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# OAR Box 1313 Prepped by LaTeia Shed



### Document

Number: 

# 93 ) ll-B-6 7
Docket Number: 

# A-88-0 2

Printed 6/12/2008 9:03:31 AM

Sheet 93 of 99

# MR I lf l P. 2 MIDWES TRESEARC H INSTITUT E Suit e 35 0 40 1 Harriso n Oak s Boulevar d Cary , Nort h Carolin a 2751 3 Telephon e (919 ) 467-521 5 FA X (919 ) 467-806 0 

## A-88-0 2 TT-fc-fe T

Date : Jul y6 , 198 9 Subject : Summar yo f Mesh-Pa d Mis t Eliminato r Cos t Dat a fo r Har d an d Decorativ e Chromiu mElectroplatin g and Chromic Aci d Anodizin g Mode l Plant s Chromiu mElectroplatin g NESHA P EP AContrac t No . 68-02-3817 ; ES D Projec t 85/02 a MR I Projec t 7717- K From : Mar yJ d Caldwel l , '7 j

Robi n Barker ^ ' . j To : Andre

wM

. Smit h 7' j JA N I 8|99 l u 8 ESD/ISB/SS S (MD-13 ) ; :-^-«

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. S

. Environmenta l Protectio n Agenc yt 5?& A! R SV)fW f | Researc h Triangl e Park , N.C

. 2771 1 7 :

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I . Introductio n Thi s memorandu mpresent s th e capita l an d annualize d cost s o f mesh

pad mis t eliminator s use d t o contro l chromiu memission s fro mth e har d and decorativ e chromiu melectroplatin g and chromi c aci d anodizin g mode l plants
. Eac hmode l plan t i s compose d o f variou s size s o f mode l tanks
. Th e mode l tank s ar e arrange d i n si x contro l devic e configurations
. Figure s 1 throug h6 presen t th e ventilatio n syste mschemati c and ductwor k specification s fo r eac hcontro l devic e configuration
. Tabl e 1 present s th e mode l plan t parameter s o n whic hth e installe d capita l and annualize d cost s ar e based
. Fo r mode l tank s tha t requir e mor e tha n 34 0 cubi c meter s pe r minut e ( m /min ) (12,00 0 cubi c fee t pe r minut e [f t /min] ) o f ventilatio n air , tw o o r mor e mesh-pa d mis t eliminator s i n paralle l wer e use d t o contro l emission s fro mth e platin g tank s becaus e mesh-pa d mis t eliminator s ar e designe d t o handl e maximu mairflow s o f 34 0 m /mi n (12,00 0 f t /min)
. However , th e vendo r o f th e contro l device , ChromeTech , Inc. , o f Bedford , Ohio , indicate s ther e ma yb e desig n problem s wit hmesh-pa d mis t eliminator s size d fo r flo wrate s abov e 23 0 m/mi n (8,00 0 f t /min)
. Th e constructio n o f th e fram e holdin g th e mes hpad s o n unit s designe d t o handl e airflow s i n exces s o f 23 0 m/mi n (8,00 0 f t /min ) wil l probabl y requir e structura l modification s s o tha t th e pad s wil l no t b e pulle d ou t o f th e frame
. Currently , ther e ar e n o unit s i n servic e tha t ar e designe d fo r airflow s ove r approximatel y17 0 m/mi n (6,00 0 f t /min)
. ChromeTech , Inc. , provide d capita l cos t estimate s an d operatin g parameter s use d t o calculat e annualize d cos t dat a fo r mesh-pa d mis t

/P. 3

eliminator s base do nth e mode l plan t informatio npresente dabove. 2 - 4 Capita l cos t estimate s an doperatin g parameter s wer e obtaine dfo r fou r differen t size s o f mesh-pa dmis t eliminator s specifie di nth e mode l plants . Operatin g parameter s provide db y ChromeTech , Inc. , includ e th e fa nan dwashdownwate r pum phorsepowe r requirements , washdownfrequency , wate r consumptio nrates , maintenanc e an doperatin g hours , andth e lif e expectanc y

o f th e units . Al l cos t dat a ar e presente di nNovembe r 198 8 dollars . Dat a source s an dcos t factor s use dt o calculat e capita l an d annualize dcost s o f mesh-pa dmis t eliminator s ar e presente di nTabl e 2 . II . Capita l Cost s o f Mesh-Pa dMis t Eliminator s Tabl e 3 present s th e capita l cost s fo r th e fou r size s o f mesh-pa d mis t eliminator s specifie di nth e mode l plants . Th e capita l cost s includ e the purchas e cos t o f th e contro l devic e an dauxiliarie s suc ha s inle t an d outle t transitio nzones , exhaus t fan s an dmotors , washdownpump s an d motors , an

dstack ; direc t installatio ncost s fo r erection , electrica l panel s an

dwiring , instrumentatio nan dcontrols , an

dpiping ; an

dstartu p costs . Installatio ncost s ar e base do nth e assumption s tha t th e contro l devic e woul db e installe do nth e roo f o f th e platin g shop , tha t th e roo f i s 6. 1 meter s (m ) (2 0 fee t [ft] ) high , an dtha t th e roo f woul drequir e no majo r structura l modification s t o suppor t th e weigh t o f th e contro l device . Th e purchase dequipmen t cos t als o include s taxe s andfreigh t costs , whic har e assume dt o b e 3 an d5 percen t o f the ' bas e equipmen t cost , respectively . Th e startu pcos t i s assume dt o be 1 percen t o f th e purchase dequipmen t cost . III . Annualize dCost s o f Mesh-Pa dMis t Eliminator s Tabl e 4 present s annualize dcost s fo r th e fou r size s o f mesh-pa d mis t eliminato r unit s specifie di nth e mode l plants . Th e annualize dcost s includ e direc t operatin g cost s suc ha s utilities ; operator , supervisor , an dmaintenanc e labo r an dmaterials ; mesh-pa dreplacement ; indirec t operatin g cost s suc ha s overhead , propert y taxes , insuranc e an d administration ; an

