 

Subtotal - Direct Installation Costs 

TOTAL DIRECT COSTS (TDC) 

INDIRECT INSTALLATION COSTS 

Engineering Costs (Included in above costs) 

Construct. & Field Expenses (Included in above costs) 

Contractor Fees (Included in above costs) 

Start-up (Included in above costs) 

Perfonnance Test (Included in above costs) 

Contingency (3% of PEC) 

TOTAL INDIRECT COSTS. IC 

TOTAL CAPITAL INVESTMENT (Tel) 

App A - RAG Cost Effectiveness 9-6-2013.xtsx Unit 231-B10l SCR 

COST ($) 

3,998,493 

3,998,493 

o 

---

o 

3,998,493 

119.955 

119,955 

4,118,447 

5 of 66 
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PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

COST COMPONENT: 

ANNUAL DIRECT COSTS 

Operation and Maintenance Labor 

Maintenance Labor and Material (2.75% of TCI) 

Annualized Cost Factor 

Replacement Life (years) = 

Interest Rate (%) 

Annualized Cost Factor 

Replacement cost 

Subtotal- Operation and Maintenance Labor 

Utilities 

Ammonia Cost 

Catalyst Replacement Cost 

Electricity Cost 

Subtotal - Utilities 

TOTAL ANNUAL DIRECT COSTS· 

COST COMPONENT: 

TOTAL ANNUAL O&M COSTS 

Annualized Cost Factor 

Equipment Life (years) = 

Interest Rate (%) = 

Annualized Cost Factor 

CAPITAL RECOVERY COSTS 

TOTAL CAPITAL REQUIREMENT 

TOTAL ANNUAL CAPITAL REQUIREMENT 

TOTAL ANNUAliZED COST 

(Total annual O&M cost and annualized capital cost) 

App A - RACT Cost Effectiveness 9-6-2013.xlsx Unit 231-B101 SCR 

COST ($) 

113,257 

113.257 

10 

21.83 

0.25 

2,046 

34,054 

0.1 

36,100 

149,357 

COST ($) 

149,357 

10 

21.83 

0.25 

4,118,447 

1,043,985 

1.193,342 

6of66 
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PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

Source l:nit 231·BIOI 

Control SNCR 

Rated Heat Input 104.5 

~umber of Burners 26.0 

Baseline Actual Emissions 13.73 

Current Emission Rate 0.030 

Control Efficiency 40% 

Heater Capacity 110.3 

Burner Heat Release Rate 5.2 

Evaluated at New Firing Limit at 2012 Cost and Efficiencies 

MMBtulhr 

Burners 

tpy 

IbfMMBtu 

GJlhr 

GJlhr 

Costs derived from Alternative Control Techniques Document - NOx Emissions from Process Heaters (Revised) - EPA-453/R·9J.-034 

DiRECT COSTS 

COST COMPONENT: 

Purchased Equipment Costs 

Equipment Cost (EC) 

Instrumentation (Included in above costs) 

Sales taxes (Included in above costs) 

Freight (Included in above costs) 

Subtotal- Purchased Equipment Costs (PEC) 

Direct Installation Costs (Based on Vendor Discussion) 

Foundations & supports; handling & erection; electrical; piping; 

etc. 

Site Preparation I Buildings· Included above 

Subtotal - Direct Installation Costs 

TOTAL DIRECT COSTS (TDC) 

INDIRECT INSTALLA TlON COSTS 

Engineering Costs (Included in above costs) 

Construct. & Field Expenses (Included in above costs) 

Contractor Fees (Included in above costs) 

Start-up (Included in above costs) 

Performance Test (Included in above costs) 

Contingency (3% of PEC) 

TOTAL INDIRECT COSTS. IC 

TOTAL CAPITAL INVESTMENT (TCI) 

App A - RAeT Cost Effectiveness 9·6-2013.xlsx Unit 231-B101 SNCR 

COST (5) 

750,605 

750,605 

o 

o 

750,605 

22,518 

22,518 

773,123 

7 of 66 
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PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

COST COMPONENT: 

ANNUAL DIRECT COSTS 

Operation and Maintenance Labor 

Maintenance Labor and Material (2.75% ofTCl) 

Annualized Cost Factor 

Replacement Life (years) = 

Interest Rate (%) = 

Annualized Cost Factor 

Replacement cost 

Subtotal- Operation and Maintenance Labor 

Utilities 

Ammonia Cost 

Electricity Cost 

Subtotal - Utilities 

TOTAL ANNUAL DIRECT COSTS8 

COST COMPONENT: 

TOTAL ANNUAL O&M COSTS 

Annualized Cost Factor 

Equipment Life (years) = 

Interest Rate (%) = 

Annualized Cost Factor 

CAPITAL RECOVERY COSTS 

TOTAL CAPITAL REQUIREMENT 

TOTAL ANNUAL CAPITAL REQUIREMENT 

TOTAL ANNUALIZED COST 

(Total annual O&M cost and annualized capital cost) 

App A - RACT Cost Effectiveness 9-6-2013.xlsx Unit 231-B101 SNCR 

COST ($) 

21,261 

21,261 

10 

21.83 

0.25 

2,046 

0.1 

2,046 

23,307 

COST ($) 

23,307 

10 

21.83 

0.25 

773,123 

195,979 

219,286 

8of66 
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PES Refinery 

Heater Firing Rate Increase Plan Approval 

Unit 865-11H1 RACT Cost EHectiveness Summary 

A B C D E F G H 

Current Control Maximum Post Potential 2012 Total 

Control Option Design Firing Emission Rate Potential Emissions Efficiency Control Emissions NO, Capital Cost 2012 O&M Cost 

(MMBtu/hr) (lb/MMBtu)l (TPY) (%) @ Design Firing Reduced ($) ($) 

(TPY) (TPY) 

ULNB&SCR 87.3 0.03 11.5 %% 0.5 11.0 NA NA 

SCR 87.3 0.03 11.5 85% 1.7 9.8 NA NA 

LNB&SNCR 87.3 0.03 11.5 70% 3.4 8.0 NA NA 

LNB& FGR 87.3 0.03 11.5 55% 5.2 6.3 NA NA 

SNCR 87.3 0.03 11.5 40% 6.9 4.6 694,045 20,796 

ULNB 87.3 0.03 11.5 0% 11.5 0.0 NA NA 

Calculation : A • B • 8760 / 2000 = C' (1 - D) = C-E 

Technicallnfeasibilities: 

SCR would not physically fit the plot space and there is not adequate pressure to overcome the SCR pressure drop; therefore, SCR is infeasible 

FGR installation would require the installation of mechanical draft burners, which is a major re-design of the unit; therefore FGR is infeasible 

Notes: 

1 ULNB are planned to be installed on the Unit 865-11H1 heater and the current emission rate is assumed to be 0.03 lb/ MMBtu. 

2 See "RACT Cost Summary" tab for details on the Annualized Cost Factor (ACF). 

App A - RACT Cost Effectiveness 9-6-2013.xlsx 865-UH1 RACT 

t' 

2012 Annualized 2012 Cost 

Cost2 Effectiveness 

($) ($/Ton) 

NA NA 

NA NA 

NA NA 

NA NA 

196,729 42,874 

NA NA 

= (G' ACF) + H = I / F 

9 of 66 
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Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

Source lInit 865-11Hl 

Control S"ICR 

Rated Heat Input 87.3 

N umber of Burners 8.0 

Baseline Actual Emissions 11.47 

Current Emission Rate 0.030 

Control Efficiency 40% 

Heater Capacity 92.1 

Burner Heat Release Rate 14.3 

Evaluated at New Firing Limit at 2012 Cost and Efficiencies 

MMBtulhr 

Burners 

tpy 

IblMMBtu 

GJlhr 

GJlhr 

Costs derived from Altl!1'native Control Techniques Document - NOx Emissions from Process Heaters (R~ised) - EPA-4531R-93-034 

DIRECT COSTS 

COST COMPONENT: 

Purchased Equipment Costs 

Equipment Cost (EC) 

Instrumentation (Included in above costs) 

Sales taxes (Included in above costs) 

Freight (Included in above costs) 

Subtotal- Purchased Equipment Costs (PEC) 

Direct installation Costs (Based on Vendor Discussion) 

Foundations & supports; handling & erection; electrical; piping; 

etc. 

Site Preparation I Buildings- Included above 

SUbtotal- Direct Installation Costs 

TOTAL DIRECT COSTS (TDC) 

INDIRECT INSTALLA TION COSTS 

Engineering Costs (Included in above costs) 

Construct. & Field Expenses (Included in above costs) 

Contractor Fees (Included in above costs) 

Start-up (Included in above costs) 

Performance Test (Included in above costs) 

Contingency (3% of PEC) 

TOTAL INDIRECT COSTS, IC 

TOT AL CAPITAL INVESTMENT (TCI) 

App A - RACT Cost Effectiveness 9-6-2013.xlsx Unit 865-11H1 SNCR 

COST ($) 

673,830 

673.830 

o 

o 

673.830 

20,215 

20,215 

694,045 

10 of 66 
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PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

COST COMPONENT: 

ANNUAL DIRECT COSTS 

Operation and Maintenance Labor 

Maintenance Labor and Material (2.75% ofTCl) 

Annualized Cost Factor 

Replacement Life (years) 

Interest Rate (%) = 

Annualized Cost Factor 

Replacement cost 

Subtotal - Operation and Maintenance Labor 

Utilities 

Ammonia Cost 

Electricity Cost 

Subtotal- Utilities 

TOT AL ANNUAL DIRECT COSTS· 

COST COMPONENT: 

TOTAL ANNUAL O&M COSTS 

Annualized Cost Factor 

Equipment Life (years) = 

Interest Rate (%) = 

Annualized Cost Factor 

CAPITAL RECOVERY COSTS 

TOTAL CAPITAL REQUIREMENT 

TOTAL ANNUAL CAPITAL REQUIREMENT 

TOTALANNUALlZED COST 

(Total annual O&M cost and annualized capital cost) 

App A - RACT Cost Effectiveness 9-6-2013.xlsx Unit 865-11Hl SNCR 

COST(S) 

19.086 

19,086 

10 

21.83 

0.25 

1,709 

0.1 

1,709 

20,796 

COST ($) 

20,796 

10 

21.83 

0.25 

694.045 

175,933 

196,729 

11 of 66 
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Heater Firing Rate Increase Plan Approval 

Unit 865-11H2 RACT Cost Effectiveness Summary 

A B C D E F G 1-1 

Current Control Maximum Post Potential 2012 Total 

Control Option Design Firing Emission Rate Potentia 1 Emissions Efficiency Control Emissions NO, Capital Cost 2012 O&M Cost 

(MMBtu/hr) (lb/MMBtu)l (I'rY) (%) @ Design Firing Reduced ($) ($) 

(TPY) (TPY) 

ULNB&SCR 64.2 0.113 31.8 96% 1.3 30.5 3,631,525 125,523 

SCR 64.2 0.113 31.8 85% 4.8 27.0 3,071,944 110,135 

ULNB 64.2 0.113 31.8 73% 8.4 23.3 559,581 15,388 

LNB&SNCR 64.2 0.113 31.8 70% 9.5 22.2 857,483 28,316 

LNB&FGR 64.2 0.113 31.8 55% 14.3 17.5 512,272 22,250 

SNCR 64.2 0.113 31.8 40% 19.1 12.7 577,165 20,607 

Cakulation = A • B • 8760 / 2000 = C' (1 - D) =C-E 

Notes: 

1 Unit 865-111-12 is projected to be above PADEP presumptive RACT firing limits and assumed NO, emission rate limit ofO.1l3Ib/MMBtu is used. 

2 See "RACT Cost Summary" tab for details on the Annualized Cost Factor (ACF). 

App A· RACT Cost Effectiveness 9-6-2013.xlsx 86S-11H2 RACT 

~ 

2012 Annualized 2012 Cost 

Effectiveness 

($) ($/Ton) 

1,046,078 34,287 

888,841 32,909 

157,237 6,737 

245,679 11,045 

152,106 8,704 

166,913 13,132 

= (G • ACF) + 1-1 = I / F 

12 of 66 
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Healer Firing Rate Increase Plan Approval 

NO. RACf Co •• rol Cost Effectiv .... ' 

Source lInit865-1lH2 

Control ULNB&SCR 

Rated lies. Input 64.2 

Number of Burners 8.0 

Basd'M Actual Emissions 31.78 

Current Emission Rate 0.113 

Cootrol Effici.ncy 96~. 

He.ler Capacity 67.7 

Bumer lIesl Rele.,e Rale 10.8 

Evaluated at New Firilll Limit at 2012 Cost and Efficiencies 

MMBlulhr 

BUfners 

tpy 

IblMMBtu 

GJlhr 

GJlbr 

Cosl, derived from Alter""tive Colllro! T ecilniqlles Doell""''''' NOx EmissioltS from Process Heater> (Rt!t';sed) - EPA-453IR-93-034 

IDIRECT COSTS - ULNB 

COST COMPONENT: 

Purchased Equipment Costs 

Equipment Cost (EC) 

Instrumentation (10"10 ofEC) 

Sales taxes (5% ofEC) 

Freight (8% ofEC) 

Sllbtotal- Purcnased Elfllipment Costs (PEG) 

Direct Installation Costs (Based on Vendor Discussion) 

Foundations & supports; handling & erection; electrical; 

piping: etc. 

Site Preparation / Buildings- Included above 

SlIbtotaJ - Direct InstaIlation Com 

TOTAL DIRECT COSTS (TOC) ULNB 

INDIRECT INSTALU170N COSTS - ULNB 

Engineering Costs (5% ofPEC) 

Construct. & Field Expenses (InclUded in above costs) 

Contractor Fees (l0"!, ofPEC) 

Start-up (l%ofPEC) 

Performance Te .. (1% of PEC) 

Contingency (3% ofPEC) 

TOTAL INDIRECT COSTS, IC - ULNB 

DIRECT COSTS - SCII 

Purchased Equipment Costs 

Equipment Cost (EC) 

Instrumentation (Included in above costs) 

Sales taxes (Included in above costs) 

Freight (Included in above costs) 

SPbtotal- l'llrchased Elfllipment Costs (PEG) 

Direct Instal/atioH Costs 

Foundations & supports; handling & erection: electrical; 

piping; etc. 

Site Preparation / Buildings-Included above 

SlIbtotaJ - Direct Instaliati"" Costs 

I TOTAL DIRECT COSTS (TDC) - SCII 

INDIRECT INSTALLATION COSTS - SCII 

Engineering Costs (Included in above costs) 

C struet & Feld Expenses (In I d d· bove costs) 

! 

on I cue ma 

Contractor Fees (inCluded in above costs) 

Stan.up (Included In above costs) 

Performance Test (Included in above \:osts) 

Contmgency (3% of PEC) 

I TOTAL INDIRECT COSTS, IC - sell 

ITOT At CAPITAL INVESTMENT (TCI) - ULNB 

ITOTAL CAPITAL INVESTMENT (TCI) - SCR 

ITOTAL CAPITAL INVESTMENT (TCI) 

App A - RACT Cost Effectiveness 9-6-2013 .• ls. Unit 865-11H2 ULNB & SCR 

COST ($) 

379.120 

37.912 

18.956 

30.330 

466,317 

o 

466,.317 

23.316 

46.632 

4.663 

4.663 

13.990 

93.263 

2.982.470 

2,982.470 

o 

-

o 

2.982.470 

., - ,., 

89.474 

89,474 

559.581 

3.071,944 

3.631,525 

13 of 66 
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Healer Firing Rale increaS<' Plan Approval 

NO. RACT Conlrol C .. II1IT.<ti ...... 

COST COMPONI1NT: 

ANNUAL DIRECT COSTS 

Operation and Mainlenance Labor 

Maintenance Labor and Matenal (2.75% of TCi) 

Annualized COSI Faclor 

Replacement Life (years) ~ 

Interest Rate (%) = 

Annualized Cost Factor 

Replacement cost 

...v.hin/111 - Operation alld MainJelUlnce Labor 

U,ilities 

Ammonia Cost 

Catalyst Replacement Cost 

Electricity CoS! 

