Review Draft

Completion of the tabs in this spreadsheet is OPTIONAL.

Any cost information that you provide would be very useful to EPA for purposes of evaluating the costs of control measures that may be considered as regulatory options.

Cost information from within the last 10-12 years is requested (e.g., costs dating back to 1998).

Cost information could come from vendor quotes for APCD or equipment changes that either have been implemented or were not implemented.

The EPA recognizes that cost information can be sensitive. You may claim any information provided in this spreadsheet as confidential business information (CBI) and EPA will

handle the information accordingly. The EPA's procedures for handling CBI are described in the letter that accompanied the pulp and paper information collection request (ICR).

If your spreadsheet response contains any CBI, please be sure to follow the instructions in section C2 of the survey overview document for submitting CBI.

Because this spreadsheet is an optional component of your ICR response, it may be submitted later than the other portions of your response. 

EPA requests that you supply the cost information requested in this spreadsheet by {INSERT DATE 60 DAYS FOLLOWING ICR SUBMITTAL DATE}.

Two tables are included in this spreadsheet: APCD costs, and Equip change costs

The EPA is particularly interested in costs of the following air pollution control devices (APCD). Please supply this information using the APCD costs template.

 - Recovery furnace scrubbers, dry sorbent injection/fabric filter (DI/FF), selective catalytic reduction (SCR), or selective non-catalytic reduction (SNCR)

 - Black liquor oxidizer incinerators or thermal oxidizers

 - Lime kiln electrostatic precipitators (ESP)

 - Bleach plant CO control devices

The EPA is particularly interested in costs of the following process changes or equipment changes/upgrades. Please supply this information using the Equip change costs template.

 - Changing from a direct contact evaporator (DCE) to non-direct contact evaporator (NDCE) recovery furnace

 - Changing from a wet bottom ESP to a dry bottom ESP

 - Changing from a dry bottom/wet PM return ESP to a dry bottom/dry PM return ESP

 - Adding chambers/fields to an existing ESP 

 - Installation of quarterary air ports in the recovery furnace to improve combustion efficiency

 - Process changes to improve lime mud washing or to control makeup water quality in the causticizing area

 - Replacing a recovery furnace with a black liquor gasification system 

Notes EPA-HQ-OAR-2007-0544-DRAFT-0006.xls 1 of 12
OMB Control No: xxxx-xxxx

Expiration Date: xx/xx/xxxx

Review Draft

Complete the table below for air pollution control devices (APCD) installed/retrofitted in 1998 or later. 

If any responses to the following questions are not known, please indicate UK (unknown) or NA (not available). 

Follow instructions in section D5 of the survey overview document to populate this table

Instruction:

Provide for all entries. This should 

match NEI Site ID used in other 

portions of your survey response.

Line IDs should match those used in other portions of your survey 

response. Enter Pulping line ID for pulp mill equipment, Bleaching line 

ID for bleach plant equipment, or Emission Unit ID of paper machine 

with which paper mill equipment are affiliated. If equipment is shared 

between 2 lines (e.g., chemical recovery equipment serving 2 pulping 

lines) then indicate both Line IDs separated by an underscore "_." See 

subpart S definitions of "pulping line" and "bleaching line" if needed.

Enter Emission Unit ID(s) controlled by 

the APCD

Survey overview reference:

Field: NEI Site ID

Line ID (Pulping line ID, Bleaching line ID, or paper machine 

Emission Unit ID) Emission Unit ID

Example entry: 99999 Kraft1 RF1

99999 Kraft1 RF1

99999 Kraft1 LK1

APCD costs EPA-HQ-OAR-2007-0544-DRAFT-0006.xls 2 of 12
Do any of the responses (individual cells) you entered in this tab contain CBI? Yes/No

Do you consider the entire contents of this spreadsheet tab to be CBI? Yes/No

 If yes, be sure to shade the CBI-containing cells red and submit this spreadsheet according to the section C1 of the survey overview document.

Enter APCD_ID for which cost 

information is being provided

Was the APCD retrofitted on an 

existing emission unit? Select yes/no

Was the APCD installed at the 

same time the emission unit 

was newly installed? Select 

yes/no

Identify the expected equipment life 

of the installed control device. This 

should be provided in years and 

estimated from the initial date of 

installation.

CAPITAL COSTS

Year of the capital costs (e.g., 2006). EPA 

will use to scale costs to the current year used 

for regulatory analyses. 

APCD_ID Retrofit to existing emission unit? 

Installation on new emission 

unit?

Expected control device 

equipment life (in yrs) Base year for capital costs (XXXX)

SCRB1 yes no 15 2001

SNCR1 yes no 20 2001

ESP1 yes no 20 2001

APCD costs EPA-HQ-OAR-2007-0544-DRAFT-0006.xls 3 of 12
Include in the Purchased 

Equipment Costs the cost of 

control device and any required 

ancillary equipment (e.g., fans, 

pumps, ductwork), 

instrumentation, sales tax, and 

freight. 