dcapita l recover y

costs . Utilit y cost s includ e th e cost s o f electricit y an dwate r require dt o operat e the mesh-pa dmis t eliminators . Th e annua l electrica l cos t result s fro m bot hth e additiona l horsepowe r requiremen t neede db y th e fa nt o overcome th e pressur e dro padde dt o th e ventilatio nsystem b y th e contro l device , an

dth e horsepowe r neede dt o operat e th e washdownwate r pumps . The incrementa l fanelectrica l cost s wer e calculate dbase do nth e followin g equation : Fanelectrica l cost , $/y r = [(0.74 6 kW/hp)(hp)(t)](c ) where , k W = kilowat t h p= horsepowe r requiremen t t = operatin g time , h/yr c = electrica l cost , $0.0461/kilowatt-hour(kWh) 6



## <=£ -P. 4

Th e washdow

nwate r pump s ar e operate dfo r approximatel y 5 minute s pe r 8-hou r shif t t o was hdow nth e pad s i nth e mis t eliminator . Th e pum p electrica l cost s wer e calculate dbase do nth e followin g equation : Pum pelectrica l cost , $/yr = [(0.74 6 kW/hp)(hp)(t p )(t cd ) ](c ) where , k W = kilowat t h p= horsepowe r requiremen t t n= operatin g time o f pum ppe r hou r o f contro l devic e operation , v 0.01 0 h/ h t C( j = operatin g time o f contro l device , h/yr c = electrica l cost , $0.0461/kilowatt-hour(kWh ) Th e tota l annua l electrica l cos t o f th e mis t eliminato r i s equa l t o th e su m o f th e fa nan

dwashdownwate r pum pelectrica l costs . Wate r consumptio ncost s ar e associate dwit hth e washdowno f th e mesh-pa dmis t eliminator . Fo r th e purpose s o f thi s analysis , i t wa s assume dtha t th e washdow nwate r i s recycle dt o th e process , a s i s typicall y

th e case . Th e amoun t o f washdow nwate r require dandth e frequenc y

o f th e washdow

nwa s provide db

y ChromeTech , Inc. , fo r eac hsiz e o f mesh-pa dunit . Th e wate r cost s fo r mesh-pa dmis t eliminator s wer e calculate dusing th e followin g equation : Wate r cost , $/y

r = [(v)(f)(s)](c ) where , v = volume o f wate r pe r washdown , liter s (gallons ) f = frequenc y

o f washdown , No . o f times/8-hou r shif t s = numbe r o f 8-hou r shift s pe r year , No./y r c = wate r cost , $0.20/1,00 0 liter s ($0.77/1,00 0 gallons ) Mes hpa dreplacemen t cost s wer e include dbecaus e th e estimate dlif e o f th e pad s i s les s tha nth e estimate dlif e o f th e contro l device . ChromeTech , Inc. , estimate s tha t mos t facilitie s wil l nee dt o replac e th e mes hpad s every

4 years . Th e mes hpadmateria l i s estimate dt o cos t approximatel y

$10,600/ m

($300/f t ) o f material. 4 Mes hpadreplacemen t cost s includ e the replacemen t cos t o f th e pad s an dth e transportatio nan d disposa l cost s associate dwit hth e use dpads . Th e annualize dreplacemen t cost s o f the mes hpad s wer e calculate dusin g th e followin g equation : Replacemen t cost , $/y r = [(v)(c)](CRF p ) where , v = volum e o f pa dmateria l require dfo r eac hcontro l device , m (f t ) c = cos t o f pa

dmaterial , $10,600/ m ($300/f t ) CRF- , = capita l recover y facto r o f 0.3154 , base donaninteres t rat e o f 1 0 percen t an

da depreciabl e lif e o f 4 year s fo r th e mes hpads . Th e transportatio nan ddisposa l cost s fo r the mes hpadmateria l wer e calculate dbasedonth e followin g equation :

•*3P. 5

Disposa l an

dtransportatio ncost , $/y r = [(N)(dc ) + (N)(tc)](CRF_ ) where , N = numbe r o f 55-gallo ndrums , V/V^ , rounde dupt o th e neares t whol e numbe r V = volum e o f pa dmateria l dispose dfo r eac hcontro l device , 0 1 (f t ) (se e Tabl e 4 ) 3 V d= volum e o f 55-gallo ndrum , §.2 1 m (7.3 5 f t ) d c = disposa l cost , $50.00/dru m t c = transportatio ncost , $40.00/dru m CRF - = capita l recover y facto r o f 0.3154 , base do naninteres t rat e o f 1 0 percen t an