SlIbtotal- Utilities 

l U lAL Al'Il"lUAL lJIKL"l "u"'" 

COST COMPONl1i11T: 

TOTAL ANNUAL O&'M COSTS 

Annualized Cost Factor 

Equipment Life (years) ~ 

Interest Rate (%) = 

Annualized Cost Factor 

CAPITAL RECOVERY COSTS 

TOTAL CAPITAL REQUIREMENT 

TOTAL ANNUAL CAPITAL REQUIREMENT 

TOTALA/,;'!'>VALIZED COST 

(T oID.I a"""al OdM cost and a"""aii",d ct1pilal cost) 

10 

21.83 

10 

21.83 

App A . RACT Cost Effectiveness 9·6-2013 .• ls. Unit 865-11H2 ULNB & 5CR 

COST(S) 

99,867 

99,867 

0.25 

4,735 

20,921 

OJ 

25,650 

I 

125,523 

COST(S) 

125,523 

0.25 

3,631,525 

920,555 

i 

1,046,078 

14 of 66 
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Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

Source Unit 865-l1H2 

Control SCR 

Rated Heat Input 64.2 

Number of Burners 8.0 

Baseline Actual Emissions 31.78 

Current Emission Rate 0.113 

Control Efficiency 85% 

Heater Capacity 67.7 

Burner Heat Release Rate 10.8 

Evaluated at New Firing Limit at 2012 Cost and Efficiencies 

MMBtu/hr 

Burners 

tpy 

IblMMBtu 

GJ/hr 

GJ/hr 

Costs derived from Alternative Control Techniques Document - NOx Emissions/rom Process Heaters (Revised) - EPA-453/R-93-034 

DIRECT COSTS 

COST COMPONENT: 

Purchased Equipment Costs 

Equipment Cost (EC) 

Instrumentation (Included in above costs) 

Sales taxes (Included in above costs) 

Freight (Included in above costs) 

Subtotal - Purchased Equipment Costs (PEC) 

Direct Installation Costs 

Foundations & supports; handling & erection; electrical; piping; 

etc. 

Site Preparation I Buildings- Included above 

Subtotal - Direct Instal/ation Costs 

TOTAL DIRECT COSTS (TDCj 

INDIRECT INSTALLATION COSTS 

Engineering Costs (Included in above costs) 

Construct. & Field Expenses (Included in above costs) 

Contractor Fees (Included in above costs) 

Start-up (Included in above costs) 

Performance Test (Included in above costs) 

Contingency (3% ofPEC) 

TOTAL INDIRECT COSTS, IC 

TOTAL CAP IT AL INVESTMENT (TCI) 

App A· RACT Cost Effectiveness 9-6-2013.xlsx Unit 86S-11H2 SCR 

COST ($) 

2,982,470 

2,982,470 

o 

... 

o 

2,982,470 

89,474 

89,474 

3,071,944 

lS of 66 
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PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

COST COMPONENT: 

ANNUAL DIRECT COSTS 

Operation and Maintenance Labor 

Maintenance Labor and Material (2.75% ofTCI) 

Annualized Cost Factor 

Replacement Life (years) = 

Interest Rate (%) 

Annualized Cost Factor 

Replacement cost 

Subtotal - Operation and Maintenance Labor 

Utilities 

Ammonia Cost 

Catalyst Replacement Cost 

Electricity Cost 

Subtotal - Utilities 

TOTAL ANNUAL DIRECT COSTS· 

COST COMPONENT: 

TOTAL ANNUAL O&'M COSTS 

Annualized Cost Factor 

Equipment Life (years) = 

Interest Rate (%) = 

Annualized Cost Factor 

CAPITAL RECOVERY COSTS 

TOTAL CAPITAL REQUIREMENT 

TOTAL ANNUAL CAPITAL REQUIREMENT 

TOTAL ANNUALIZED COST 

(Total annual O&M cost and annualized capital cost) 

App A RAG Cost Effectiveness 9-6-2013.xlsx Unit 865-11H2 SCR 

COST(S) 

84,478 

84,478 

10 

21.83 

0.25 

4,735 

20,921 

0.3 

25,656 

110,135 

COST(S) 

110,135 

10 

21.83 

0.25 

3,071,944 

778,707 

888,841 

16 of 66 
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PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

Source lJnit 865-IIH2 

Control lJLNB 

Rated Heat Input 64.2 

Number of Burners 8.0 

Baseline Actual Emissions 31.78 

Current Emission Rate 0.113 

Control Efficiency 73% 

Heater Capacity 67.7 

Burner Heat Release Rate 10.8 

Evaluated at New Firing Limit at 2012 Cost and Efficiencies 

MMBtu/hr 

Burners 

tpy 

IblMMBtu 

GJlhr 

GJ/hr 

Costs derived from Alternative Control Techniques Document- NOx Emissions/rom Process Heaters (Revised) - EPA-4531R-93-034 

DIRECT COSTS 

COST COMPONENT: 

Purchased Equipment Costs 

Equipment Cost (EC) 

Instrumentation (10% ofEC) 

Sales taxes (5% ofEC) 

Freight (8% of EC) 

Subtotal- Purchased Equipment Costs (PEC) 

Direct Instal/ation Costs (Based on Vendor Discussion) 

Foundations & supports; handling & erection; electrical; piping; 

etc. 

Site Preparation I Bui Idings- Included above 

Subtotal- Direct Installation Costs 

TOTAL DIRECT COSTS (TDC) 

INDIRECT INSTALLATION COSTS 

Engineering Costs (5% ofPEC) 

Construct. & Field Expenses (Included in above costs) 

Contractor Fees (10% of PEC) 

Start-up (1% ofPEC) 

Performance Test (1% ofPEC) 

Contingency (3% ofPEC) 

TOTAL INDIRECT COSTS, IC 

TOTAL CAPITAL INVESTMENT (TCI) 

App A - RACT Cost Effectiveness 9-5-2013,xlsx Unit 855-11H2 ULNB 

COST ($) 

379,120 

37,912 

18,956 

30,330 

466,317 

o 

o 

466,317 

23,316 

46,632 

4,663 

4,663 

13,990 

93,263 

559,581 

17 of 55 
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PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

COST COMPONENT: 

ANNUAL DIRECT COSTS 

Operation and Maintenance Labor 

Maintenance Labor and Material (2.75% of TCI) 

Annualized Cost Factor 

Replacement Life (years) 

Interest Rate (%) 

Annualized Cost Factol 

Replacement cost 

SublOtaI- Operlllion and Maintenance Labor 

Utilities 

None 

Subtotal- Utilities 

TOTAL ANNUAL DIRECT COSTS· 

COST COMPONENT: 

TOTAL ANNUAL O&M COSTS 

Annualized Cost Factor 

Equipment Life (years) = 

Interest Rate (%) 

Annualized Cost Factor 

CAPITAL RECOVERY COSTS 

TOTAL CAPITAL REQUIREMENT 

TOTAL ANNUAL CAPITAL REQUIREMENT 

TOTAL ANNUALIZED COST 

(Total annual O&M cost and annualized capital cost) 

App A - RACT Cost Effectiveness 9-6-2013.xlsx Unit 865-11H2 UlNB 

COST ($) 

15,388 

15,388 

10 

21.83 

0.25 

0.0 

15,388 

COST ($) 

15,388 

10 

21.83 

0.25 

559,581 

141,848 

157,237 

18of66 
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PES Refinery 

C Heater Firing Rate In<",.,., Plan Approval 

NO, RACT Control CO" Ellf<:Iiv ..... ' 

Sou,.. Unit 865-IIHZ 

Control LNB&SNCR 

Ra .... lleatlnput 64.Z MMBhlfbr 

Nwnber of ll&arners 8.Il Burnen 

Baseline Actu.ai Emissions 31.78 tpy 

CUrTeDt Emission Rate 0.113 Ib/MMBru 

ControJ Efficiency 70"1. 

Heater C.pacity 67.7 GJ/hr 

Burner H •• t Release Rate 10.8 GJlbr 

Evaluated.l N("W Firing Limit at 2012 C.,t and Effldenties 

C.,,,, derived rrom AI1_", Control Techniques n-mOftt - NOx Elffissions frOlff I'rocfls fl.", .... (R"'''d) EPA-lS3/R-9J.034 

COST COMPONENT: COST(S) 

DIRECT COSTS - !.NB 

Purchased £quipmenl COSIS 

Equipment Cost (Eel 189.917 

Instrumentation (lO% ofEC) 18,992 

Sales taxes (5% ofEC) 9,496 

Freight (8% ofEC) 15,193 

Sub.OIoJ - PII,dws.d Eqllipmml Com (PEC) Z33,593 

Direct Insto/Jalion Costs IBoscd on Vendor Discussion) 

Foundations & supports; handling & erection; eleetrical; plping: 

etc, 0 

Site Preparation I Buildings- Included above --- ---- SNbtotaJ - Dir«1 I Ifstall_ion CnstJ 0 

TOTAL DIRECT COSTS ([DC) - LNB 133,598 

INDIRECT INST:4LL4TION COSTS - LNB 

Engineering Costs (5% ofPEC) 11.680 

Construct. & Field Expenses (Included in above eosts) 

Contractor Fees (l on/o ofPEC) 23.360 

Start~up 0% ofPEC) 2.336 

Performance Test (1 % of PEC) 2,336 

Contingency (3616 ofPEC) 7,008 

TOTAL INDIRECT COSTS, IC - LNB 44>,710 

DIRECT COSTS - SNCR 

Purchased Equipment C 05/5 

Equipment Cost {Eel 560.355 

lnstrumemation (Included jn above cost,,) -- -

Sales taxes (Included in above costs) -- -

Freight (Included in above costs) 

SM_oJ - PII,cMased EqltipIMlfJ Com (PEe) 560,355 

DireCI Imaol/alion Cos's (Based on Vendor Discussion) 

Foundations & supports; handling & erection: electrical: piping; 

etc, 0 

Sile Preparation! Buildjngs~ Included above --0-- SMlnoIaJ ~ Dir~cll"'JIaJhUi.o" Costs 

TOT:4L DIRECT COSTS ITDCI- SNCR 56O,3SS 

INDIRECT JNSTALL4TION COSTS - SNCR 

Engineering Costs (Included in abovc costs) 

Construct & field Expenses (Included in above costs) 

Contractor Fees (Included in above costs) -_. Start·up (lnduded in above costs) 

Perfonnance Test (Included in above costs) -- Contingency (3% ofPEC) 16,811 

TOTAL INDIRECT COSTS, IC - SNCR 16,811 

TOTAL CAPITAL INVESTMENT (TCI) - LNB 280,318 I 

TOTAL CAPITAL INVESTMENT (l'CI) - SNCR 577,165 I 

TOTAL CAPITAL INVESTMENT (TCI) 857,483 I 

App A - RACT Cost Effectiveness 9-G-2013.xI5X Unit 86S-11H2 LNB & SNCR 19 of 66 
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Heater Firing Rate Increase Plan Approval 

NO. RACf Control Co •• ElIKtI"" .... 

COST COMPONENT: 

ANNUAL DIRECT COSTS 

Operalion and Maintenance Labor 

Maintenance Labor and Material (2,75% ofTef) 

Annuo{izeJ Cost Fac/or 

Replacement Life (years) = 

Interest Rate ('Yo) ~ 

Annualized Cost Factor 

Replacement coo 

S,,_ol· ()p<ralkmllJld M"mu"mu:e L,u",r 

l.ilililie3 

AmmomaCOS1 

Electricity Cost 

Salnotol. Uti/It ... 

TOTAL ANNUAL DIRECT COSTS' 

COST COMPONENT: 

TOTALANNlJAL OAM COSTS 

Annualized COSl FacIOI' 

Equipmenl Life (years) "" 

futerest Rate (11;0) = 

Annualized Cost Factor 

CAPITAL RECOVERY COSTS 

TOTAL CAPITAL REQUIREMENT 

TOTAL ANNlJAL CAPITAL REQUIREMENT 

TOTAL ANNlJALIZED COST 

(1''''''' _01 O&M CQSt IlJId /1JJ".0Iju;J cop/ttll cost) 

COST(S) 

~ 

23,581 

10 

2L83 

025 

4,735 

OJ 

4.735 

28,316 

COST(S) 

2ll,J16 

10 

21.83 

0,25 

857,483 

217,363 

245,679 

App A· RACT Cost Effectiveness 9-6-2013.xI5x Unit 865-11H2 LNB & SNCR 20 of 66 
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PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

Source Unit 86~IIH2 

Control LNB& FGR 

Rated Heat Input 64.2 

Nwnbel" or Rumen 8.0 

Baseline Actual Emissions 31.78 

CUrTen. Emission Ratt- 0.113 

Control Efficiency 55°/. 

Healel" Capacity 67.7 

Bumer Heat Release Rate 10.8 

Evaluated at New Firing Limit at 2012 Cost and Efficiencies 

MMBtulhr 

Bumen 

tpy 

Ib/MMBIu 

GJ/hr 

GJlhr 

Costs derived rrom AIt01lllliw Cortlrol Teclrniqlles /JocII",enJ. NOx Elftissions/ro'" Process Healers (Revised) - EPA-453/R-93-034 

COST COMPONENT: COST (5) 

DIRECT COSTS - LNB 

Purchased Equipment COSIS 

Equipment Cost (EC) 189,917 

Instrumentation (10% ofEC) 18,992 

Sales taxes (5% ofEC) 9,496 

Freight (8% ofEC) 15,193 

Subtolal - PIIrclrased EqllipmenJ Costs (PEe) 233,598 

Direct Installalion Costs (Based on Vendor Discussion) 

Foundations & support.<;; handling & erection; electrical; piping; 

etc. 0 

Site Preparation / Buildings-Included above -- - ---- Subtotal. Dinct lnSlaJlaJion Cmlt 0 

TOTAL DIRECT COSTS (FOC) - LNB 233,598 

INDIRECT INSTALLATION COSTS - LNB 

Engineering Costs (5% of PEe) 11,680 

Construct & Field Expenses (Included in above costs) -- -

Contractor Fees (10% ofPEC) 23,360 

Start-up (I % ofPEC) 2.336 

Perfonnance Test (1% of PEe) 2,336 

Contingency (3% of PEe) 7,008 

TOTAL INDIRECT COSTS.IC - LNB 46,720 

DIRECT COSTS - FGR 

Purchased EqUipment Costs 

Equipment Cost (Ee) 225,197 

Instrumentation (Included in above costs) -- - Sales taxes (Included in above costs) -- -

Freight (Included in above costs) -- -

SIIblo/aJ - l'Mrc._d EquipmenJ Costs (PEC) 225,197 

Direcllnstallation Costs (Based on Vendor Discussion) 

Foundations & support.<;; handling & erection; electrical; piping; 

etc. 0 

Site Preparation I Buildings- Included above -- - ---- Subtotal - Dinct lnstllllaJio" Costs 0 

TOTAL DIRECT COSTS (FOC) - FGR 225,197 

INDIRECT INSTALLATION COSTS - FGR 

Engineering Costs (Included in above costs) -- - Construct & Field Expenses (Included in above costs) -- -

Contractor Fees (Included in above costs) -- -

Start-up (Included in above costs) -- -

Perfonnance Test (Included in above costs) -- -

Contingency (3% ofPEC) 6.756 

TOTAL INDIRECT COSTS.IC - FGR 6,756 

TOTAL CAPITAL INVESTMENT (TCI) - LNB 280,318 

TOTAL CAPITAL INVESTMENT (TCI) - FGR 231,953 

TOTAL CAPITAL INVESTMENT (TCI) 512,272 

App A - RACT Cost Effectiveness 9-6-2013.xlsx Unit 865-11H2 LN8 & FGR 210166 
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PES lIefine'Y 

He~ter Firing Rale IncR'ase Plan Approval 

NO. RACT Contl1ll Cost Efrecd ....... 

COST COMPONENT: 

ANNUAL DIRECT COSTS 

Operation and Maintenance Labor 

Ma.inlenance Labor and Material (2.75% of Tel) 

Annualized Cost Fac/or 

Replacement Life (years) = 

Interest Rate (%) = 

Annualized Cost Factor 

Replacement cost 

SlIblotiJl- o,wlflliOlt IUUi Mlliltlmana Lllbor 

Ulilities 

Electricity Cost 

Sltblotol. UtUItW 

TOTAL AI'INUAL DIRECT COSTS' 

COST COMPONENT; 

TOTAL ANNlJAL OdM COSTS 

Annualized Cost Fac/or 

Equipment Life (years) = 

Interesf Rate (0/.:.) .... 

Annualized Cost Factor 

CAPITAL RECOVERYCOSTS 

TOTAL CAPITAL REQUIREMENT 

TOTAL ANNIJAL CAPITAL REQUIREMENT 

TOTALANM.JALIZEDCOST 

IT- """,,01 O&M ant IIntl""IfJIoIl1.d CIIpiUIJ Ctnl) 

COST ($) 

~ 

14,087 

10 

21.83 

0.25 

8,163 

8,163 

22,250 

COST ($) 

22,250 

10 

21.83 

0.25 

512.272 

129,856 

152,106 

App A - RAeT Cost Effect;vene .. 9-&-2013.><ls. Unit 865-11H2 LNB & FGR 22 of 66 

C 

c 

PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

Source Unit 865-11H2 

Control SNCR 

Rated Heat Input 64.2 ~1:\1Btu/hr 

Number of Burners 8.0 Burners 

Baseline Actual Emissions l1.78 tpy 

Current Emission Rate O.lIl IblMMBtu 

Control Efficiency 40% 

Heater Capacity 67.7 GJ/hr 

Burner Heat Release Rate 10.8 GJ/hr 

Evaluated at New Firing Limit at 2012 Cost and Efficiencies 

Costs derived from Alternative Control Techniques Document - NOx Emissions from Process Heaters (Revised) - EPA-45llR-9l-034 

DIRECT COSTS 

COST COMPONENT: 

Purchased Equipment Costs 

Equipment Cost (EC) 

Instrumentation (Included in above costs) 

Sales taxes (Included in above costs) 

Freight (Included in above costs) 

Subtotal- Purchased Equipment Costs (PEC) 

Direcllnslallalion Costs (Based on Vendor Discussion) 

Foundations & supports; handling & erection; electrical; piping; 

etc. 

Site Preparation / Buildings- Included above 

Subtotal- Direct Installation Costs 

TOTAL DIRECT COSTS (TDC) 

INDIRECT INSTALLATION COSTS 

Engineering Costs (Included in above costs) 

Construct. & Field Expenses (Included in above costs) 

Contractor Fees (Included in above costs) 

Start-up (Included in above costs) 

Performance Test (Included in above costs) 

Contingency (3% of PEC) 

TOTAL INDIRECT COSTS, IC 

TOTAL CAPITAL INVESTMENT (TCI) 

App A - RACT Cost Effectiveness 9-6-2013.xlsx Unit 865-11H2 SNCR 

COST ($) 

560,355 

560,355 

o 

---

o 

560,355 

16,811 

16,81I 

577,165 

23 of 66 
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PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

COST COMPONENT: 

ANNUAL DIRECT COSTS 

Operation and Maintenance Labor 

Maintenance Labor and Material (2.75% of TCI) 

Annualized Cost Factor 

Replacement Life (years) = 

Interest Rate (%) = 

Annualized Cost Factor 

Replacement cost 

Subtotal- Operation and Maintenance Labor 

Utilities 

Ammonia Cost 

Electricity Cost 

Subtotal- Utilities 

TOTAL ANNUAL DIRECT COSTS· 

COST COMPONENT: 

TOTAL ANNUAL O&M COSTS 

Annualized Cost Factor 

Equipment Life (years) = 

Interest Rate (%) = 

Annualized Cost Factor 

CAPITAL RECOVERY COSTS 

TOTAL CAPITAL REQUIREMENT 

TOTAL ANNUAL CAPITAL REQUIREMENT 

TOTAL ANNUALIZED COST 

(Total annual O&M cost and annualized capital cost) 

App A - RACT Cost Effectiveness 9-6-2013.xlsx Unit 865-11H2 SNCR 

COST ($) 

15,872 

15,872 

10 

21.83 

0.25 

4,735 

0.3 

4,735 

20,607 

COST ($) 

20,607 

10 

21.83 

0.25 

577,165 

146,306 

166,913 

24 of 66 
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PES Refinery 

Heater Firing Rate Increase Plan Approval 

Unit 210-HI01 RACT Cost Effectiveness Summary 

A B C 

Control Option Design Firing 

Current 

Potential Emissions 

74.8 

74.8 

74.8 

192 0.089 74.8 

2 0.089 74.8 

192 0.089 74.8 

Calculation - A • B • 8760 / 2000 

Technicallnfeasibilities: 

FGR would not physically fit the plot space; therefore, it is infeasible. 

Notes: 

D 

Control 

(%) 

96% 

85% 

70% 

66% 

55% 

40% 

(' 

E 

Maximum Post 

F 

Potential 

NO, 

G H 

2012 Total I 2012 O&M Cost 

Capital Cost 

I Current generation UNLB is considered to be 0.03Ib/MMBtu, which represents a 66% reduction from 0.0891b/MMBtu. 

2 See "RACT Cost Summary" tab for details on the Annualized Cost Factor (ACF). 

App A - RACT Cost Effectiveness 9-6-2013.xlsx 210-HIOl RACT 

2012 Annualized 

Cost2 

2,213,176 

1,742,936 

470,240 

NA 

r 

2012 Cost 

Effectiveness 

30,796 

27,397 

57,667 

9,477 

NA 

10,825 

=l/F 

25 of 66 
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PES Refinery 

Heater Firing Rate Increase Plan Approval 

NO. RACT Co.trol Cost Err.div ..... 

Source U.it 210-HIOI 

Co.trol ULNB&SCR 

Rated Heat I.put 192.0 

Number of Burners 6.0 

Baseline Actual Emissions 74.85 

Currenl Emission Rate 0.089 

Control Efficiency 96% 

Heater Capacity 202.6 

Burner Heal Rei" .... Rate 40.4 

Evaluated.! New Firing Limit.t 2012 Cost and Efficiencies 

MMBtulbr 

Burners 

Ipy 

IblMMBtu 

GJlbr 

GJlbr 

Costs derived from AllaMlive Control Tee/flliques Document - NOx Emissions from Process Healers (R""iseJ) - EPA-4531R-93-0J4 

COST COMPONE!'!T: COST ($) 

DfRECJ COSTS - ULNB 

Purchased Equipment Cosls 

EqUIpment Cost (EG) 1.133,816 

lnstrumenlation ( I 0% of EG) 113,382 

Sales laxes (5% ofEe) 56,691 

Freight (S% ofEG) 90,705 

Sublolal- PllrcltaseJ Eqllipment Costs (PEe) 1,394.593 

Direclinslaliafion C()st.~ (Based on Vendor Discussion) 

Foundanons & supporu~ handling & erection; elecrrical; piping; 

etc, 0 

Sile Preparation I Buildings-Included above ---

S"hlolal- Direcl/1ISIaUalion Costs 0 

TOTAL DIRECT COSTS (rDC) - UUIB 1,394,593 

INDIRECJ fNSTALLATfON COSTS - UfNB 

Engineering CoslS (5% of PEe) 69,730 

Construcl. & Field Expenses (Included in above cosls) --- Contractor Fees (10% ofPEC) 139,459 

Slart-up (l%ofPEC) 13,946 

Performance Te" (1% ofPEC) 13.946 

Conlingency (3% o(PEe) 41.838 

TOTAL fNDfRECT COSTS, IC - ULNB 278,919 

DIRECT COSTS - SCR 

Purchased EqUipment Costs 

Equipmenl CoS! (EC) 5.767.459 

Instrumentation (Included in above costs) 

Sales taxes (Included in above costs) --- Freighl (Included in above costs) ---

S"blolal- P",chased EqllipmenJ Costs (PEC) 5.767,459 

Direct Installation Costs 

Foundations & supports: handling & erection; electrical; piping; 

etc, 0 

Sire Preparation l Buildings- Included above 

Sllhlolal- DireclInstallalion Costs 0 

TOTAL DIRECT COSTS (!DC) - SeR 5,767,459 

!ND/RECJ INSTALLATION COSTS - SeR 

Engineering Costs (Included in above costs) --- Construct. & Field Expenses (Included in above costs) - Contractor Fees (Included in above cOSts) -- Slart-up (Included in above costs) -

Performance Test {Included 10 above cOStS} --- Contingency (3% o(PEC) 173,024 

TOTAL fNDlRECJCOSTS, IC· SeR 173,024 

TOTAL CAPITAL INVESTMENT (TCI) - llLNB 1,673,512 

TOTAL CAPITAL INVESTMENT (TCI)- SCR 5,940.483 

TOTAL CAPITAL INVESTMENT (TCI) 7,613,995 

App A - RACT Cost Effectiveness 9-6-2013 .• ls. Unit 210-H101 ULNB & SCR 26 of 66 
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PES Refinery 

Heater Firing Rate Inerea ... Plan Approval 

NO. RACT Control Cost Effectiveness 

COST COMPONENT: 

ANNUAL DIRECT COSTS 

Operation and Maintenance lAbor 

Maintenance Labor and Material (2.75% ofTCIl 

Annualized Cost Faclor 

Replacement Life (years) = 

IntereSl Rate (%) 

Annuahzed Cost Factor 

Replacement cosr 

Su.btotal - Operation Dnd Maintenance lAbor 

Utilities 

Anunonia Cost 

Catalyst Replacement Cost 

Electricity Cost 

Subtotal .. Utilities 

IIJI~L ANN I JAI , UlKM .. LUI> 1 1>' 

COST COMPONENT: 

TOTAL ANNUAL O&M COSTS 

Annualized Cost Faelor 

Equipment Life (years) 

Interest Rare (%) = 

Annualized Cost Factor 

CAPITAL RECOVERY COSTS 

TOTAL CAPITAL REQUIREMENT 

TOTAL ANNUAL CAPITAL REQu/REMEtvT 

TOTAL ANNUALlZEn COST 

(Total an""a! (J&M cost and annuali",d capital cost) 

10 

21.83 

J() 

21.83 

App A .. RACT Cost Effectiveness 9-<i .. 2013.xlsx Unit 21()"H10l ULNB & SCR 

COST(S) 

209.385 

209,385 

0.25 

11,152 

62,568 

0.8 

73,721 

283,106 

COST ($) 

283,106 

0.25 

7,613,995 

1,930,071 

2,213,176 

27 of 66 
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PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

Source Unit 210-HlO] 

Control SCR 

Rated Heat Input 192.0 

Number of Burners 6.0 

Baseline Actual Emissions 74.85 

Current Emission Rate 0.089 

Control Efficiency 85% 

Heater Capacity 202.6 

Burner Heat Release Rate 40.4 

Evaluated at New Firing Limit at 2012 Cost and Efficiencies 

MMBtu/hr 

Burners 

tpy 

Ib/MMBtu 

GJ/hr 

GJ/hr 

Costs derived from Alternative Control Techniques Document- NOx Emissions/rom Process Heaters (Revised) - EPA-4531R-93-034 

DIRECT COSTS 

COST COMPONENT: 

Purchased Equipment Costs 

Equipment Cost (EC) 

Instrumentation (Included in above costs) 

Sales taxes (Included in above costs) 

Freight (Included in above costs) 

Subtotal- Purchased Equipment Costs (PEC) 

Direct Installation Costs 

Foundations & supports; handling & erection; electrical; piping; 

etc. 

Site Preparation I Buildings- Included above 

Subtotal - Direct Installation Costs 

TOTAL DIRECT COSTS (TDC) 

INDIRECT INSTALLATION COSTS 

Engineering Costs (Included in above costs) 

Construct. & Field Expenses (Included in above costs) 

Contractor Fees (Included in above costs) 

Start-up (Included in above costs) 

Performance Test (Included in above costs) 

Contingency (3% ofPEC) 

TOTAL INDIRECT COSTS, IC 

TOT AL CAPITAL INVESTMENT (TCn 

App A RACT Cost Effectiveness 9-6-2013.xlsx Unit 210-H10l SCR 

COST (5) 

5,767,459 

5,767,459 

o 

---

o 

5,767,459 

173.024 

173,024 

5,940,483 

28 of 66 
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PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

COST COMPONENT: 

ANNUAL DIRECT COSTS 

Operation and Maintenance Labor 

Maintenance Labor and Material (2.75% ofTCI) 

Annualized Cost Factor 

Replacement Life (years) = 

Interest Rate (%) = 

Annualized Cost Factor 

Replacement cost 

Subtotal - Operation and Maintenance Labor 

Utilities 

Ammonia Cost 

Catalyst Replacement Cost 

Electricity Cost 

Subtotal - Utilities 

TOTAL ANNUAL DIRECT COSTS8 

COST COMPONENT: 

TOTAL ANNUAL O&M COSTS 

Annualized Cost Factor 

Equipment Life (years) 

Interest Rate (%) = 

Annualized Cost Factor 

CAPITAL RECOVERY COSTS 

TOTAL CAPITAL REQUIREMENT 

TOTAL ANNUAL CAPITAL REQUIREMENT 

TOTAL ANNUALIZED COST 

(Total annual O&M cost and annualized capital cost) 

App A - RACT Cost Effectiveness 9-6-20 13.l<lsl< Unit 2l0-HlOl SCR 

COST ($) 

163,363 

]63,363 

to 

21.83 

0.25 

11,152 

62,568 

0.8 

73,721 

237,084 

COST ($) 

237,084 

10 

21.83 

0.25 

5,940,483 

],505,852 

1,742.936 

29 of 66 
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PES Refinery 

H •• ter Firing Rate mere ... Plan Appro. a1 

NO. RAeT Control Con EIf.di ....... 

Sou ..... Unit Zl~HIOI 

Control LNB&SNCR 

Rarod Hea,lnpu' )91.0 

NlUllber GrBumers 6.0 

Basetil'le Actual Emissions 74.85 

Currenl Emission Rate 0._ Control Errldency 70% 

Hea .... C.p.<ily 202.6 

Bumer Heat Release Rate 41).4 

Evaluated •• New Firinc Umit 8r2012 CDSt anti E.ffir~ncies 

MMBhlfhr 

B ........ 

.py 

IblMMBtu 

GJ/hr 

GJ/hr 

Cos'" deri .... rrom Altmr<lti ... CO/IJrI)/ T ecbi'l"" Dtx:tt""~1 • NUx £",/$.""'" fro". _us H.III .... (R".,.4) • EPA-453IR·9J.034 

COST COMPONENT: COST($l 

DIRECT COSTS - L'JB 

Purchased Equipment C 05/$ 

Equipment CoS! (Eel 6.503.358 

Instrumentation (100/0 ofEC) 650,336 

Sales taxes (5% ofEe) 325.168 

Freight (8% ofEC) 520.269 

SabtOlal. PW",.a..ed £'1"lpmM1 CMls (PEC) 7.999.131 

Direct Ins/allat/on Costs (Based on Vendor Discussion) 

Foundations & suppons~ handhng & erection; electrical; piping; 

etc 0 

Site Preparation;' Buildings-Included above --- ---- S"blOfai - Dirrd lnstallalimt eMU 0 

TOTAL DIRECT COSTS (rOC)· LNB 7,999,13) 

INDIRECT INSTALLATION COSTS - LNB 

Engineering COSfS (5% of PEe} 399.957 

Construct & Field Expenses (Included in above costs) 

Contractor Fees (10% ofPEC) 799.913 

Start-up (1% ofPEC) 79.991 

Perfonnance Test (1%ofPEC) 79.991 

Contingency (3% ofPEC} 239.974 

TOTAL INDIRECT COSTS. IC - LNS 1,599,826 

DIRECT COSTS· SNCII 

Purchased Equipment Cos's 

Equipment Cost (Ee) 1.08l.241 

Instrumentarion (Included in above costs) --- Sales taxes (Included in above costs) ---

Freight (Included in above costs) ---

S .. 610141- PNrc~.4 £'1"1_,,, Costs (PEC) ),(l8),l41 

Direct Installation Costs (Based on Vendor Discussion) 

Foundations & supports; handljng & erection: electrical: pipmg; 

Cle. 0 

Slfe Preparation J Buildtngs~ lncluded above --0-- S .. btotal - Dinct Ilf.fIallllllwn Com 

TOTAL DIRECT COSTS (TOC) - SIVCR 1,IJII1.24 I 

INDIRECT INSTALLATION COSTS - SNCR 

Engineering Costs (Induded in above costs) 

Construct & Field Expenses (Included in above COSts) _. 