da depreciabl e lif e o f 4 year s fo r th e mes hpads . Th e annua l cos t o f operatin g labo r i s base do nth e amoun t o f labo r require dt o operat e th e contro l devic e plu s supervision . Th e operato r labo r i s base donvendo r estimate s fo r labg r hour s require dpe r day o f operation , anda labo r rat e o f $8.37/hour . Th e operato r labo r i s independen t o f bot hth e contro l devic e siz e an dth e numbe r o f operatin g hour s pe r day . Th e superviso r labo r cos t i s assume dt o be 1 5 percen t o f th e operato r labo r cost . Th e annua l cos t o f maintenanc e labo r fo r eac hcontro l devic e i s basedo nvendo r estimate s o f the maintenanc e hour s require dpe r 2,00 0 hour s o f operation , an da maintenanc e labo r rat e o f $9.21/hour . » Th e maintenanc e labo r i s independen t o f th e contro l devic e size . Th e annua l cos t o f maintenanc e material s i s assume dt o be 10 0 percen t o f th e maintenanc e labo r cost . Indirec t cost s includ e overhead , propert y taxes , insurance , an d administration . Th e overhea dcos t wa s calculate dbase don6 0 percen t o f the su m o f th e operator , supervisor , an dmaintenanc e labo r plu s an y materia l costs . Propert y taxes , insurance , an dadministration e wer e collectivel y

assume dt o be 4 percen t o f th e tota l capita l cost . 5 Capita l recover y

cost s associate dwit hth e mesh-pa dmis t eliminato r unit(s) , whic har e th e cost s o f capita l sprea dove r th e depreciabl e lif e o f th e contro l device , wer e calculate dusin g th e followin g equation : CR C = [TCC][.(i(l+i} n )/((l+i} n -l) l where , CR C = capita l recover y cost , $/y

r TC C = tota l capita l cos t o f contro l device(s) , $ i = annua l interes t rate , 1 0 percen t n= depreciabl e life , 1 0 year s IV . Mode l Plan t Capita l Cost s Thi s sectio npresent s the installe dcapita l an dannualize dcost s o f mesh-pa dmis t eliminator s fo r the hardan ddecorativ e chromiu m platin g an

d chromi c aci danodizin g mode l plants . Th e mode l plan t cost s ar e represen tativ e o f contro l cost s fo r ne w sources . Th e capita l cost s fo r 

# fP. 6

ventilatio nhood s an

dductwor kwer e no t include di nth e capita l cost s fo r contro l device s becaus e plant s mus t typicall y instal l ventilatio nhood s an dductwor kt o compl y

wit hoccupationa l healt hstandard s tha t regulat e employe e exposur e t o chromiu m emission s i nth e workplace . However , additiona l ductwor ki s require dfo r mesh-pa dmis t eliminato r systems , comparedt o typica l ventilatio nsystems . Typica l ventilatio nsystem s hav e multipl e tank s connecte dvi a shor t run s o f ductwor ktha t carr y larg e airflows . Th e mest*i-pa dmis t eliminato r vendo r indicate dtha t fo r airflow s greate r tha n34 0 m

/mi n(12,00 0 f t /min) , th e exhaus t stream shoul db e spli t an ddirecte dt o multiple , small , mesh-pa dunits . Thi s splittin g o f the exhaus t stream

require s additiona l ductwork . Therefore , th e cos t o f additiona l ductwor ki s include di nth e mode l plan t capita l cos t estimate s fo r mesh-pa dmis t eliminato r systems . Tabl e 5 present s th e purchase dequipment , additiona l ductwork , installation , startup , an dtota l capita l cost s o f mesh-pa dmis t eliminator s fo r th e hardan ddecorativ e chromiu m platin g an

dchromi c aci d anodizing mode l plants . Th e capita l cos t estimates , wit hth e exceptio no f the additiona l ductwor kcost s an dinstallatio ncosts , wer e compile dfro m Tabl e 3 a s describe dbelow . HardChromiu

m Platin g Smal l mode l plan t = Colum nDcost s Mediu m mode l plan t = Colum nA + B + 2(Colum

nC ) cost s Larg e mode l plan t = 2[Colum nA+ B +2(ColumnC ) costs ] Decorativ e Chromiu

m Platin g Smal l mode l plan t = Colum nDcost s Mediu m mode l plan t = 2(Colum nDcosts ) Larg e mode l plan t = 5(Colum nC costs ) Chromi c Aci dAnodizin g Smal l mode l plan t = Colum nDcost s Larg e mode l plan t = 4(Colum nC costs ) Th e additiona l ductwor kexpens e fo r eac hmode l plan t wa s estimate d b y comparin g th e tota l ductwor kexpens e associate dwit hth e ventilatio n systems speciall y

designe dt o accomodat e installatio no f th e mesh-pa dmis t eliminator s a t eac hmode l plan t (Figure s 1-6 ) wit hth e ventilatio nsystem s designe dbase do ntypica l plan t practices . Schematic s o f thes e typica l systems ar e show

ni nChapte r 5 o f th e Chromiu m Electroplatin g Backgroun d InformationDocument . Installatio ncost s fo r eac hmode l plan t includ e th e direc t installatio ncost s o f eac huni t an danindirec t cos t o f $7,00 0 tha t cover s the cos t o f engineerin g services , contractor s fees , an dcontingencies . The mesh-pa dmis t eliminato r vendo r provide dth e amoun t o f th e indirec t cost s o na per-model-plan t basis . Therefore , mode l plan t installatio n cost s wer e assume dt o be $7,00 0 plu s th e cos t o f th e direc t installatio n

-<£> "P. 7

o f th e unit , calculate da s describe dabov e fo r th e othe r capita l cos t estimates . V . Mode l Plan t Annualize dContro l Cost s Th e annualize dcost s fo r th e mode l plant s ar e presente din Tabl e 6 . Th e annualize dcos t estimates , wit hth e exceptio no f th e labo r requirements , indirec t cost s an dchromi c aci drecover y credits , wer e compile dfro

m Tabl e 4 a s describe dbelow . HardChromiu

m Platin g Smal l mode l plan t = Colum nD t cost s Mediu m mode l plan t = Colum nk x + B t + 2(Colum

nC t ) cost s Larg e mode l plan t = 2[Colum nA 2 + B 2 + 2(Colum

nC 2 ) costs ] Decorativ e Chromiu

m Platin g Smal l mode l plan t = Colum nD i cost s Mediu m mode l plan t = 2(Colum nD 2 costs ) Larg e mode l plan t = 5(Colum nC 2 costs ) Chromi c Aci dAnodizin g Smal l mode l plan t = Colum nU* cost s Larg e mode l plan t = 4(Colum nC 2 costs ) Th e operator , supervisor , an dmaintenanc e labo r requirement s fo r eac hmode l plan t wer e calculate dbase donth e assumptio ntha t th e labo r require dt o operat e an dmaintai nmor e tha non e contro l devic e increase d th e labo r requiremen t b y onl y 3 0 percen t fo r eac hadditiona l contro l device , insteado f increasin g th e labo r requiremen t b y 10 0 percent . Fo r example , fo r th

e mediu m har dchromiu

m platin g mode l plant , whic hrequire s a tota l o f fou r contro l devices , th e operato r an dmaintenanc e labo r requiremen t wa s calculate da s follows : Operato r an

dmaintenanc e labor , $/y r = 1,240+0.3(1,240)+0.3(1,240) + 0.3(1,240 ) = ($1,240)(1.9 ) = $2,400 ; insteado f ($1,240)(4 ) = $5,96 0 Th e maintenanc e materia l cost , whic hi s base do n10 0 percen t o f th e maintenanc e labo r fo r eac hcontro l device , wa s assume dt o increas e 10 0 percen t fo r eac hadditiona l contro l devic e fo r th e mode l plant s an d ca nb e compute dfro

m Tabl e 4 . Th e indirec t cost s fo r eac hmode l plan t includ e overhead , propert y taxes , insurance , an

dadministration . Th e overhea dcos t i s base do n6 0 percen t o f th e su

m o f th e operator , supervisor , an dmaintenanc e labo r plu s th e materia l cost s fo r eac hmode l plant . Th e propert y taxes , insurance , an dadministratio nar e equa l t o 4 percen t o f th e tota l capita l cos t fo r

^P. 8

eac hmode l plant . Fo r example , fo r the mediu m har dchromiu

m platin g mode l plant , the indirec t cost s wer e calculate da s follows :
overhea dtaxes , ins. , adm . Indirec t costs , $/y

r = 0.6 0 [(1.9)($l,240)+4($640 ) ] + [0.04($66,000) ]

= $2,950+$2,64 0 = $5,60 0 Th e chromi c aci drecover y credit s ar e calculate dbase do nth e estimate dremova l efficienc y fo r mesh-pa dmis t eliminator s and10 0 percen t recover y o f th e chromi c aci dcapture db y th e contro l device . Th e chromi c aci drecover y

credi t i s calculate dusin g th e following equation : Chromi c aci drecover y credit , $/y

r = [ER][Eff][1.923][C ] where , E

R= uncontrolle dhexavalen t chromiu m emissio nrat e pe r plant , kg/yr (lb/yr ) Ef f = efficienc y

o f contro l device , decima l percen t 1.92 3 = rati o o f chromi c aci dmolecula r weigh t (100 ) t o hexavalen t chromiu m molecula r weigh t (52 ) C = cos t o f chromi c aci d(Cr0 3 ) , $3.28/k g ($1.49/lb ) Th e critica l variable s influencin g mesh-pa dmis t eliminato r annualize dcost s ar e th e labo r an dmaterials , an

dindirec t costs .



# 7P. 9



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o : i : l : Figur e 1 . Ventilatio nsyste m schemati c an

dductwor kspecification s fo r the 12-f t mode l tankuse di nth e smal l har dchromium , smal l an d mediu m decorativ e chromium , an dsmal l chromi c aci danodizin g mode l plants .


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. Ventilatio n syste m schemati can d ductwor k specification s fo ron e o f th e 12-f t mode l tank s use d i n th e mediu m an d larg e har d chromiu m platin g mode l plant s

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Figur e 3

. Ventilatio n syste m schemati can d ductwor k specification s fo rth e 12-f t an d 4-f t mode l tank s use d i n th e mediu m an d larg e har d chromiu m platin g mode l plants

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Figur e 4

. Ventilatio n syste m schemati can d ductwor k specification s fo rth e 25-f t mode l tan k use d i n th e mediu m an d larg e har d chromiu m platin g mode l plants

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- ^P.1 3


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Figur e 5 . Ventilatio nsyste m schemati c an

dductwor kspecification s fo r th e 12-f t mode l tan kuse di nth e larg e decorativ e chromium platin g mode l plant .

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### Figur e 6

. Ventilatio nsyste mschemati c an dductwor

k specification s fo r

th e 30-f

t mode l tan k use d i nth e larg e chromi c ad danodizin g mode l plant

. 