Contractor fees (lncluded in above costs) --- Start~up {Included in above costs) 

Perfonnance Tess (Included in above COStS; 

i 

Contingency (3% ofPEC) 32.437 

TOTAL INDIRECT COSTS. IC - SNCR 32.437 

ITOTAL CAPITAL INVESTMENT (TCl)· DID 9.598.957 

TOTAL C,-\PIT AL INVESTMENT (TCI) - SNCR t,1I3.678 

TOTAL CAPITAL INYESTMENT (TCI) 10.712,635 

App A - RACT eost Effectiveness 9-6-2013.xl •• Unit 21D-H10l LNB & SNCR 

I 

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Heater Firing Rate Increase Plan Approval 

N(h RACT Control Cost Effectiveness 

COST COMPONENT: 

ANNUAL DIRECT COSTS 

Operatian and Maintenance Labar 

Maintenance Labor and Material (2.75% ofTCI) 

Annualized Cast Factor 

Replacement Life (years) = 

Interest Rate (%) = 

Annualized Cost Factor 

Replacement cost 

S"blotaJ - Operation and Maintenance Labor 

Ulililies 

Ammonia Cost 

Electricity Cost 

S"blolaJ - Utilities 

TOTAL ANNUAL DIRECT COSTS' 

COST COMPONENT: 

TOTAL ANNUAL O.lMCOSTS 

Annualized emil Factor 

Equipment Life (yean,) = 

Interest Rate (%) = 

Annualized Cost Factor 

CAPITAL RECOVERY COSTS 

TOTAL CA PITAL REQUIREMENT 

TOTAL ANNUAL CAPITAL REQUIREMENT 

TOTAL ANNUALIZED COST 

(Total tulnllaJ OdM cost ad annlla/iz,ed capital con) 

COST(S) 

294,597 

294,597 

10 

21.83 

0.25 

11,152 

0.8 

11,153 

305,750 

COST(S) 

305,750 

10 

21.83 

0.25 

10,712,635 

2,715,545 

3,021,296 

App A - RACT Cost Effectiveness 9-6-2013.xlsx Unit 21()-H101 LNB & SNCR 310166 
J 

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PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

Source llnit 210-HI01 

Control llLNB 

Rated Heat Input 192.0 

Number of Burners 6.0 

Baseline Actual Emissions 74.85 

Current Emission Rate 0.089 

Control Efficieney 66% 

Heater Capacity 202.6 

Burner Heat Release Rate 40.4 

Evaluated at New Firing Limit at 2012 Cost and Effieiencies 

MMBtulhr 

Burners 

tpy 

IblMMBtu 

GJlhr 

GJlhr 

Costs derived from Alternative Control Techniques Document - NOx Emissions/rom Process Heaters (Revised) - EPA-453/R-93-034 

DIRECT COSTS 

COST COMPONENT: 

Purchased Equipment Costs 

Equipment Cost (EC) 

Instrumentation (10% of EC) 

Sales taxes (5% ofEC) 

Freight (8% ofEC) 

Subtotal- Purchased Equipment Costs (PEC) 

Direct Installation Costs (Based on Vendor Discussion) 

Foundations & supports; handling & erection; electrical; piping; 

etc. 

Site Preparation I Buildings- Included above 

Subtotal- Direct Installation Costs 

TOTAL DIRECT COSTS (TDC) 

INDIRECT INSTALLA TION COSTS 

Engineering Costs (5% of PEC) 

Construct. & Field Expenses (Included in above costs) 

Contractor Fees (10% of PEC) 

Start-up (1% ofPEC) 

Performance Test (I % of PEC) 

Contingency (3% ofPEC) 

TOTAL INDIRECT COSTS, IC 

TOTAL CAPITAL INVESTMENT (TCI) 

App A RACT Cost Effectiveness 9-6-2013.xlsx Unit 210-HIOl UlNB 

COST ($) 

1,133,816 

113,382 

56,691 

90,705 

1,.394.593 

o 

o 

1,.394.593 

69,730 

139,459 

13,946 

13,946 

41.838 

278.919 

1,673.512 

32 of 66 
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PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

COST COMPONENT: 

ANNUAL DIRECT COSTS 

Operation and Maintenance Labor 

Maintenance Labor and Material (2.75% of TCI) 

Annualized Cost Factor 

Replacement Life (years) = 

Interest Rate (%) = 

Annualized Cost Factor 

Replacement cost 

Subtotal - Operation and Maintenance Labor 

Utilities 

None 

Subtotal- Utilities 

TOTAL ANNUAL DIRECT COSTS· 

COST COMPONENT: 

TOTAL ANNUAL O&M COSTS 

Annualized Cost Factor 

Equipment Life (years) = 

Interest Rate (%) = 

Annualized Cost Factor 

CAPITAL RECOVERY COSTS 

TOTAL CAPITAL REQUlREM/:"'NT 

TOTAL ANNUAL CAPITAL REQUIREMENT 

TOTAL ANNUALIZED COST 

(Total annual O&M cost and annualized capital cost) 

App A - RACT Cost Effectiveness 9-6-2013.xlsx Unit 2lD-HlDl ULNB 

COST ($) 

46,022 

46,022 

10 

21.83 

0.25 

0.0 

46,022 

COST ($) 

46,022 

10 

21.83 

0.25 

1,673,512 

424,218 

470,240 

33 of 66 
, 

PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

Source Unit 210-HI01 

Control SNCR 

Rated Heat Input 192.0 

Number of Burners 6.0 

Baseline Actual Emissions 74.85 

Current Emission Rate 0.089 

Control Efficiency 40% 

Heater Capacity 202.6 

Burner Heat Release Rate 40.4 

Evaluated at New Firing Limit at 2012 Cost and Efficiencies 

MMBtu/br 

Burners 

tpy 

Ib/MMBtu 

GJ/br 

GJ/br 

Costs derived from AlternaiWe Control Techniques Document - NOx Emissions from Proces,~ Heaters (Revised) - EPA-4531R-9J-034 

DIRECT COSTS 

COST COMPONENT: 

Purchased Equipment Costs 

Equipment Cost (EC) 

Instrumentation (Included in above costs) 

Sales taxes (Included in above costs) 

Freight (Included in above costs) 

Subtotal- Purchased Equipment Costs (PEC) 

Direct Installation Costs (Based on Vendor Discussion) 

Foundations & supports; handling & erection; electrical; piping; 

etc. 

Site Preparation I Buildings- Included above 

Subtotal- Direct Instalifltion Costs 

TOTAL DIRECT COSTS (TDC) 

INDIRECT INSTALLATION COSTS 

Engineering Costs (Included in above costs) 

Construct. & Field Expenses (Included in above costs) 

Contractor Fees (Included in above costs) 

Start-up (Included in above costs) 

Performance Test (Included in above costs) 

Contingency (3% of PEC) 

TOTAL INDIRECT COSTS. IC 

TOTAL CAPITAL INVESTMENT (TCI) 

App A - RACT Cost Effectiveness 9-6-2013.xlsx Unit 21O-Hl0l SNCR 

COST ($) 

1,081,241 

1,081,241 

o 

---

o 

1,081,241 

32,437 

32,437 

1,113,678 

34 of 66 
PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

COST COMPONENT: 

ANNUAL DIRECT COSTS 

Operation and Maintenance Labor 

Maintenance Labor and Material (2.75% of TCI) 

Annualized Cost Factor 

Replacement Life (years) = 

Interest Rate (%) = 

Annualized Cost Factor 

Replacement cost 

Subtotal- Operation and Maintenance Labor 

Utilities 

Ammonia Cost 

Electricity Cost 

Subtotal - Utilities 

TOTAL ANNUAL DIRECT COSTS· 

COST COMPONENT: 

TOTAL ANNUAL O&M COSTS 

Annualized Cost Factor 

Equipment Life (years) = 

Interest Rate (%) = 

Annualized Cost Factor 

CAPITAL RECOVERY COSTS 

TOTAL CAPITAL REQUIREMENT 

TOTAL ANNUAL CAPITAL REQUIREMENT 

TOTAL ANNUALIZED COST 

(Total annual O&M cost and annualized capital cost) 

App A - RACT Cost Effectiveness 9-6-2013.xlsx Unit 21O-HlOl SNCR 

COST ($) 

30,626 

30,626 

10 

21.83 

0.25 

11,152 

0.8 

11,153 

41,779 

COST ($) 

41,779 

JO 

21.83 

0.25 

1,113,678 

282,306 

324,085 

35 of 66 
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PES Refinery 

Heater Firing Rate Increase Plan Approval 

Unit 210·H201 RACT Cost Effectiveness Summary 

A fl C D E F G H 

Current Maximum Post Potential 

Control Option Design Firing Potential Emissions Control 

Efficiency Control Emissions NO. 2012 Total 12012 Annualized I 2012 Cost 

Capital Cost 2012 O&M Cost . ($) Cost2 Effecliveness 

ULNB&SCR 

SCR 

LNfl& SNCR 

LNB&FGR 

SNCR 

ULNB 

Technicallnfeasibilities: 

2000 

70% 

55% 

40% 

0% 

@ Design Firing 

TPY) 

1.3 

5.0 

10.0 

15.0 

20.0 

33.4 

C· (1. D) 

Reduced 

(TPY) ($) 

32.0 NA NA 

28.4 NA NA 

23.4 13A74,367 375,519 

18.4 NA NA 

13.4 1,317,284 41,199 

0.0 NA NA 

=C- E 

SCR would not physically fit the plot space and there is not adequate pressure to overcome the SCR pressure drop; therefore, SCR is infeasible. 

FGR installation would require the installation of mechanical draft burners, which is a major re-design of the unit; therefore FGR is infeasible. 

Notes: 

1 ULNB is already installed on the Unit 210-H201 heater. 

2 See "RACT Cost Summary" tab for details on the Annualized Cost Factor (ACF). 

App A - RACT Cost Effectiveness 9-6-2013.l<lsl< 210-H201 RACT 

($) 

1 375,117 1 28,098 

I NA I NA 

I = (G • ACF) + H I - I / F 

36 of 66 
PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOJ. RAcr Control Cost ER'ettiveness 

Source Unit 2111-8201 

Control LNB& SNCR 

Rated Heat Input 254.0 

Nwnber of Bumen 8.0 

Baseline Actual Emissions 33.38 

CUInn! Emission Rate 0.030 

Control Efficiency 70°/. 

Heater Capacity 268.0 

Bumer Heat Release Rate 39.8 

Evaluated lit New Firing Limit at 2012 Cost and Efficiencies 

MMBlUlhr 

Bumers 

tpy 

Ib/MMBIu 

GJIhr 

GJ/hr 

COSh derived from Allernlllive ColllroJ Tecltniques Docllmellt. NOx Emissiollsft'o", Process Hetllers (Revised) - EPA-453fR-93-034 

COST COMPONENT: COST(S) 

DIRECT COSTS· LNB 

Purchased Equipment Costs 

Equipment Cost (Ee) 8.236.506 

Instrumentation (10% ofEC) 823,651 

Sales taxes (5% ofEC) 411,825 

Freight (8% ofEC) 658,920 

Subtotal - Purchased Equipment CosJs (PEe) 10,130,902 

Direct Inslal/alian Costs (Based on Vendor D;~'cuss;on) 

Foundations & supports; handling & erection; electrical; piping; 

etc. 

Site Preparation I Buildings-Included above ... ° Subtotal - Dinct I"stal/OIio" Costs 0 

TOTAL DIRECT COSTS (TDC) . LNB 10,130,902 

INDIRECT INSTALLATION COSTS· LNB 

Engineering Costs (5% ofPEC) 506.545 

Construct. & Field Expenses (Included in above costs) ... 

Contractor Fees (10% ofPEC) 1,013.090 

Start·up (1% ofPEC) 101.309 

Performance Test (I % ofPEC) 101.309 

Contingency (3% ofPEC) 303.927 

TOTAL INDIRECT COSTS, IC· LNB 2,026,180 

DIRECT COSTS· SNCR 

Purchased Equipment Costs 

Equipment Cost (EC) 1.278.916 

Instrumentation (Included in above costs) ... 

Sales taxes (Included in above costs) ... 

Freight (Included in above costs) ... 

S"btotal - Purchased Eq"ipmelll Costs (PEC) 1,278,916 

Direct Installation Costs (Based on Vendor Discussion) 

Foundations & supports; handling & erection: electrical; piping; 

etc. 

Sitc Preparation I Buildings~ Included above ... ° S"btotaI - Direct /"sJa//atio" Costs 0 

TOTAL DIRECT COSTS (TDC)· SNCR 1,278,916 

INDIRECT INSTALLATION COSTS· SNCR 

Engineering Costs (Included in abovc costs) ... 

Construct. & Field Expenses (Included in above costs) ... 

Contractor Fees (Included in above costs) ... 

Start-up (Included in above costs) ... 

Performance Test (Included in above costs) ... 

Contingency (3% ofPEC) 38,367 

TOTAL INDIRECT COSTS, IC· SNCR 38.367 

TOTAL CAPITAL INVESTMENT (TCI) - LNB 12,157,os3 

TOTAL CAPITAL INVESTMENT (TCI) - SNCR 1,317,284 

TOTAL CAPITAL INVESTMENT (TCI) 13,474.367 

App A - RACT Cost Effectiveness 9-6-2013.xlsx Unit 21()-H201 LNB & SNCR 370166 
, 

, 

PES Refiru>ry 

Healer Firing Ral.lncrease Plan Approval 

NO. RACf COII'rol C •• , Elfecli ....... 

COST COMPONENT: 

ANNUAL DIRECTCOSrs 

Operation and Maintenance Labor 

MainlenatlCe Labor and Matenld (2,751% of Tel) 

Annualized Cost Factor 

Replacement lIfe {years)"'-

IntereSi Rate (%) = 

Annualized Cost Factor 

Replacement cos! 

s..btotl1l- (}p<!NliOll4fld MsinI_c< LIlJwr 

Uiilii.ies 

Ammonia Cost 

Electriclty Cost 

5Mbtoll1l- UlilitiD 

IRECT COSTS" 

COST COMPONENT: 

;a OdMCOSTS 

Annualized COSI FaclOr 

Equipmenl Life (years) "'" 

}nterest Rate (%) "'" 

Annualized Cost factor 

CAPITAL RECOVERY COSTS 

TOTAL CAPITAL REQUIREMENT 

TOTAL ANNUAL CAPITAL REQUIREMElVT 

TOTAL ANNUALIZED COST 

(1'01'" ""'".'" OdM wst IUId "" .... I1I;:<tl copitl1l cos/) 

COST/5) 

370.545 

370,545 

10 

21.83 

0.25 

4,973 

0.4 

4,973 

375,519 

COST/5) 

375,519 

10 

21.83 

0.25 

13,474.367 

3,415.616 

3,791,135 

App A . RACT Cost Effectiveness 9-6-2013.xl .. Unit 21Q-H201 LNB & SNCR 380166 
PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

Source Unit 210-H201 

Control SNCR 

Rated Heat Input 254.0 

Number of Burners 8.0 

Baseline Actual Emissions 33.38 

Current Emission Rate 0.030 

Control Efficiency 40% 

Heater Capacity 268.0 

Burner Heat Release Rate 39.8 

Evaluated at New Firing Limit at 2012 Cost and Efficiencies 

MMBtu/hr 

Burners 

tpy 

IblMMBtu 

GJ/hr 

GJ/hr 

Costs derived from Alternative Control Techniques Document - NOx Emissions/rom Process Heaters (Revised) - EPA-453/R-93-034 

DIRECT COSTS 

COST COMPONENT: 

Purchased Equipment Costs 

Equipment Cost (EC) 

Instrumentation (Included in above costs) 

Sales taxes (Included in above costs) 

Freight (Included in above costs) 

Subtotal- Purchased Equipment Costs (PEC) 

Direct Installation Costs (Based on Vendor Discussion) 

Foundations & supports; handling & erection; electrical; piping; 

etc. 

Site Preparation / Buildings- Included above 

Subtotal- Direct Installation Costs 

TOTAL DIRECT COSTS (TDC) 

INDIRECT INSTALLATION COSTS 

Engineering Costs (Included in above costs) 

Construct. & Field Expenses (Included in above costs) 

Contractor Fees (Included in above costs) 

Start-up (Included in above costs) 

Performance Test (Included in above costs) 

Contingency (3% ofPEC) 

TOTAL INDIRECT COSTS, IC 

TOTAL CAPITAL INVESTMENT (TCI) 

App A - RACT Cost Effectiveness 9-6-2013.xlsx Unit 21O-H201 SNCR 

COST ($) 

1,278,916 

1.278.916 

o 

o 

. 1.278,916 

38,367 

38.367 

1,317.284 

39 of 66 
, 

" 

PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

COST COMPONENT: 

ANNUAL DIRECT COSTS 

Operation and Maintenance Labor 

Maintenance Labor and Material (2.75% of TCI) 

Annualized Cost Factor 

Replacement Life (years) 

Interest Rate (%) = 

Annualized Cost Factor 

Replacement cost 

Subtotal - Operation and Maintenance Labor 

Utilities 

Ammonia Cost 

Electricity Cost 

Subtotal- Utilities 

TOTAL ANNUAL DIRECT COSTS8 

COST COMPONENT: 

TOTAL ANNUAL O&M COSTS 

Annualized Cost Factor 

Equipment Life (years) 

Interest Rate (%) 

Annualized Cost Factor 

CAPITAL RECOVERY COSTS 

TOTAL CAPITAL REQUIREMENT 

TOTAL ANNUAL CAPITAL REQUIREMENT 

TOTAL ANNUALIZED COST 

(Total annual O&M cost and annualized capital cost) 

App A - RACT Cost Effectiveness 9-6-2013.xlsx Unit 210-H201 SNCR 

COST ($) 

36,225 

36,225 

10 

21.83 

0.25 

4,973 

0.4 

4,973 

41,199 

COST ($) 

41,199 

10 

21.83 

0.25 

1,317,284 

333,918 

375,117 

40 of 66 
f:' f' 

PES Refinery 

Heater Firing Rate Increase Plan Approval 

Unit 866-12Hl RACT Cost Effectiveness Summary 

A B C D E F G H 

Current Control Maximum Post Potential 

2012 Total 

Control Option Design Firing Emission Rate Potential Emissions Efficiency Control Emissions @ NO, Capital Cost 2012 O&M Cost 

(MMBtu/hr) (lb/MMBtu)t (TPY) (%) Design Firing Reduced ($) ($) 

(TPY) (TPY) 

ULNB&SCR 61.2 0.113 30.3 %% 1.2 29.1 3,518,199 121,208 

SCR 61.2 0.113 30.3 85% 4.5 25.7 2,984,767 106,538 

ULNB 61.2 0.113 30.3 73% 8.0 22.2 533,432 14,669 

LNB&SNCR 61.2 0.113 30.3 70% 9.1 21.2 838,966 27,585 

LNB& FGR 61.2 0.113 30.3 55% 13.6 16.7 503,525 21,628 

SNCR 61.2 0.113 30.3 40% 18.2 12.1 560,828 19,936 

Calculation = A • B * 876()L 2000 = C' (1- D) =C-E 

Notes: 

t Unit 866-12111 is projected to be above PADEP presumptive RACT firing limits and assumed NO, emission rate limit of 0.113 Ib/MMBtu is used. 

2 See "RACT Cost Summary" tab for details on the Annualized Cost Factor (ACF). 

App A - RACT Cost Effectiveness 9-6-2013.l<lsl< 866-12Hl RACT 

f' 

2012 Annualized 2012 Cost 

Cost2 Effectiveness 

($) ($1 Ton) 

1,013,036 34,831 

863,147 33,524 

149,889 6,737 

240,255 11,331 

149,267 8,960 

162,101 13,379 

= rG* ACF) + H = II F 

41 of 66 
PES Refinery 

Heater Firing Rate Increase Plan Approval 

NO. RACf Conlrol C""I Effectiveness 

Source Unit 866-12HI 

Control ULNB&SCR 

Rated Heat Inppt 61.2 

N umber of Burners 6.0 

Baseline Actual Emissions 30.29 

Current Emission Rate 0.113 

Control Efficiency 96~~ 

H.ater Capacity 64.6 

Burner Heat Rei .... Rate 13.8 

Evaluated at New Firing Limit at 2012 Cost and Efficiencies 

MMBlulhr 

Burnen 

tpy 

IblMMBtp 

GJlhr 

GJlbr 

Cosl, derived fmmAllunal/ve COIIlroi Techlfiqll(!s Docllmelfl- NOx Emissionsfrom Process Healers (R ... -iseli) EPA-4531R·93-1134 

COST COMPONENT: COST(S) 

DIRECT COSTS· ULNB 

Purchased Equipment Costs 

Equipment COSt (Ee) 361.404 

instrumentation (10% of EC) 36,140 

Sales taxes (5% ofEC) 18,070 

Freight (8% ofEC) 28,912 

SubtOlal· Purchased EquipmenJ Costs (PEq 444,527 

Direct Installation CoSls (Based on Vendor Discussion) 

Foundations & supports; handling & erec-tion~ electrical; piping; 

ere, 0 

Site Preparation I Buildings-Included above --- SuDtOlal· Direcl {""aI/ali_ Costs 0 

TOTAL DIRECT COSTS (TDC) - ULNB 444,527 

INDIRECT INSTALUTJON COSTS - ULNB 

Engineering Costs (5% of PEC) 22,226 

Construct. & Field Expenses (included in above costs) --- Contractor Fees (10% ofPEC) 44,453 

Start-up (I%ofPEC) 4,445 

Performance Test (1% ofPEC) 4,445 

Contmgency (3% ofPEC) 13,336 

TOT AI. INDIRECT COSTS, IC - ULNS 88,905 

DIRECT COSTS - SCR 

Purchased Equipment Costs 

Equipmem Cost (EC) 2,897,832 

Instrumentation (Included in above costs) ---

Sales taxes (Included in above costs) --- Freight (Included in above costs) -.-

SIlDtOlal· Purchased EquipmenJ Costs (PEq 2,897,832 

DirectlnSJallaf;on Costs 

Foundations & suppons: handling & erection~ electrical; piping; 

etc. 0 

Site Preparation I Bui1dings~ Included above .. 

Subtotal- Direct {_al'alion Costs 0 

TOTAL DIRECT COSTS (TDC) - SCR 2,897,832 

INDIRECT INSTALL4TlON COSTS - SCR 

Engineering Costs (Included in above costs) 

Construct. & Field Expenses (Induded in above costs) 

ContraCtor Fees (Included in above costs) 

Start-up (Included in above costs) 

Performance Test (Included tn above costs) --- Contingency (3% ofPEC) 86,935 

TOTAL INDIRECT COSTS, IC - SCR 86,935 

TOTAL CAPITAL INVESTMENT (TCI). ULNB 533,432 

TOTAL CAPITAL L,,"VESTMENT (TCI) - SCR 2,984,767 

TOTAL CAPITAL INVESTMENT (TCI) 3.518,199 

App A - RACT (ost Effectiveness 9-6-2013.xlsx Unit 866-12Hl ULNB & S(R 42 of 66 
PES Refinery 

Heater Firing Rat(' IlK1'I!aS<' Plan Approval 

NO. RACf Conlrol Cos, EfTectiveness 

COST COMPONENT: 

ANNUAL DIRECT COSTS 

Operation and Maintenance Labor 

Maintenance Labor and Material (2.75% ofTen 

Annualized Cost FaClOr 

Replacement Life (years) ~ 

Interest Rate (%) = 

Annualized Cost Factor 

Replacement cost 

Slibiotal- Operlllion and Maintenance La"or 

Utilities 

AmmomaCost 

Catalyst Replacement Cost 

Electricity Cost 

Sub/oIlll. Ulilities 

I U I AL ."""'IUAL IJUUA.I LU:>I:> 

COST COMPONENT: 

TOTAL ANNUAL O&M CaSTS 

A.nnualized Cost Factar 

Equipment Life (years) ~ 

Interest Rate (%) 

Annualized Cost Factor 

CAPITAL RECOVERY COSTS 

TOTAL CAPITAL REQUIREMENT 

TOTAL ANNUAL CAPITAL REQUIREMENT 

TOTAL ANNUALIZED COST 

(T oI4ianlUlai (J&M cost and anm,aii:ed capillll cost) 

JO 

21.83 

10 

21.83 

App A - RACT Cost Effectiveness 9-6-2013.xlsx Unit 866-12Hl ULNB & SCR 

COST(S) 

96,750 

96,750 

0.25 

4.513 

19,943 

0.3 

24,457 

121,208 

COST(S) 

121,208 

0.25 

3.518.199 

891,828 

1,013,036 

43 of 66 
PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

Source {] nit 866-12 HI 

Control SCR 

Rated Heat Input 61.2 

Number or Burners 6.0 

Baseline Actual Emissions 30.29 

Current Emission Rate 0.113 

Control Efficiency 85% 

Heater Capacity 64.6 

Burner Heat Release Rate 13.8 

Evaluated at New Firing Limit at 2012 Cost and Efficiencies 

MMBtulbr 

Burners 

tpy 

IblMMBtu 

GJlbr 

G.I/br 

Costs derived rrom Alternative Control Techniques Document - NOx Emissions from Process Heaters (Revised) - EPA-453/R-93-034 

DlRECTCOSTS 

COST COMPONENT: 

Purchased Equipment Costs 

Equipment Cost (EC) 

Instrumentation (Included in above costs) 

Sales taxes (Included in above costs) 

Freight (Included in above costs) 

Subtotal- Purchased Equipment Costs (PEC) 

Direct installation Costs 

Foundations & supports; handling & erection; electrical; piping; 

etc. 

Site Preparation f Buildings- Included above 

Subtotal - Direct Installation Costs 

TOTAL DIRECT COSTS (TDC) 

INDIRECT INSTALLATION COSTS 

Engineering Costs (Included in above costs) 

Construct. & Field Expenses (Included in above costs) 

Contractor Fees (Included in above costs) 

Start-up (Included in above costs) 

Performance Test (Included in above costs) 

Contingency (3% of PEC) 

TOTALlNDIRECT COSTS. iC 

TOTAL CAPITAL INVESTMENT (TCI) 

App A RACT Cost Effectiveness 9-6-2013.xlsx Unit 866-12Hl SCR 

COST ($) 

2,897,832 

2,897,832 

o 

o 

2.897,832 

86,935 

86.935 

2.984.767 

44 of 66 
PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACf Control Cost Effectiveness 

COST COMPONENT: 

ANNUAL DIRECT COSTS 

Operation and Maintenance Labor 

Maintenance Labor and Material (2.75% ofTCI) 

Annualized Cost Factor 

Annualized Cost Factor 

Replacement cost 

Subtotal- Operation and Maintenance Labor 

Utilities 

Ammonia Cost 

Catalyst Replacement Cost 

Electricity Cost 

Subtotal - Utilities 

AL DIRECT COSTS· 

COST COMPO~ENT: 

TOTAL ANNUAL O&M COSTS 

Annualized Cost Factor 

Annualized Cost Factor 

CAPITAL RECOVERY COSTS 

Replacement Life (years) 

Interest Rate (%) 

Equipment Life (years) 

Interest Rate (%) 

TOTAL CAPITAL REQUIREMENT 

TOTAL ANNUAL CAPITAL REQUIREMENT 

TOTAL ANNUALIZED COST 

(Total annual O&M cost and annualized capital cost) 

App A RACT Cost Effectiveness 9-6-2013.xlsx Unit 866-12Hl SCR 

1 

21.83 

10 

21.83 

COST ($) 

82,081 

82,081 

0.25 

4,513 

19,943 

0.3 

24,457 

]06,538 

COST ($) 

106,538 

0.25 

2,984,767 

756,608 

863,147 

45 of 66 
" 

" 

PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

Source Unit 866-12Hl 

Control ULNB 

Rated Heat Input 61.2 

Number of Burners 6.0 

Baseline Actual Emissions 30.29 

Current Emission Rate 0.113 

Control Efficiency 73% 

Heater Capacity 64.6 

Burner Heat Release Rate 13.8 

Evaluated at New Firing Limit at 2012 Cost and Efficiencies 

MMBtulhr 

Burners 

tpy 

IblMMBtu 

GJ/hr 

GJ/hr 

Costs derived from Alternative Control Techniques Document - NOx Emissions from Process Heaters (Revised) - EPA4531R-93-034 

DIRECT COSTS 

COST COMPONENT: 

Purchased Equipment Costs 

Equipment Cost CEC) 

Instrumentation (10% ofEC) 

Sales taxes (5% ofEC) 

Freight (8% of EC) 

Subtotal- Purchased Equipment Costs (PEC) 

Direct Installalion Costs (Based on Vendor Discussion) 

Foundations & supports; handling & erection; electrical; piping; 

etc. 

Site Preparation! Buildings- Included above 

Subtotal- Dired Installation Costs 

TOTAL DIRECT COSTS (TDC) 

INDIRECT INSTALLATION COSTS 

Engineering Costs (5% of PEe) 

Construct. & Field Expenses (Included in above costs) 

Contractor Fees (10% ofPEC) 

Start-up (I % of PEC) 

Performance Test (I % of PEe) 

Contingency (3% of PEe) 

TOTAL iNDiRECT COSTS, iC 

TOTAL CAPITAL INVESTMENT (TCI) 

App A - RACT Cost Effectiveness 9-6-2013,xlsx Unit 866-12Hl ULNB 

COST(S) 

361.404 

36,140 

18,070 

28,912 

444,527 

o 

o 

444,527 

22,226 

44,453 

4,445 

4,445 

13,336 

88,905 

533,432 

46 of 66 
, 

PES Refinery 

Heater Firing Rate Increase PIan Approval 

NOx RACT Control Cost Effectiveness 

COST COMPONENT: 

ANNUAL DIRECT COSTS 

Operation and Maintenance Labor 

Maintenance Labor and Material (2.75% ofTC1) 

Annualized Cost Factor 

Replacement Life (years) = 

Interest Rate (%) = 

Annualized Cost Factor 

Replacement cost 

Subtotal- Operation and Maintenance Labor 

Utilities 

None 

Subtotal - Utilities 

TOTAL ANNUAL DIRECT COSTS· 

COST COMPONENT: 

TOTAL ANNUAL O&M COSTS 

A nnualized Cost Factor 

Equipment Life (years) = 

Interest Rate (%) = 

Annualized Cost Factor 

CAPITAL RECOVERY COSTS 

TOTAL CAPITAL REQUIREMENT 

TOTAL ANNUAL CAPITAL REQUIREMENT 

TOTAL ANNUALIZED COST 

(Total annual O&M cost and annualized capital cost) 

App A - RACT Cost Effectiveness 9-6-2013.xlsx Unit 866-12Hl ULNB 

COST ($) 

14.669 

14,669 

10 

21.83 

0.25 

0.0 

]4,669 

COST ($) 

14,669 

10 

21.83 

0.25 

533,432 

135,220 

149,889 

47of66 
, 

, 

I'FS Refinery 

Heater Fjring Rate Increase Plan Approval 

NO> RACT C.ntrol Cos, Eft'ftd •• ...., 

SoIDU lInit 866-1201 

Control LNB & SNCR 

Rat ... Hea' Input 6).2 

Number of Bumers 6.0 

Baseli .. Actual Emi ....... 30.29 

Current Emission Ra~ 0.113 

Control Effictel'KY 70%, 

Heater Capacity 64.6 

Burner Hea. Re&e~ Rate 13.8 

Evalual'" at New Firillll Limit at 2011 Co ....... Efficiencies 

MMBtvJhr 

Bumen 

tpy 

IblMMBtu 

GJIbr 

GJIbr 

Co,,,, ... ri .... from All.",";"" CnnJrt>l Tdlflq ... Doc.m.", • NO. EmissWi<. fr-I'rocw; H.lllers (R_.d) • EPA-453/R·93-034 

COST COMPONENT; COST(S) 

DIRECT COSTS· LNB 

Purchased Equipment Casts 

Equipment Cost (Ee) 188.440 

Instrumentation (10% ofEC) 18.844 

Sales rllXcs(5% ofEC) 9,422 

Freight (8% ofEC) 15,075 

Stlbt,lIuJ • P,m:Aase4 EqKipllU:nJ Costs (PEe; 231,78) 

Direct InstaJlation Cos/s (Based on Vendor Discussion) 

Foundations & supports; handling & erection; electrical; piping~ 

etc. 0 

Site Preparation! Bui1dings-lncluded above ... ---- SllbtoluJ· Dir<Ct IlfstuJladtm em .. 0 

TOTAL DIRECT COSTS rmC) . LN8 231,781 

INDIRECT INSTALLATION COSTS· LNB 

Engineering Costs (S% ofPEC) 11.589 

Construct. & Field Expenses (Included in aoove costs) ... 

ContracTor fees (I!l"/' ofPEC) 23.178 

Start-up (l%ofPEC) 2.318 

Performance Test (J% ofPEC) 2)18 

Contingency (3% ofPEC) 6.953 

TOTAL INDIRECT COSTS, IC· LNB 46,3lI6 

DIRECT COSTS· SNCR 

Purchased Equipmenl Costs 

Equipment Cost (ECl 544,494 

Instrumentation (Included in abovc costs) ... 

Sales taxes (Included in above costs) ... 

Freight (Included in above eosts) ---

S.DtoIuJ. PrucAfJ!J<ti EqMip""'lft COIls (PEC) 544.494 

DiN!CI/nslal/alion CaSiS (Based on Vendor Dis('lw.ion) 

Foundations & supports; handlmg & erection; electrical; piping; 

etc, 0 

Site Preparation J Buildings- lncluded above ... 

Sflbtola/ ~ Di,eCl InSlfllllllion CoSB --0--

TOTAL DIRECT COSTS (TDC) . SNCR 544,494 

INDIRECT INSTALLATION COSTS· SNCR 

Engineering Costs (Included in above costs) 

Construct & Field Expenses (Included tn above costs) 

Contractor Fees (Included in above costs) _. 

Stan-up (Included in above costs) 

Penonnancc Test (Included in above costs) ... 