# fcTABL E 1 . MODE L PLAN T PARAMETER S FO RTH E HAR DAN D DECORATIV E CHROMIU M PLATINGAND CHROMI C ACI DANODIZINGMODE L PLANT S
Mode l operatio n Sma l I Plan t siz e Medium Larg e Har dchromium

platin g Operatin g time , h/yr Percen t tim e electrode s ar e energize d Tota l ampere-hour s pe r yea r No . o f tank s Dimension s o f tanks , (l,w,d ) i n(ft )

Ventilatio nrat e pe r tank , m/mi n(ft/mln )

No . o f contro l device s Contro l devic e configuratio n, Siz e o f eac hcontro l device , m/mi n(ft/min )
Uncontrolle dhexavalen t chromium emissio nrate , kg/y r (lb/yr ) Decorativ e chromiu

m platin g Operatin g time , h/yr Percen t tim e electrode s ar e energize d Tota l ampere-hour s pe r yea r No . o f tank s Dimension s o f tanks , (l,w,d, ) m (ft ) Ventilatio nrat e pe r tank , m/mi n(ft/min ) No . o f contro l device s Contro l devic e configuratio n, Siz e o f eac hcontro l device , m/mi n(ft*vmin ) Uncontrolle dhexavalen t chromium emissio nrate , kg/y r (lb/yr ) Chromi c aci danodizin g Operatin g time , h/yr Percen t time electrode s ar e energize d No . o f tank s Dimension s o f tanks , (l,w,d, ) m (ft ) Ventilatio nrat e pe r tank , m/mi n(ft/min ) No . o f contro l device s Contro l devic e configuratio n, , Siz e o f eac hcontro l device , m/mi n(ft/min ) Uncontrolle dhexavalen t chromium emissio nrate , kg/y r (lb/yr ) 2,00 0
7 0 fi 5.0x10 ° I 3.6 , 1.1 , 1. 8 (12.0 , 3.5 , 6.0 )

29 7 (10,500 )

Figur e 1 29 7 (10,500 )

5 0 (110 )
2,00 0
6 0 fi 3.0x10 6 1 3.6 , 1.1 , 1. 8 (12.0 , 3.5 , 6.0 ) 29 7 (10,500 ) 1 Figur e 1 29 7 (10,500 ) 6. 0 (13.0 )
2,00 0 7 0 1 3.6 , 1.1 , 1. 8 (12.0 , 3.5 , 6.0 ) 29 7 (10,500 ) 1 Figur e 1 29 7 (10,500 ) 3. 3 (7.2 ) 3,50 0
7 0 fi 42x10 ° 4 1.2 , 1.2 , 3. 0 (4.0 , 4.0 , 10.0 ) 2 fi 3.6 , 1.2 , 1. 8 (12.0 , 4.0 , 6.0 ) 7.6 , 0.9 , 1. 8 (25.0 , 3.0 , 6.0 ) 5 7 (2,000 ) 2 fi 17 0 (6,000 ) 53 1 (18,750 ) 4 Figure s 2 , 3 , an d4 17 0 (6,000 ) 23 0 (8,000 ) 2 fi 28 0 (10,000 ) 42 0 (925 )
4,00 0
6 0 fi 12x10 ° 2 2 fi 3.6 , 1.1 , 1. 8 (12.0 , 3.5 , 6.0 ) 2 fi 29 7 (10,500 ) 2 Figur e 1 2 fi 29 7 (10,500 ) 2 4 (53 ) 6,00 0
8 0 fi 160x10 ° 8 2 fi 1.2 , 1.2 , 3. 0 (4.0 , 4.0 , 10.0 ) 4 fi 3.6 , 1.2 , 1. 8 (12.0 , 4.0 , 6.0 ) 2 fi 7.6 , 0.9 , 1. 8 (25.0 , 3.0 , 6.0 ) 2 fi 5 7 (2,000 ) 4 fi 17 0 (6,000 ) 2 fi 53 1 (18,750 ) 8 Figure s 2 , 3 , an d 2 fi 17 0 (6,000 ) 2 fi 23 0 (8,000 ) 4 fi 28 0 (10,000 ) 1,60 0 (3,530 )
6,00 0
6 0 fi 120x10 ° 5 5 fi 3.6 , 1.8 , 2. 7 (12.0 , 6.0 , 9.0 ) 5 fi 25 5 (9,000 ) 5 Figur e 5 5 fi 29 7 (10,500 ) 24 0 (530 )
6,00 0 4 0 2 2 fi 9.1 , 1.5 , 2. 7 (30.0 , 5.0 , 9.0 ) 2 § 53 1 (18,750 ) 4 Figur e 6 4 fi 28 0 (10,000 ) 4 0 (88 )

T l inP.1 6


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TABL E 2 . ANNUA L OPERATIN GCOS T FACTOR S Cos t categorie s Cos t factor s Direc t operatin g cost s 1 . Operatin g la^o r a . Operato r 5 b . Superviso r 2 . Maintenan§e 1 0 a . Labo r ' b . Material s

i 3 . Replacemen t part s (mes hpad )

4 . Transportatio nan ddisposa l o f use dmes hpad s $8.37/ h 1 5 percen t o f l a $9.21/ h 10 0 percen t o f 3 a 31. 5 percen t o f capita l cos t o f mes hpa dmateria l @ $300/f t a $50/dru m disposa l (plu s 1 0 percen t tax ) $40/dru m transportatio n(plu s 1 0 percen t tax ) 

### 5 . Utilitie s 6 a . Electricit y b . Wate r Indirec t operatinqcost s 

### 6 . 7 . 8 . 9 . 10 .
Cred i Overhea d Propert y tax

T 5 Insuranc e Administratio n Capita l recover y


### t s Chromi c aci drecover y $0.0461/kW h $0.77/1,00 0 ga l

6 0 percen t o f la+lb+3a+3 b 1 percen t o f capita l cos t 1 percen t o f capita l cos t 2 percen t o f capita l cos t 16. 3 percen t o f capita l cos t o f mesh-pa dmis t eliminato r

$3.28/k g 1 1 j*Base do naninteres t rat e o f 1 0 percen t an da mes hpadlif e o f 4 years . Base do naninteres t rat e o f 1 0 percen t an da nequipmen t lif e o f 1 0 years .