Contingency (3% ofPEC) 16.335 

TOTAL INDIRECT COSTS. IC - SNCR 16,335 

TOTAL CAPITAL INVESTMENT (TCI) - LNB 278,137 

TOTAL CAPITAL INVESTMENT (TCI) - SNCR 560.828 

iTOTAL CAPITAL INVESTMENT (TCI) 838,966 

App A· RACT Cost Effectiveness 9·6-2013 .• ls. Unit 866-12Hl LNB II< 5NCR 48 0166 
, 

PES Refin.ry 

H •• ter Firing Ralelncrease Plan Approval 

NO. RACT Control COlI' Elle<ti ...... 

COST COMPONE"', 

ANNUAL DIRECT COSTS 

Opera/ion and Maintenance Labor 

Mamtenance Labor and Material (2.75%1 ofTeT) 

Annualized COSI Factor 

Replacement Life (years) ~ 

Interest Rate (%) "'" 

Annualized Cost Faelor 

Replacement cost 

SlI.blatsJ - OperatiOlf IUUI MtlbUelJanu Labor 

Utilities 

AmmoniaCoSl 

Electricity Cost 

8u_lIl. UIi/i1in 

TOTAL ANNUAL DIRECT COSTS' 

COST COMPONENT, 

TOTAL ANNUAL 0&111 CUSTS 

Annualized COSI FacioI' 

Equipment Life (years) = 

Interest Rate (%) = 

Annualized Cost Factor 

CAP/TAL RECOI'ERYCOSTS 

TOT.4L CAPITAL REQUIREMENT 

TOTAL ANNUAL CAPITAL REQUIREMENT 

TOTALA1VNUALIZEJ) C08T 

(TO/Ill _ul 0&111 oost #1"/ lUI""lIli;,ed C/I{JItal <",I) 

COST(S) 

23,072 

Zl,IJ72 

10 

21.83 

0,25 

4,513 

0,3 

4,514 

I Z7,585 

COST(S) 

Z7,5llS 

10 

21.83 

0,25 

838,966 

212,669 

248,255 

App A - RACT Cost Effectiveness !H-2013.xls. Unit 866-12Hl LNB & SNCR 49 of 66 
FES Refinery 

H •• ler Firing Ral. Incre ... Flan Appnwal 

NO. RACT eontml C." EIf.di ....... 

SOUIU Unit 861>-12Hl 

e •• trol LNB&FGR 

Rated Ileat Input 6t.2 

Number of Bumen 6.0 

Baseline Actual Emissions 30.29 

Curftn( Emis$ion Kale 0.113 

Contml Efficiency 550/. 

Healn eapadty 64.6 

Burner Ileal R.a.- Rate 1l.8 

E.alualed al New FiJi", Lilnit al 2012 C." and Emde""ies 

MMBtulhr 

Burners 

Ipy 

Il>lMMBIU 

GJ/hr 

GJIhr 

eMU derived from Allenlati,'r Omtrol T«II1fiIlIU!S lJ.ocM",ell1-NOx EIlfLUimufro/lt Process HMos (Rel'ised) .. EPA-4SJ/R-9J..034 

COST COMPONENT: COST(S) 

DlREC7' COSTS - LNS 

Purchased Equipment Costs 

Equipment Cost (EC) 188,440 

Instrumentation (10"10 orEe) 18.844 

Sales taxes (5% cfEe) 9,422 

Freight (8% of Ee) 15,075 

Sltbto,aJ. PIIrdtlU<d EqMipMml C",'s (PEe) 231,781 

Direct ilUlallation Cos/s (Bwed on Vendor Discussion) 

Foundations & supports; handling & erection: dectrical; piping: 

ete. 0 

Site Prepanlfjon I BuiJdings~ Included above ---- Sltbrolai - Di"~ct InstaJWioR Costs 0 

TOTAL DIRECT COSTS (rOC) - LNS 231,781 

INDIRECT INSTALLATION COSTS - LNB 

Engineering Costs (5% ofPEC) 11.589 

Construct. & Field Ex.penses (included in above costs I 

Contractor Fees (J 0% ofPEC) 23,178 

Stan-up (1% ofPEC) 2,318 

Perfonnance Test (1°/(, ofPEC) 2,318 

Contingency (3% of PEC) 6,953 

TOTAL INDIRECT COSTS. IC - LNB 46,356 

DIRECT COSTS - FGR 

PurchasedEqllipment Costs 

Equipment Cost (EC) 218,823 

InsrrumenlatlOn (Included in above costs) --- Sales taxes (Included in above costs) 

Freight (included In above costs) ---

5Mbtolal- PIIrcltlllli.d Eqllipment Costs (PEe) 218,823 

Direclln.HallCilion COSIS (Based on Vendor Discussi(mj 

Foundations & supports~ handling & erection; electricat piping; 

etc. 0 

Site Preparation / Buildings~ Induded above 

Subtotal ~ Dine,lnstaJUtJimt. ('osIs --0--

TOTAL DIREC7' COSTS (TDCJ - FGR 218,8Z3 

INDIRECT INSTALLATION COSTS - FGR 

Engmeering Costs (Included in above costs) --- Construct & Field Ex.penses{mcluded in above costs) ---

Contractor Fees (Included in above costs) ---

Start-up (Included in above costs) 

Perfonnance Test (Included in above costs) 

Contingency (3% ofPEC) 6.565 

TOTAL INDIRECTCOSTS.IC - FGR 6,565 

TOTAL CAPITAL INVESTMENT (TCI) - LNB 278,137 

TOTAL CAPITAL I~VESTMENT (TCI) - FGR 225,388 

TOTAL CAPITAL rNVESTME~T (TCI) 503,525 

App A - RAG Cost Effectiveness 9-6-2013.xl .. Unit 866-12Hl LNB & FGR 50 of 66 
PES Refinery 

Heater Firing Ratelno,,_ Plan Approval 

NO. RACT Control Cost En<cliv ...... 

COST (''OMPONENT: 

ANNUAL DIRECT COSTS 

Operation and MaintenanL'e Labor 

Maintenance Labor and Material (2,75% of Ie I) 

Annualized COS! Factor 

Replacemenl Life (years) = 

Interest Rate (%) "" 

Annualized Cost Factor 

Replacement cOSt 

SlllitOiai ~ OpttrtJlj(lfllUUl MaiII1elJdlfce lAbt.W 

Utililies 

Electricity Cost 

SltbIO/oJ - Ulilllie> 

TOTAL ANNUAL DIRECT COSTS· 

COST COMPONENT: 

TOTAL ANNUAL OdM COSTS 

Annualized Cost Pac/or 

Equipment Life (yellTS) "" 

Interest Rate {%) = 

Annualized Cost Factor 

CAPITAL RECOVERY COSTS 

TOTAL CAPITAL REQUIREMENT 

TOTAL ANNUAL CAPITAL REQUIREME"T 

TOTALANNIJALIZEDCOST 

(Total PIJMaI O&M CMI iUUI tmllualiud capital cost) 

COST(S) 

~ 

13,847 

10 

21.83 

0,25 

7.781 

7,781 

21,628 

COST(S) 

21,628 

10 

21.83 

0.25 

503.525 

127,639 

149,267 

App A - RACT COst EffectIveness 9-6·2013.xl .. Un~ 866-12Hl LNB & FGR 

I 

Sl0166 
, 

, 

PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

Source Unit 866-12HI 

Control Sl'iCR 

Rated Heat Input 61.2 

N umber of Burners 6.0 

Baseline Actual Emissions 30.29 

Current Emission Rate 0.113 

Control Efficiency 40% 

Heater Capacity 64.6 

Burner Heat Release Rate 13.8 

Evaluated at New Firing Limit at 2012 Cost and Efficiencies 

MMBtulhr 

Burners 

tpy 

Ib/MMBtu 

GJlhr 

GJlhr 

Costs derived (rom Alternative Control Techniques Document- NOx Emissions/rom Process Heaters (Revised) - EPA-453/R-93-034 

DIRECT COSTS 

COST COMPONENT: 

Purchased Equipment Costs 

Equipment Cost (EC) 

Instrumentation (Included in above costs) 

Sales taxes (Included in above costs) 

Freight (Included in above costs) 

Subtotal- Purchased Equipment Costs (PEC) 

Direct Installation Costs (Based on Vendor Discussion) 

Foundations & supports; handling & erection; electrical; piping; 

etc. 

Site Preparation I Buildings- Included above 

Subtotal - Direct Installation Costs 

TOTAL DIRECT COSTS (TDC) 

INDIRECT INSTALLATION COSTS 

Engineering Costs (Included in above costs) 

Construct. & Field Expenses (Included in above costs) 

Contractor Fees (Included in above costs) 

Start-up (Included in above costs) 

Performance Test (Included in above costs) 

Contingency (3% ofPEC) 

TOTAL INDIRECT COSTS. IC 

TOTAL CAPITAL INVESTMENT (TCI) 

App A RACT Cost Effectiveness 9-6-2013.xlsx Unit 866-12Hl SNCR 

COST ($) 

544,494 

544,494 

o 

o 

544,494 

16.335 

16.335 

560.828 

52 of 66 
" 

" 

PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

COST COMPONENT: 

ANNUAL DIRECT COSTS 

Operation and Maintenance Labor 

Maintenance Labor and Material (2.75% ofTCl) 

Annualized Cost Fac/or 

Replacement Life (years) 

Interest Rate (%) = 

Annualized Cost Factor 

Replacement cost 

Subtotal- Operation and Maintenance Labor 

Utilities 

Ammonia Cost 

Electricity Cost 

Subtotal- Utilities 

TOTAL ANNUAL DIRECT COSTSs 

COST COMPONENT: 

TOTAL ANNUAL O&M COSTS 

Annualized Cost FaClOr 

Equipment Life (years) = 

Interest Rate (%) = 

Annualized Cost Factor 

CAPITAL RECOVERY COSTS 

TOTAL CAPITAL REQUIREMENT 

TOTAL ANNUAL CAPITAL REQUIREMENT 

TOTAL ANNUALIZED COST 

(Total annual O&M cost and annualized capital cost) 

App A - RACT Cost Effectiveness 9-6-2013.xlsx Unit 866-12Hl SNCR 

COST ($) 

15,423 

]5."23 

10 

21.83 

0.25 

4,513 

0.3 

.... ';;] .. 

]9,936 

COST ($) 

]9,936 

10 

21.83 

0.25 

560,828 

142.164 

162,10] 

53 of 66 
(" f" 

PES Refinery 

Heater Firing Rate Increase Plan Approval 

Unit 868-8H101 RACT Cost Effectiveness Summary 

A B C D E F G II 

Current Control Maximum Post Potential 2012 Total 

Control Option Design Firing Emission Rate Potential Emissions Efficiency Control Emissions NO. Capital Cost 2012 O&M Cost 

(MMBtu/hr) (TPY) @ Design Firing Reduced ($) (lb/MMBtu)l (%) (TPY) (TPY) ($) 

ULNB&SCR 60 0.113 29.7 96% 1.2 28.5 3,472,395 119,468 

SCR 60 0.113 29.7 85% 4.5 25.2 2,949,422 105,087 

ULNB 60 0.113 29.7 73% 7.9 21.8 522,973 14,382 

LNB&SNCR 60 0.113 29.7 70% 8.9 20.8 1,057,946 33,519 

LNB&FGR 60 0.113 29.7 55% 13.4 16.3 726,468 27,607 

SNCR 60 0.113 29.7 40% 17.8 11.9 554,204 19,666 

Calculation = A • B • 8760 / 2000 = C· (1- DJ =C-E 

Notes: 

1 Unit 868-81:1101 is projected to be above PADEP presumptive RACT firing limits and assumed NO, emission rate limit of 0.113 Ib/MMBtu is used. 

2 See "RACT Cost Summary" tab for details on the Annualized Cost Factor (ACF). 

App A - RACT Cost Effectiveness 9-6-2013.)(lsl( 868-8HIOl RACT 

~ 

2012 Annualized 2012 Cost 

Cost2 Effectiveness 

($) ($/Ton) 

999,686 35,060 

852,736 33,782 

146,950 6,737 

301,697 14,513 

211,759 12,965 

160,151 13,482 i 

= (G* ACFJ + H = I / F . 

54 of 66 
(, PES Refinery 

Heater Firing Rate Increase Plan Approval 

NO. RACT Control Cost EfI'ectiven .. , 

Source Unil 868-3HIOI 

Control ULNB&SCR 

Rated neal Input 60.0 MMBtulhr 

Number or Burners 4.0 Burners 

Baseline Actual Emissions 29.70 tpy 

Current Emission Rate 0.113 IblMMBtu 

Control Efficiency 968

;. 

Heater Capacity 63.3 GJ/hr 

Burner Heat Release Rate 20.3 GJlhr 

Evaluated at New Firing Limit at 2012 Cost and Efficiencies 

C05rs d.ri,ed rrom AllulUlli". Control Techniques DocumenJ· NOx Emissionsfrom Process HeIllus (Revi5etI) • EPA.-453/R-93-034 

COST COMPONENT: COST ($) 

DJRECTCOSTS - ULNB 

Purchased Equipment Costs 

EquIpment Cost (EC) 354,317 

Instrumentation (10% ofEe) 35.432 

Sales taxes (5% ofEe) 17.716 

Freight (8% ofEe) 2S.345 

Sublolal. Purcluzsed EquipmenJ Costs (PEe) 435.810 

Direct Installation Costs (Based on Vendnr Discussion) 

Foundations & supports~ handling &. erection; electrical; piping; 

etc. 0 

Site Preparation I Buildings-Included above .. - Subtotaf· Direcllnstallali,m Costs 0 

"!VTAL DIRECT COSTS rrDC)· ULNB 435.810 

(, INDIRECT INSTALLATION COSTS· ULNB 

Engineering Costs (5% ofPEC) 21.791 

Construct. & Field Expenses (Included in above costs) 

ConlTllCtor Fees (10% or PEe) 43.581 

Start-up (1 % ofPEC) 4,358 

Perfonnance Test (1% ofPEC) 4,358 

Comingency(3% of PEe) 13,074 

TOTAL INDIRECT COSTS. Ie - ULNB 87.162 

DIRECT COSTS - SCR 

Purchased Eqllipmenf Costs 

Equipment Cost (ECI 2.863.517 

Instrumentation (Included in above costs) . --

Sales taxes (Included in above costs) ... 

Freight (Included in above costs) .. -

Sublolal· Purchased Equip",enJ Costs (PEe) 2,363,517 

Direct }ns/alia1ion Costs 

Foundations & supports; handling & erection; electrical; piping; 

etc. 0 

Site Preparation I Buildings· Included above 

Sllblolaf· Direcl Installation Costs 0 

TOTAL DIRECT COSTS rrDC) - SCR 2,863,517 

INDIRECT INSTALLATION COSTS - SCR 

Engineering Costs (included in above costs) -- . 

Construc£, & Field Expenses (Included in aoove costs) ... 

Contractor Fees (lncluded in above costs) 

Start-up (Included in above costs) 

Performance Test (Included in above costs) --

Contingency (3% ofPEC) 85.906 

TOTAL INDIRECT COSTS. IC - SCR 85,906 

TOTAL CAPITAL Thc'VESTMENT (TCI)· lJLNB 522,973 

TOTAL CAPITAL INVESTMENT (TCI) • SCR 2.949.422 

TOTAL CAPITAL INVESTM ENT (TCI) 3,472.395 

App A· RAeT Cost Effectiveness 9-6-2013.xlsx Unit 868-8H10l UlNB & SCR 55 of 66 
(; 

, 

PES Refinery 

Heater Firing Rate Increase Plan Appro. al 

NO. RACT Control Cost Err.ctive ..... 

COST COMPONENT: 

ANNUAL DIRECT COSTS 

Operation and Mainlenance Lebor 

Maintenance Labor and Material (2.75% ofTCI) 

Annualized Cost Factor 

Replacement Life (years) 

Interest Rate C%): 

Annualized Cost Factor 

Replacement cost 

Subtotal ~ Operation lind MllintentlllCt! Lahor 

Utilities 

Ammonia Cost 

Catalyst Replacement Cost 

Electricity Cost 

Subtotal - Utililies 

IIUIAJ .AI'II'IUA. UIKI>t.:1 t.:Ul!).il!) 