# A

### 1 6

TABL E 3 . CAPITAL COST S O F MESH-PADMIS T ELIMINATO R
Mis t eliminato r siz e B C ~ Contro l devic e parameter s Oesi c ssig qga s flo

w rate , actua l m/mi n (ft-Vmin) 1
- ' Pressur e drop , kP a (in . w.c. )

Fanstati c pressure , kP a (in . w.c. ) Fanmoto r size , h

p(kw) c Cos t data d 1 . Basi c mis t eliminato r 2 . Inle t an

doutle t transition 3 . Fa nan

dmoto r 4 . Washdow

nwate r pum

pan dmoto r 5 . Stac k 6 . Bas e equipment 6 . 7 . Sale s taxe s an

dfreigh t 8 . Tota l purchase dequipment , $ 3 9 . Installation 10 . Startup 1 17 0 (6,000 ) 0.7 5 (3.0 ) 1. 2 (5 )

7. 5 (5.6 )

4,00 0 3,60 0 70 0 30 0 5750 3 69 0 9,29 0 2,00 0 9 0 23 0

(8,000 ) 0.7 5 (3.0 ) 1. 2 (5 )

1 0 (7.5 )

5,30 0 Include di

nbasi c 3,90 0 80 0 40 0 10,40 0 83 0 11,23 0 2,00 0 110 28 0

(10,000 ) 0.7 5 (3.0 ) 1. 2 (5 )

1 5 (11 )

5,50 0 mis t eliminato r 4,50 0 90 0 70 0 11,60 0 93 0 12,53 0 2,00 0 13 0 34 0

(12,000 ) 0.7 5 (3.0 ) 1. 2 (5 )

1 5 (11 )

6,00 0 5,10 0 1,00 0 80 0 12,90 0 1,04 0 I3;§4 0 2,00 0 14 0 11 . Tota I ca pi ta I cost , $ J 11,40 0 13,30 0 14,70 0 16,10 0

a Mis t eliminato r size s ar e ranke dfro m th e lowes t ga s flo w rat e (Colum

nA ) t o th e highes t ga s flo w rat e (Colum

nD) . Ga s strea

m temperatur e i s 27" C (80"F) , ga s strea m moistur e conten t i s 2 percent , an d altitud e i s 30 5 m

(1,00 0 ft) . ^Paramete r provide db y ChromeTech , Inc . Capita l cost s presente di nthi s tabl e ar e base donChromeTech , Inc. , estimate s only . ChromeTech , Inc. , provide dbas e equipmen t andinstallatio ncost s i nNovembe r 198 8 dollars . Cost s wer e rounde dt o neares t $10 . e Su m o f 1 through5 . Sale s taxe s an

dfreigh t cost s ar e 3 an d5 percent , respectively , o f bas e equipmen t costs . 9Su m o f 6 an

d7 . Include s al l cost s associate dwit hinstalling instrumentation , electrica l components , an d piping ; an

derection . Ooe s no t includ e cos t o f engineerin g services , contracto r fee , o r contingencies . Assume dtha t contro l device s ar e installe do nthe roo f o f a plan t tha t i s .6. 1 m (2 0 ft ) highan

dno structura l modification s ar e necessary . '.On e percen t o f tota l purchase dequipmen t cost . J Su m o f 8 , 9 , an

d10 . Cost s wer e rounde dt o neares t $100 .

#TABL E 4
. ANNUALIZE D COST S O F MESH-PA D MIS TELIMINATO R Mis t eliminato r size * A j A

2 B J 8 2 Cj C 2 D l ° 2 Contro l devic e parameters Ga s flo wrate , actua l nr/mi n (ft/min )
Operatin g hours/y r Frequenc y ofwashdown
. No
. times/8 h o foperatio n Volum e o fwate rpe rwashdown , liter s (gal ) Incrementa l fa n moto rsize , k W(hp ) Operato rhours/y r Maintenanc e hours/y r Lif e expectancy o fpa d material , yr b Lif e expectancy ofunit , v r Volum e o fpa d material , m (f t ) b c 17 0 (6.000 ) 3,50 0 1 3 8 (10 )

. 9 (2.5 ) 62. 5 7 0 4 1 0 13 (4.7 ) 17

0 (6,000 ) 6,00 0 1 38 (10 ) 1. 9 (2.5 ) 62. 5 12 0 4 10 0.1 3 (4.7 ) 230

(8,000 ) 3,50 0 1 7 6 (20 ) 3. 7 (5 ) 62. 5 7 0 4 1 0 0.1 7 (6.0 ) 230

(8,000 ) 6.00 0 1 76 (20 ) 3. 7 (5 ) 62. 5 12 0 4 1 0 0.1 7 (6.0 ) 280

(10,000 ) 3,50 0 1 95 (25 ) 5. 6 (7.5 ) 62. 5 70 4 1 0 0.2 1 (7.4 ) 28 0 (10.000 ) 6,00 0 1 9 5 (25 ) 5. 6 (7.5 ) 62. 5 12 0 4 1 0 0.2 1 (7.4 ) 340

(12,000 ) 2,00 0 1 9 5 (25 ) 5. 6 (7.5 ) 62. 5 4 0 4 1 0 0.2 6 (9.2 ) 340

(12,000 ) 4.00 0 1 9 5 (25 ) 5. 6 (7.5 ) 62. 5 8 0 4 1 0 0.2 6 (9.2 ) Cos tdata " 1 . 2 . 3 . 4 . 5 . 6 . Utilitie s Operator , superviso rand maintenanc e labo r Maintenanc e materia l Mesh-pad replacement 6 Indirec t cost s Capita l recovery 30 0 1,24 0 640 47 0 1,59 0 1.86 0 53

0 1,71 0 1.11 0 47 0 2.15 0 1.86 0 61 0

1,24 0 640 590 1.66 0 2.17 0 1.04 0

1.71 0 1.11 0 590 2,22 0 2.17 0 91 0

1,24 0 640 75 0 1.72 0 2,40 0 1.56 0

1.71 0 1.11 0 750 2,28 0 2,40 0 52

0 970 37 0 93 0 1,44 0 2.62 0 1,04 0

1,34 0 74 0 93 0 1,89 0 2,62 0 7 . Tota l annualize d cost , $ 9 6,10 0 7.80 0 6,90 0 8.80 0 7,70 0 9,'800 6.90 0 ,60 0 *V(is t eliminato rsize s ar e ranke d fro m th e lowes t ga s flo wrat e (Colum n A ) t o th e highes t ga s flo wrat e (Colum n D )
. Columns A
. an d A presen t annualize d cost s fo rth e 17 0 m/mi n (6,00 0 ft/min ) uni t base d o n operatin g time s o f3,50 0 an d 6,00 0 h/yr , respectively
. Column s B an d B presen t annualize d cost s fo rth e 23 0 nr/ral n (8,00 0 ft/mln ) uni t base d o n operatin g time s o f3.50 0 an d 6,00 0 h/yr , respectively
. Column s C
. an d C presen t annualize d cost s fo rth e 280 nr/mi n (10,00 0 ft/min ) uni t base d o n operatin g time s o f3,50 0 and 6,00 0 h/yr
. respectively
. Column s 0 an d D , presen t annualize d cost s fo rth e 340 nr/mi n (12,00 0 ft/min ) uni t based o n operatin g time s o f2,00 0 and 4,00 0 h/yr , respectively
. fyalue fo rparamete rprovide d b y ChromeTech , Inc
. c Th e Incrementa l fa n moto rsiz e I s th e additiona l horsepowe rrequire d t o operat e wit h th e contro l devic e ove rth e horsepowe r require d t o operat e th e ventilatio n syste m only
. Annualize d cost s ar e presente d i n Novembe r198 8 dollar s an d were calculate d fro m th e contro l devic e parameter s provide d b y ChromeTech , Inc. , an d th e operatin g hours specifie d above
. Cost factor s ar e presente d i n Tabl e 2
. Al l cost s were rounded t o th e neares t SIO
. e Include s pa

d replacemen t and transportatio n and disposa l cost s fo ruse d pads
. Include s overhead , propert y tax , insurance , and administration
. ^Al l cost s were rounded t o th e neares t $100
. Number s ma y not add exactl y due t o independen t rounding
.

^ 3P.1 9

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### 18

TABL E 5
. MOOE L PLAN T CAPITAL COS T ESTIMATE S FO R MESH-PA D MIS T ELIMINATORS * (Novembe r
Typ e o f operatio n
Har d chromiu m

platin g Tota l purchase d equipmen t (TPE ) Incrementa l ductwor k cost c Installatio n cos t Startup ( 1 percen t o f TPE ) Tota l capita l cost , $ Decorativ e chromiumplating e Tota l purchase d equipmen t (TPE ) Incrementa l ductwor k cost c Installatio n cos t Startup ( 1 percen t o f TPE ) Tota l capita l cost , $ Chromi c aci d anodizin g Tota l purchase d equipmen t (TPE ) Incrementa l ductwor k cost c Installatio n cos t Startup ( 1 percen t o f TPE ) Tota l capita l cost , $ |*A1 1 cos t dat a wer e rounde d t o th e Smal l mode l plan t cost s ar e equa l mediummode l plan t cost s ar e equa ' time s Column C i n Tabl e 3
. Larg e th e mediu mmode l plant
. 198 8 Dollars ) Mode l plan t siz e Smal l

13,90 0 

### 0 9,00 0 

### 10 0 23,00 0

13,90 0 

### 0 9,00 0 

### 10 0 23,00 0

13,90 0 

### 0 9,00 0 

### 10 0 23,00 0

neares t $100
. 

### t o t o Mediu m

45,60 0 4,90 0 15,00 0 

### 50 0 66,00 0

27,90 0 

### 0 11,00 0 

### 30 0 39,20 0

th e cost s presente d i n Column su mo f Column s Aand B plu s mode l plan t cost s Estimate d cos t o f additiona l ductwor k .syste m t o accommodat e installatio n o f Installatio n cost s includ e th e direc t uni t plu s a n indirec t cos t o f $7,00 0 engineerin g services , contractor s e Smal l mode l plan t cost s ar e equa l ar e twic e th e require d t o modif ytypica l c mesh-pa d mis t cos t fo r th e i pe r plan t tha t eliminator
.

nstallatio n o f cover s th e co s fees , and contingencies
. 

### t o th e cost s presente d i n Column 

### Larg e

91,20 0 9,80 0 23,00 0 

### 90 0 124,90 0

62,70 0 6,80 0 17,00 0 

### 70 0 87,20 0

50,10 0 26,10 0 15,00 0 

### 50 0 91,70 0

D ; and 

### tw o cos t o f aptur e
eac h t o f 

### D ; mediummode l plan t cost s ar e tw o time s th e cost s presente d i n Column D ; larg e mode l plan t cost s ar e equa l -Colum n C i n Tabl e 3
. Smal l mode l plan t cost s ar e equa l larg e mode l plan t cost s ar e equa l Colum n C i n Tabl e 3
. 