COST COMPONENT: 

TOTAl.AN.NUAL O&MCOSTS 

Annualized Cost Factor 

Equipment Life (ye",,) ~ 

Interest Rate (% 1 

Annualized Cost Factor 

CAPITAL RECOVERY COSTS 

TOTAL CAPITAL REQUiREMENT 

TOTAL ANNUAL C4PITAL REQUlREME/'.T 

TOTAL ANlVUALIZED COST 

(T0/4lo_al O&M cost and annuoli;:eJ capital cost) 

10 

21,83 

10 

21,83 

App A - RAeT Cost Effectiveness 9-6-2013 .• 15' Unit 868-8HIOI ULNB & SCR 

COST(S) 

95,491 

95,491 

0.25 

4,425 

19,552 

0.3 

23,978 

119,468 

COST(S) 

119,468 

0.25 

3.472,395 

880,217 

999.686 

56 of 66 
(., 

PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

Source Unit 868-8HIOI 

Control SCR 

Rated Heat Input 60.0 

Number of Burners 4.0 

Baseline Actual Emissions 29.70 

Current Emission Rate 0.113 

Control Efficiency 85% 

Heater Capacity 63.3 

Burner Heat Release Rate 20.3 

Evaluated at New Firing Limit at 2012 Cost and Efficiencies 

MMBtulbr 

Burners 

tpy 

IblMMBtu 

GJlbr 

GJlbr 

Costs derived from Alternative Control Techniques Document - NOx Emissions from Process Heaters (Revised) - EPA-453/R-93-034 

DIRECT COSTS 

COST COMPONENT: 

Purchased Equipment Costs 

Equipment Cost (EC) 

Instrumentation (Included in above costs) 

Sales taxes (Included in above costs) 

Freight (Included in above costs) 

Subtotal- Purchased Equipment Costs (PEC) 

Direct instal/at ion Casts 

Foundations & supports; handling & erection; electrical; piping; 

etc. 

Site Preparation I Buildings- Included above 

Subtotal- Direct Installation Costs 

TOTAL DIRECT COSTS (TDC) 

iNDIRECT INSTALLATION COSTS 

Engineering Costs (Included in above costs) 

Construct. & Field Expenses (Included in above costs) 

Contractor Fees (Included in above costs) 

Start-up (Included in above costs) 

Performance Test (Included in above costs) 

Contingency (3% ofPEC) 

TOTAL INDIRECT COSTS, IC 

TOTAL CAPITAL INVESTMENT (TCI) 

App A - RACT Cost Effectiveness 9-6-2013.xlsx Unit 868-8H10l SCR 

COST ($) 

2,863,517 

2,863,517 

o 

---

o 

2,863,517 

85,906 

85,906 

2.949.422 

57 of 66 
" 

PES Refinery 

Heater Firing Rate Increase Plan Approval 

JliOx RACT Control Cost Effectiveness 

COST COMPONENT: 

ANNUAL DIRECT COSTS 

Operation and Maintenance Labor 

Maintenance Labor and Material (2.75% ofTCl) 

Annualized Cost Factor 

Replacement Life (years) 

Interest Rate (%) 

Armualized Cost Factor 

Replacement cost 

Subtotal- Operation and Maintenance Labor 

Utilities 

Ammonia Cost 

Catalyst Replacement Cost 

Electricity Cost 

Subtotal - Utilities 

TOTAL ANNUAL DIRECT COSTS· 

COST COMPONENT: 

TOTAL ANNUAL O&'M COSTS 

Annualized Cost Factor 

Equipment Life (years) 

Interest Rate (%) 

Armualized Cost Factor 

CAPITAL RECOVERY COSTS 

TOTAL CAPITAL REQUIREMENT 

TOTAL ANNUAL CAPITAL REQUIREMENT 

TOTAL ANNUALIZED COST 

(Total annual O&'M cost and annualized capital cost) 

App A - RACT Cost Effectiveness 9-6-2013.xlsK Unit 868-8H10l SCR 

COST ($) 

81.109 

81,109 

10 

21.83 

0.25 

4,425 

19,552 

0.3 

23,978 

105,087 

COST ($) 

105,087 

10 

21.83 

0.25 

2.949,422 

747,649 

852,736 

58 of 66 
c 

, 

PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

Source Vnit 868-8H]0] 

Control llLNB 

Rated Heat Input 60.0 

N um ber of Burners 4.0 

Baseline Actual Emissions 29.70 

Current Emission Rate 0.113 

Control Efficiency 73% 

Heater Capacity 63.3 

Burner Heat Release Rate 20.3 

Evaluated at New Firing Limit at 2012 Cost and Efficiencies 

MMBtulbr 

Burners 

tpy 

IblMMBtu 

GJ/hr 

GJlbr 

Costs derived from Alternative Control Techniques Document - NOx Emissions/rom Process Heaters (Revised) - EPA-453/R-93-034 

DIRECT COSTS 

COST COMPONENT: 

Purchased Equipment Costs 

Equipment Cost (EC) 

Instrumentation (10% ofEC) 

Sales taxes (5% of EC) 

Freight (8% of EC) 

Subtotal- Purchased Equipment Costs (PEC) 

DireCIInslallation Costs (Based on Vendor Discussion) 

Foundations & supports; handling & erection; electrical; piping; 

etc. 

Site Preparation I Buildings- Included above 

Subtotal - Direct Installation Costs 

TOTAL DIRECT COSTS (l'DC) 

INDIRECT INSTALLATION COSTS 

Engineering Costs (5% of PEC) 

Construct. & Field Expenses (Included in above costs) 

Contractor Fees (10% of PEC) 

Start-up (1% ofPEC) 

Performance Test (1 % of PEC) 

Contingency (3% ofPEC) 

TOTAL INDIRECT COSTS. IC 

TAL CAPITAL INVESTMENT (TCI) 

App A - RACT Cost Effectiveness 9-6-2013.xlsx Unit 868-8H10l UlNB 

COST ($) 

354,317 

35,432 

17,716 

28,345 

435,810 

o 

o 

435,8]0 

21,791 

43,581 

4,358 

4,358 

13,074 

87,162 

522.973 

59 of 66 
, 

PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

COST COMPONENT: 

ANNUAL DIRECT COSTS 

Operation and Maintenance Labor 

Maintenance Labor and Material (2.75% ofTCI) 

Annualized Cost Factor 

Replacement Life (years) = 

Interest Rate (%) = 

Annualized Cost Factor 

Replacement cost 

Subtotal- Operation and Maintenance Labor 

Utilities 

None 

Subtotal- Utilities 

TOTAL ANNUAL DIRECT COSTS· 

COST COMPONENT: 

TOTAL ANNUAL O&M COSTS 

Annualized Cost Factor 

Equipment Life (years) = 

Interest Rate (%) 

Annualized Cost Factor 

CAPITAL RECOVERY COSTS 

TOTAL CAPITAL REQUJREMENT 

TOTAL ANNUAL CAPITAL REQUIREMENT 

TOTAL ANNUALIZED COST 

(Total annual O&M cost and annualized capital cost) 

App A RACT Cost Effectiveness 9·6·2013.xlsx Unit 868-8H 101 ULNB 

COST ($) 

14,382 

14,382 

10 

21.83 

0.25 

0.0 

14,382 

COST ($) 

14,382 

10 

21.83 

0.25 

522,973 

132,568 

146,950 

60of66 
, 

, 

i 

PES Refinery 

Heater Firing Rate Increase Plan Approval 

NO. !tACT Control Co .. EfIf<li ....... 

Sourer Uni'~HIOI 

Control LNB& SNCR 

Raled Heal Input 611.0 

Nwnber ofBumen 4.0 

Basetinr Actual Emissions 29.70 

Cumnt Emission Rate 0.113 

Control Ellk:i.l1(y 70°/. 

Heator Capacity 63.3 

Burner H •• I Release Rate 20.3 

E"aluatfod at New FiliAl Limit at 2012 Cost and Efficiencies 

MMBtulhr 

B ......... 

Ipy 

IbiMMlltu 

GJlhr 

GJlhr 

C .... dl'ri .... r ...... AIt<mtatiw C."",t7/ Technu,. .. lJocIl"' ... t - NO:r Emiss;ons/rom Ptoa:ss n"", ... (RtMsell) • EPA-45JIR-93-034 

DIRECT COS-m . LNS 

COST COMPONENT: 

Purchased £quipmertl Costs 

Equipment Cost (EC) 

Instrumentation (10% ofEC) 

Sales taxes (5% ofEC) 

Freight (8% ofEC) 

Direct b1s1allalio11 Costs (Based on Ve"dor Discussion) 

Foundations & supports: handling & erect1on; elecrncaL piplng; 

etc, 

Site Preparation j Buildings- Induded above 

!lMb/otai - D/ncJ f1tSlaillAtiotr Costs 

TOTAL DIRECT COS-m (l'DC)· LNS 

INDIRECT INSTALLATION COS-m - LNS 

Engineering Costs (5% ofPEC) 

Construct. & Field Expenses (Included in above costs) 

Contractor Fees (I 0%, ofPEC) 

Stan·up (1 % ofPECj 

Performance Test (1% ofPEC} 

Contingency (30/0 of PEC) 

TOTAL INDIRECT COS-m. /(' - V"S 

DIRECT COS-m • SNCR 

Purchased Equipment C 05/$ 

Equipment COS! (EC) 

Instrumentation (lnc1uded in abovc costs) 

Sales taxes (Included in above costs} 

Freight (Included tn above costs) 

Direct Installation Costs (Based on Vendor Dh~cussion) 

Foundations & supports; handling & erc~tion~ eJectrical; piping; 

ele 

Site Prepanrtion J Buildings- Included above 

5MblOf1l1 ~ Dind JIIstsJlatio" Costs 

TOTAL DIRECT COS-m (l'DC! - SNCR 

INDIRECT INSTALLATION COS-m· SNCR 

Engineering Costs (Included in above costs) 

Construct. & Field Expenses (Included in above costs) 

Contractor Fees {Included in above costs) 

Start·up (Included in above costs) 

Performance Test (Included in above costs) 

Contingency (3°,0 ofPEC) 

COST(S) 

341,289 

34,129 

17.064 

27.303 

419,785 

o 

419,785 

20.989 

41.979 

4,198 

4.198 

12,594 

83,957 

538,062 

--0--

538,062 

16.142 

,TOTAL INDIRECT COSTS, /(' - SNCR 16,142 

TOTAL CAPITAL INVESTMENT (TCI - L"IB 503.742 

TOTAL CAPITAL INVESTMENT (TCI) - SNCR 

TOTAL CAPITAL I"IVESTMENT TCI 1,857,946 

App A - RACT Cost Effectiveness 9·6-2013.xlsx Untt 868-8HIOI LNB & SNCR 610166 
PES Refinery 

Heater Firing Rate Increase Plan Approval 

NO. IlACT C.ntrol C ••• Effecli ....... 

COST COMPONENT: 

ANNUAL DIRECT COSTS 

Operation and Maintenance lAbor 

Maintenance Labor and Material (2.75% ofTen 

Annualized COSI Facfor 

Replacement Life (years) = 

Interest Rate (~;&) =-

Annualized Cost Factor 

Replacement cost 

5MbtlJlal- Opt!rtllilJlf m;d Mabu~"tllfu Labo, 

Ulililies 

Ammonlll Cost 

Electricity Cost 

5Mbtolol- lJ,1l1t1r.i 

TOTAL ANNlJAL DIRECT COSTS' 

COST COMPONENT: 

TOTAL ANNUAL O&M COSTS 

Annualized Cost Factor 

Equipment Life (years) = 

Inlercst Rate (0,'0) "" 

Annualized COSI Factor 

CAPITAL RECOVERY COSTS 

TOTAL CAPITAL REQUlRE}.f£,\'T 

TOTALANNlJAL CAPITAL REQVlREME!IIT 

IVTALANNUAlJZEDCOST 

(Totollllfnllol O&M COIJt lUId lUInualizd capiIal eost) 

COST(S) 

~ 

29,1)94 

10 

21.83 

0.25 

4,425 

0.3 

4,425 

33,519 

COST(S) 

33,519 

10 

21.S3 

0.25 

1.057,946 

268.179 

3111,697 

App A - RACT Cost Effectiveness 9-6-2013,xl .. Unit 868-8HIOIlNB & SNCR 620166 
PES Refinery 

Heater Firing Rale Inc"' .... Plan Approval 

NO. RACf C ... troI C .. t EIf.cdv ...... 

Sou .... lInil868.8HIOI 

Cootrol LNB& FGR 

RaCed Heat Input 60.0 

Number .r Bumo ... 4.0 

BueliDt Actual Emissions 29.70 

CUI'I'Ut Emission Rate 0.113 

Control Elftd<n<y 55% 

Htater Capacity 63.3 

Bumer Heat R~ Rate 20.3 

Evaluated al NN Firing Limit at lOU COSI and Emcien(ie! 

MMBtulhr 

Burners 

tpy 

IblMMBru 

GJlhr 

GJlhr 

Costs derivrG from A/lenrllliw COItIro/ Teclutiq"n DocItmenJ. NOx Emissimts/rom Process HestO'S (RelTsedj - EPA4-53/R-9J..{)34 

COST COMPONENT: COST(S) 

DIRECT COSTS· WB 

Purchased Equipment Costs 

Equipment Cost (Ee) 341.289 

Instrumentation (10% of EC) 34.129 

Sales taxes (5% ofEC) 17,064 

Freight (8% ofEe) 27,303 

Subtotal. Pw,cJ"mtl EqHi_", Costs (PEe) 419,785 

Direct lnslallal;on Costs (Based on Vendor Discussion) 

Foundations & supports; handling & erection; elt>ctrical: piping; 

etc. 0 

Site Preparation I Buildings-Included above ... ---- SllbJota/ - Direct J",s/allaJimt Costs 0 

TOTAL DIRECT COSTS (FOC)· LNB 419,785 

INDIRECT lNSTALLATION COSTS· LNB 

Englneering Costs (5% ofPEC) 20,989 

Construct & Field Expenses (Included in above costs., 

Contractor Fees ( 10% of PEC) 41,979 

Start-up (1% ofPEC) 4,19R 

Pcrfonnance Test (I% ofPEC) 4,198 

Contingency (3% ofPEC) 12,594 

TOTAL INDlRECTCOSTS. IC ·LNB 83,957 

DIRECT COSTS· FGR 

Purchased Equipment Costs 

Equipment Cost (EC) 216,239 

Instrumentation (Included in above costs) ... 

Sales taxes (Included in above cost~) 

Freight (Included in above costs) ... 

Sub,,,,aI. Pwrc/Jased Equipllfeltl Costs (PEe) 216,239 

Direct Jralallalion Cost-, (Based On Vendor Dis<-:lL~sion) 

Foundations & supports; handling & erection: electrical; piplng; 

etc. 0 

Site Preparation I Buildings~ Included above 

5Mb10/4I- Dirm IltsJIIJl.t1JiOlt Costs --0--

TOTAL DIRECT COSTS (rOC) . FGR 216.239 

INDIRECT INSTALLATION COSTS· FGR 

Engineering C OS!S (lnduded in above costs) .--

Construct & f'icld Expenses (lnc1uded in above costs} ... 

Contractor Fees (Included in above costs) 

Start-up (Included in above costs) 

Perfonnance Test (Included in above costs) 

Contingency (3% of PEe) 6.4R7 

TOTAL INDIRECT COSTS. IC· FGR 6,487 

TOTAL CAPITAL INVESTMENT (TCI) . LNB 503,742 

TOTAL CAPITAL INVESTMENT (TCI) - FGR 222,726 

TOTAL CAPITAL INVESTMENT (TCI) 726,468 

App A • RACT COst Effectiveness 9·&-2013.xlsx Unit 868·8H10l LNB & FGR 630/66 
PFS Refinery 

Heater Firing Rate Increase Plan Approl.'al 

NO. RACT Control Cost ElTectiv ...... 

COST COMPONENT: 

ANNUAL DIRECT COSTS 

Operation a"d Mail1lenance Labor 

Maintenance Labor and Malerial (2.7S'!."o of Tel) 

AmtlJolizeri Cos/ Factor 

Annualized Cost Factor 

Replacement cos1 

Utilities 

Electricity Cost 

8.b/0Ia1· Utilities 

!TOTAL ANNUAL DIRECT COSTS' 

COST COMPONENT: 

roTALANNUAL O&MCOSTS 

Annualized Cost FacIOI' 

Annualized C(Jst Factor 

CAPITAL RECOVERY COSTS 

TOTAL CAPITAL REQUIREMENT 

Replacement Life (yem) ~ 

Interest Rate (I,l/~) = 

Equ;pment Life (years) ~ 

Interest Rate (% 1 '"" 

TlffAL ANNUAL CAPITAL REQUIR1:."MENT 

TOTAL ANNUALIZED C08T 

(TOIaI ... If"a1 ruM _ fUfd .... "a1i;d CtIpiI4J CO$l) 

10 

21.83 

10 

21.83 

COST (51 

~ 

19,978 

0,25 

7,629 

7,629 

27,607 

COST ($) 

27,607 

0,25 

726,468 

184,152 

211,759 

App A - RAG Cost Effectiveness 9-6-2013,.1 .. Unit 868-8H10llNB & FGR 640166 
, 

, 

PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

Source Unit 868-8 HI 01 

Control SNCR 

Rated Heat Input 60.0 

Number of Burners 4.0 

Baseline Actual Emissions 29.70 

Current Emission Rate 0.113 

Control Efficiency 40"/0 

Heater Capacity 63.3 

Burner Heat Release Rate 20.3 

Evaluated at New Firing Limit at 2012 Cost and Efficiencies 

MMBtulhr 

Burners 

tpy 

IblMMBtu 

GJlhr 

GJlhr 

Costs derived from Alternative Control Techniques Document- NOx Emissions/rom Process Healers (Revised) - EPA-4531R-93-034 

DIRECT COSTS 

COST COMPO~E~T: 

Purchased Equipment Costs 

Equipment Cost (EC) 

Instrumentation (Included in above costs) 

Sales taxes (Included in above costs) 

Freight (Included in above costs) 

Subtotal. Purchased Equipment Costs (PEC) 

Direct Installation Costs (Based on Vendor Discussion) 

Foundations & supports; handling & erection; electrical; piping; 

etc. 