### t o t o t o fiv e time s th e cost s presente d i n th e cost s presente d i n Column fou r time s th e D ; and

cost s presente d i n

/ *

### 1 9

TABL E 6
. MODE L PLAN T ANNUALIZE D COST S ESTIMATE S FO R MESH-PA D MIS T ELIMINATORS * (Novembe r 198 8 Dollars )
Typ e o f operatio n Smal l Mode l plan t siz e Mediu m Larg e Har d chromiumplatin g Utilitie s - . Operato r and maintenanc e labo r Maintenanc e material s Mesh-pa d replacement 1 ' Indirec t cost s Capita l recovery e Annualize d cost , $ f Chromi c aci d recover y Ne t annualize d cost , $ Decorativ e chromiumplatin g Utilitie s *
. Operato r an

d maintenanc e labo r Maintenanc e material s Mesh-pa d replacemen t Indirec t costs 0 Capita l recovery e Annualize d cost , $ a Chromi c aci d recovery-- 1 Ne t annualize d cos t , $ Chromi c aci d anodizin g Utilitie s h Operato r an

d maintenanc e labo r Maintenanc e material s Mesh-pa d replacemen t Indirec t cost s Capita l recover y Annualize d cost , $ Chromi c aci d recovery 9 Ne t annualize d cost , $ 

### 50 0 1,00 0 

### 40 0 90 0 1,70 0 3,80 0 8.30 0 (300 ) 

### a , uuu 50 0 1,00 0 

### 40 0 90 0 1,70 0 3,80 0 8,30 0 

### 0 8,30 0


### 50 0 1,00 0 

### 40 0 90 0 1,70 0 3,80 0 8,30 0 

### 0 

### a,3uu 2,70 0

2,40 0 2,60 0 2,60 0 5,60 0 10,80 0 26,/UO (2,600 ) 

### 24;iu u
2,10 0 1,70 0 1,50 0 1,90 0 3,50 0 6,40 0 1/,1U U (200 ) ib.yuu 9,40 0

5,30 0 8,90 0 5,10 0 13,50 0 20,40 0 62;60 0 (10,000 ) 52.6U U
7,80 0 3,80 0 5,60 0 3,80 0 9,10 0 14,20 0 44J3U U (1,500 ) 4Z,8U U
6,20 0 3,20 0 4,40 0 3,00 0 8,30 0 15,00 0 4 U IO U (300 ) 39,80 0 *A1 1 cost s ar e rounde d t o th e neares t $100
. Include s operator , superviso r and maintenanc e labor
. c Mesh-pa d replacemen t cost s ar e base d o n a 4 yea r lif e fo r th e pa d material
. Include s cos t o f mes hpa d replacemen t an d transportatio n and .disposa l cost s o f use d pads
. Include s overhead , propert ytax , insurance , and administration
. e Capita l recover yinclude s cos t o f capita l fo r mesh-pa d mis t eliminato r f unit(s ) plu s cos t o f capita l fo r incrementa l ductwork
. Chromi c aci d recover ycredit s ar e base d o n a remova l efficienc yo f 9 9 percen t fo r mesh-pa d mis t eliminator s use d i n har d chromiu mplatin g processes . Parenthese s indicat e negativ e values
. •^Chromi c aci d recover ycredit s ar e base d o n a remova l efficienc yo f 9 7 percen t fo r mesh-pa d mis t eliminator s use d i n decorativ e chromiu mand chromi c aci d anodizin g operation s


# /9P.2 1


### 20

VI * Reference s .1 . Lette r an

dcos t enclosur e fro m L . Zitko , ChromeTech , Inc., t o R . Barker , Midwes t Researc hInstitute . Novembe r 24 , 1988 . p . 1 . 2 . Referenc e 1 , pp . 3-6 . 3 . Lette r andcos t enclosur e fro m L . Zitko , ChromeTech , Inc. , t o R . Barker , Midwes t Researc hInstitute . Januar y 24 , 1989 . pp . 1-4 . 4 . Telecon . Barker , R. , MRI , t o Zitko , L. , ChromeTech , Inc . Februar y 21 , 1989 . Informatio nconcernin g mesh-pa dmis t eliminato r cos t data . 5 . EA B Contro l Cos t Manua l (Thir dEdition) , U . S . Environmenta l Protectio nAgency , Researc hTriangl e Park , Nort hCarolina . Publicatio nNo . EP

A 450/5-87-001A . February 1987 . 6 . Monthl y

Energy Review . Energ y

Informatio nAdministration . Departmen t o f Energy . Washington , D.C . Octobe r 1988 . 7 . Telecon . Caldwell , M . J. , MRI , wit hKraft , G. , America nWate r Work s Association . Marc h13 , 1989 . Informatio nconcernin g nationwid e residentia l an

dcommercia l wate r rate s fo r Januar y 1989 . 8 . Telecon . Caldwell , M . J. , MRI , wit hGlovenor , S. , Chemica l Wast e Management . Apri l 13 , 1989 . Informatio nondisposa l an d transportatio ncost s fo r soli dhexavalen t chromiu m waste . 9 . Supplemen t t o Employmen t an dEarnings , Burea uo f Labo r Statistics . Augus t 1988 . p . 55 . 10 . Monthl y

Labo r Review , Burea uo f Labo r Statistics , Volum e 112 , Numbe r 1 . Januar y

1989 . 11 . Telecon . Barker , R. , MRI , t o Jones , R. , AshlandChemica l Corp . Raleigh , Nort hCarolina . June 1 , 1989 . Informatio nconcernin g industria l grad e chromi c aci dcosts .

^•O