Site Preparation I Buildings- Included above 

Subtotal - Direct Installation Costs 

TOTAL DIRECT COSTS (TDC) 

INDIRECT INSTALLATION COSTS 

Engineering Costs (Included in above costs) 

Construct. & Field Expenses (Included in above costs) 

Contractor Fees (Included in above costs) 

Start-up (Included in above costs) 

Performance Test (Included in above costs) 

Contingency (3% of PEC) 

TOTAL INDIRECT COSTS. IC 

TOTAL CAPITAL INVESTMENT (TCI) 

App A - RACT Cost Effectiveness 9-6-2013.xlsx Unit 868-8H10l SNCR 

COST ($) 

538,062 

538.062 

o 

---

o 

538,062 

16,142 

16,142 

554,204 

65 of 66 
PES Refinery 

Heater Firing Rate Increase Plan Approval 

NOx RACT Control Cost Effectiveness 

COST COMPO~E~T: 

ANNUAL DJRECT COSTS 

Operalion and Maintenance Labor 

Maintenance Labor and Material (2.75% ofTCI) 

Annualized Cost Faelor 

Replacement Life (years) = 

Interest Rate (%) = 

Annualized Cost Factor 

Replacement cost 

Subtotal- Operation and Maintenance Labor 

Utililies 

Ammonia Cost 

Electricity Cost 

Subtotal· Utilities 

TOTAL ANNUAL DIRECT COSTS8 

COST COMPONENT: 

TOTAL ANNUAL O&M COSTS 

Annualized Cosl Faclor 

Equipment Life (years) 

Interest Rate (%) 

Annualized Cost Factor 

CAPITAL RECOVERY COSTS 

TOTAL CAPiTAL REQUiREMENT 

TOTAL ANNUAL CAPITAL REQUIREMENT 

TOTAL ANNUALIZED COST 

(Total annual O&M cost and annualized capital cost) 

App A - RACT Cost Effectiveness 9-6-2013.xlsx Unit 86B-8H101 SNCR 

COST ($) 

15,241 

15,241 

10 

21.83 

0.25 

4,425 

0.3 

4,425 

19.666 

COST ($) 

19,666 

10 

21,83 

0.25 

554,204 

14M85 

160,151 

66 of 66 
Attachment B 

AMS Plan Approval Application 

Forms 
CITY OF PHILADELPHIA 

DEPARTMENT OF PUBUC HEALTH 

PUBUC HEALTH SERVICES 

AIR MANAGEMENT SERVICES 

Nt Management ServIcaI 

321 Untvwalty Avenue 

PhIIadeI,phIe PA 19104-4543 

Phone: (215) 885-7572 

FAX: (215) 888-7693 

APPLICATION FOR PLAN APP1tOVAL TO CONSTR.UCI', MODIFY OR REAcnv ATE AN AIR 

CONTAMINATION SOURCE AND/OR AIR CLEANING DEVICE 

(Prepan "II bl/trmUl.t.iDn armpldely ill print or type in triplicll.U) 
(' t' f" 

SECTION F I - GENERAL SOURCE INFORMATION 

I. SOURCE 2. NORMAL PROCESS OPERATING SCHEDULE 

A. B C. D. E. A. B. C. D. 

TypeSoun:e Manulaclurer ModclNo. Rated Capacity Type of Materials Processed Amount Average Total % Throughput/Quarter 

(Describe) ofSoun;e (Specify units) Processed/yr. hr/day hr/yr 

(Specify units} 

I" 2"" 3n1 4'" 

I Target heaters 

See Attached Report for 

Proposed Heater Firing 

Changes 

-- 3. ESTIMATED FUEL USAGE (Specify Units) 4. ANNUAL FUEL USAGE 

--------

A. B. e. D. E. F. G. A. B. e. D. 

Used Type Fuel Average Maximum Percent Percent Ash Heating Value Annual Amounts Average Total hr/yr % '[broughput/Quarter in Hourly Hourly Rate Sulfur hr/day 

Unit Rate 

" 

2"" 3'" 4" 

See Attached Report for 

Proposed Fired Htr. Duty 

Changes 

S. IMPORTANT: Attach on a separate sheet a flow diagram of process giving all (gaseous, liquid, and solid) flow rales. Aim list raw materials charged to process equipment alld the amounts charged 

(tons/hour, etc.) at rated capacity (give maximum, minimum and average charges describing fully expected variations in production ntes). Indicate (on diall:ram) all poinlS where 

contaminalilS are controlled (location of water sprays, hoods or other pickup paints, etc.). 
c 

" 

SECTION Fl· GENERAL SOURCE INFORMATION CO~TINUEO 

6 Describe process equipments in detail. 

See Attached Report Sections 

7. Describe fully the methods used to monitor and record all opmlling conditions that may affect the emission of air contammants. Provide detailed 

infonnation to show that these methods provided are adequale. 

No New Monltoring Equipment 15 Proposed or Required 

8. Describe modifications to proces.<; equ ipments in detail. 

See Attached Report Sections 

9. Auach any and all additional infonnation necessary to adequately describe the process equipment and to plrlorrn a thorough evaluation ofthc extent and 

nature of its emissions. 

See Attached Report that includes a BATIRACT analysis 

PROVIDE EQUIPMEr-rT INFORMATION ON THlS PAGE If SOURCES DO NOT BELONG TO SPECIAL CATEGORIES IN f2 TO FS, OTHERWISE REMOVE THIS PAGE FROM Tm'i APPLlC:\ T10~ 

IF THERE ARE MORE EQUIPMENT, COpy THIS PAGE AND FlLL IN THE INFORMATION AS INDICATED 
SECTION F 2· COMBUSTION UNITS INFORMATION 

I COMBUSTION UNITS HIOI; H201; 11Hl; 11H2; 12Hl; 8HI01; BIOI· See Discussion Sections 

A. Manufacturer NA B. ModdNo. NA 

0 Rated heat input (Btulhr) E Peak heat input (Btu/hr) 

NA NA 

G. Method firing 

o Pulvenzed 0 Spreader Stoker 0 Cyclone 0 Tangential 0 Normal 0 FIUldi7.a1 ~ o Other 

2 FUEL REQUIREMENTS 

lYPE QUANTITY QUANTITY SULFUR 

HOURLY ANNUALLY 

OIL NuMBER NA NA NA 

NA 

OTHER NA NA NA 

NA 

3. COMBUSTION AIDS. CONTROLS, AND MONITORS (No New Equipment) 

o A O"erflfe jets Type Number 

i 

o B. Draft controls Type Type 

I 0 C. Oil preheat 

o D. Soot cleaning Temperature (" F) Frequency 

IDE. Slack sprays Method 

o F. Opacity monitoring device Method 

o G. Sulfur oxides monitoring device Type Method 

I8:I H. N itrogCIJ oxides monitoring device Type Method 

I8:I t Fuel metering and/or recording devices Type Method 

OJ. Atomization interlocking device Type Method 

o K. Collected flyash reentrainment prevenlative device Type 

o L. Modulating controls B Step 

Automalic 

4.0 Flyash reinjection. (De:scribeoperntion) 

NIA 

5. Describe method of supplying make up air to the furnace room. 

NIA 

USE TIllS PAGE FOR COMBUSTIOI' SOURCE. OTHERWISE REMOVE THIS PAGE FROM THIS APPLICATION 

IF THERE ARE MORE THAN OI'E UNn', COpy THIS PAGE AND FILL IN THE INFORMATION AS INDICATED 

C Unit No. NA 

F Use 

NA 

ASH BTUCOr.TENT 

NA NA 

NA NA 

Height above gmte 

Cost 

COSI 

COSI 

Cost 

Cost 
SECTION F 2 - COMBUSTION UNITS INFORMATION, CONTINUED 

6 OPERATING SCHEDULE 

- NA hours/day NA days/week NA weeks/year 

7. SEASONAL PERIODS (MONTHS) N/A 

Opa-dling using primary fuel Operaling usmg secondary fuel __ .. 

to 10 

Non.aperaling 

to 

8. If heal input is in excess of 250 x 10 " Btuihr .. describe fully the methods used 10 record the following: rale of fuel bum<XI; heating value. sulfur and ash content of 

fuels; smoke. sulfur oxides and nitrogen oxides emissions; and if electric generating plant. the average electrical output and the minimum and maximum hourly 

generation rate. 

PES will continue to monitor, record, and report witb applicable reqnirements found in tbe Pbiladelpbia Refinery'S existing Title V permit and the Consent 

Decree 

9. Describe modifications to boiler in detai I. 

See Attached Report Sections 

10. Type and method of disposal of all waste materials generat<XI by this boiler. 

(Is a Solid Waste Disposal Permit ne<XI<XI? 0 Yes 181 No) 

II. Briefly describe the method of handling the waste water Irom this boiler and its associat<XI air pollution control equipment. 

(Is a Water quality Management Pennit needed? 0 Yes 181 No) 

12. Attach any and all additional information necessary to perfonn a thorough evaluation of this boiler. 

See Attacbed Report Sections 

U~'E THIS PAGE FOR COMBUSTION SOURCE. OfHERWlSE REMOVE nIlS PAGE FROM THIS APPLICATION. 

IF THERE ARE MORE THAN ONE UNIT, COPY THIS PAGE AND FILL L"I THE INFORMATION AS INDICATED 

I 
SECfION G - FLUE AND AIR CONTAMINANT EMISSION INFORMATION 

I. STACK AND EXHAUSTER ! 

This project does 001 inwlve any changes to e'd.ting stacks or emission points. 

A. Outlet volume of exhaust gases B. Exhauster (attach fan curves) 

CFM @ ___ oF % Moisture in w.g. HP~. ___ , .. ~_~ ___ ._~_ RPM 

C Stack height above grade (It) D Stack diameter (ft) or Oulld duct area (sq. fl.) E Weather Cap 

Grade elevation ( fI) DyES o NO 

Distance from discharge to nearest property line(fi) 

F. Indicate on an attached she<:! the location of sampling ports with respect to exhaust fan. bre.x;hing. etc. Give all necessary dimensions. 

2 POTENTlAL PROCESS EMISSIONS (OUTLET FROM PROCESS. BEFORE ANY CONTROL EQUIPMENT) 

See Attached Report Sections 

(lbslhr or gr/DSCF) B. Specific gravity of particulate (not bulk den "J . Attached particle size distribution infollllation 

D. Speci fy gaseous contaminants and concentration 

Contaminant Concentration VOC Contaminants Concentration 

(1) SO, ppm (Vol.) Ibs/hr (4) ppm (Vol.) Ibslhr 

(2) NO. ppm (Vol.) Ibs/hr (5) ppm (Vol.) Ibslhr 

m CO ppm (Vol.) Ibs/hr (6) ppm (Vol.) Ibslhr 

E. Does process vent through the con!ro] device ': U YES o NO 

- If YES continue and fill out the appropriate SECTION H CONTROL EQUIPMENT 

If NO skip 10 SECTION] - MISCELLA."lEOUS INFORMATION 

F. Can the control equipment be bypassed: (If Yes, explain) U YES o NO 

3, ATMOSPHERIC EMISSIONS 

A. Particulate matter emissions (tons per year) 

See Attached Report Sections 

B. Gaseous contaminant emissions 

Contaminants Concentration VOC Contaminants Concentration 

(I) ___ (tPy) (4)_ -- Itpy) 

(2) __ (tpy) (5) (tpy) 

(3) (tpy) (6) (tpy) 

See Attacbed Report Sections 

, 
SECTION H • CONTROL EQlJIPMENT CONTINUE[) 

12. COSTS - See Attached Report Sections 

A. List costs associated with control equipment. (Ust individual controls separately) 

Control Equipment Cost 

DlTtxtCost: 

Indirect Cost: 

B Estimated annual operating costs of control equipment only. 

13. Describe modifications to control equipment in detail. 

NiA 

14. Describe in detail the method of dust removal from the air cleaning and methods of controlling fugitive emissions from dust removal, handling and disposal. 

N/A 

15. Docs air cleaning device employ hopP"" healers, hopper vibrators or hopp<r level detectors? If so, describe. 

N/A 

16. Attach manufucture:r's perfolTl1ance guarantees and/or warranties for each of the major components of the control system (or complete system). 

17. Attach the maintenance schedule for the control equipment and any part of the process equipment that if in disrepair would increase the air contaminant emissions. 

Periodic maintenance reports are to be submitted to the Department. 

Maintenance will continue to be be pro\ided as per the manufacturer's recommendations and the Title V Permit. 

18. Attach any and all additional infolTlllllion necessary to thoroughly evaluate the control equipment. 

See Attached Report Sections 

SECTION 1- MISCELLANEOUS INFORMATION 

I Specify monitoring and recording devices will be used tor monitoring and recording of tbe emission of air contammants. Provide detailed intonnation to show that 

the faCilities provided are adequate. Include cost and maintenance information. 

0 OpllCity monitoring system o SOx monitoring system 181 NOx monitormg system 

0 CO monitoring system o C02 monitoring system 181 Oxygen monitoring system 

0 HCL monitoring system o -rn.S monitoring system o H2S monitoring system 

0 Temperature monitoring system o Stack flow monitoring system o OthaIf checked. provide manufucturer's name, model no. and pertinent technical specifications. 

NO CHANGES PROPOSED FROM EXISTrNG MONITORING, AS OUTLINED IN EXISTrNG TITLE V PERMIT. 

PROVIDE CONTROL EQUlPMENT INFORMATION ON THIS PAGE IF IT PERTAINS TO TillS APPLlCA T'O~. OTHERWISE REMOV E THIS PAGF FROM THE 

APPLICATION. 

IF THERE ARE MORE OF THE SAME TYPE OF CONTROL EQUlPMEl\.'T, COpy THAT PAGE AND FILL IN THE IN.ORMATION AS I:-':OIC,o. TED 

COl\!rROL EQCIPMEN'T CA~ SE FOUND FROM A MANCFAcnJRF.R CAT A LOGUE OR VENDORS. 
" 

2. Anach Air Pollution Episode Strategy (if applicable) 

NA 

3 If the SOUf1:e is subJeCt to 25 Pa. Code Subchapter E. New SOur1:e Review requirements, 

a. Demonstrate the availability of emission offset (if applicable) 

b. Provide an analysis of alternate sites, sizes, production processes and envitonmental controltechniquc:s demonstrating thaI the benefits of the proposed 

soun:e outweigh the environmental and social costs. 

CO Dispersion modeling is required for PSD purposes. NSR for nonattainment pollutants is not applicable. See the attached Report Sections. 

4. Attach calculations and any additional infonnation necessary to thoroughly evaluate compliance with all the applicable requirements of Article III of the ru Ics and 

regulations of PbiladeJphia Air Management, Pennsylvania Department of Environmental Protection and those requirements promulgated by the Admimstro!tor of the 

United States EnvtlUnmental Protection Agency pursuant to the provisions of the Clean Air Act. 

See A ttached Report Sections 

PROVIDE COl';,ROl EQUlrMENT lNFOR~lA TtON Ol' THIS PAGE IF rr PERTAINS TO THIS '\Pl'llCATION. OTHERW lSE REMOVE TIll' I'AGE FRc)M TIlE 

APPLICATION. 

IF THERE ARE MORF. Of TIlE SAME TYPE OF CONTROL EQUIPMENT, COPY TRA T PAGE AND FllllN THE INFORMATION AS INDICATED 

CONTROL EQUIPMENT CAN BE FOUl':D FROM A MANUFACTURER CATALOGUE OR VENOOHS