Calculated by 

summing items 

in B

A. Purchased Equipment Costs

B. Direct Installation 

Costs

Purchased Equipment Costs, 

Total ($)

Foundation and 

supports, $

Handling and 

erection, $ Electrical, $ Piping, $

Insulation for 

ductwork and 

piping, $ Painting, $ Other, $ Description of other

Total Direct 

Installation 

Costs, Total $

583,800 700,500 1,335,000 58,000 1,751,000 58,000 25,000 3,927,500

2,817,000 0

1,498,000 59,900 748,700 119,800 15,000 29,900 30,000 1,003,300

APCD costs EPA-HQ-OAR-2007-0544-DRAFT-0006.xls 4 of 12
Calculated by summing items in C

TOTAL Capital Investment 

(TCI) = (A + B + C)

Calculated

Year of the operating 

costs. Operating costs 

should be provided for the 

last 12 month period 

(calendar or fiscal year) 

for which the mill has 

data.

C. Indirect Costs

TOTAL Capital Investment 

(TCI)

Engineering

Construction 

and field 

expenses Contractor fees Start-up Performance test Contingencies Total Indirect Costs, Total $

TOTAL Capital Investment, 

Total $

Base year for operating 

costs (XXXX)

500,000 584,000 584,000 58,000 36,000 175,000 1,937,000 6,448,300 2001

140,000 141,000 141,000 78,000 500,000 3,317,000 2001

300,000 295,000 150,000 15,000 15,000 75,000 850,000 3,351,300 2001

APCD costs EPA-HQ-OAR-2007-0544-DRAFT-0006.xls 5 of 12
Please identify any 

major maintenance 

materials or parts 

and specify the 

approximate annual 

expenditures per 

item used for the 

APCD.

Specify total 

annual labor 

hours and $/hr Calculated

D. Maintenance materials and replacement parts E. Operation/maintenance labor costs

Item 1 description

Item 1 cost, 

$/yr

Item 2 

description

Item 2 cost, 

$/yr

Item 3 

description

Item 3 cost, 

$/yr

Item 4 

description Item 4 cost, $/yr

Annual 

maintenance 

labor hours

Maintenance labor 

rate, $/hr

Annual 

labor costs, 

$/yr

Various parts 53,000 1,050 25.40 26,670

Parts 178,980 1,050 25.40 26,670

Materials 101,000 800 25.40 20,320

APCD costs EPA-HQ-OAR-2007-0544-DRAFT-0006.xls 6 of 12
Purchased 

electricity 

costs (specify 

kWh/yr and 

$/kWh) Calculated

Purchased 

water usage Calculated

Specify if 

natural gas 

or propane 

used (select 

from menu).

Specify 

scf/yr and 

$/scf. Calculated

Steam 

costs 

(specify lb 

per year 

and $/lb) Calculated

F. Utility costs

Electricity, 

kWhr/yr

Electricity 

rate, $/KW

Annual 

electricity 

costs, $/yr Water, gal/yr

Water rate, 

$/gal

Annual water 

costs, $/yr Fuel used

Amount 

used, scf/yr

Fuel rate, 

$/scf

Annual fuel 

costs, $/yr

Steam 

use, lb/yr

Steam rate, 

$/lb

Annual steam 

costs, $/yr

10,963,120 0.05 548,156 74,592,000 0.00058 43,263

92,740 0.05 4,637 1,512,000 0.00058 877

1,571,700 0.05 78,585

APCD costs EPA-HQ-OAR-2007-0544-DRAFT-0006.xls 7 of 12
List any additives, chemicals, or 

sorbents needed to operate the APCD

Enter the amount of additive, chemical, or 

sorbent used. Include units. If multiple types 

are used, enter the amount separated by 

commas (e.g., NaOH-4 tpy, KMnO4-0.5 tpy)

Enter estimated annual costs for any additives, 

chemicals, or sorbents needed to operate the 

APCD

G. Additive/chemical/sorbent costs

Waste treatment or disposal costs, 

$/yr Additive/chemical/sorbent type Additive/chemical/sorbent amount Additive/chemical/sorbent costs, $/year

3,190 50% caustic soda 380,000 gal/yr 390,000

urea 256 tpy 57,600

APCD costs EPA-HQ-OAR-2007-0544-DRAFT-0006.xls 8 of 12
Enter estimated annual costs for disposal of any 

additives, chemicals, or sorbents needed to 

operate the APCD

Other operating cost 

description

TOTAL Operating Costs = sum of D through I 

$/yr

Calculated

H. Additive/chemical/sorbent disposal I. Other TOTAL Operating Costs

Additive/chemical/sorbent disposal, $/yr

Describe other operating 

cost Other, $/yr TOTAL Operating Costs, $

16,000 Liquid analysis 1,800 1,082,079

268,764

199,905

APCD costs EPA-HQ-OAR-2007-0544-DRAFT-0006.xls 9 of 12
OMB Control No: xxxx-xxxx

Expiration Date: xx/xx/xxxx

Review Draft

Complete this table for any modifications to processes or equipment in the chemical recovery area (other than installation of new APCD's) that were made in 1998 

 or more recently to reduce air emissions of HAP/organics, PM, NOx, SO2, CO, or TRS or to improve combustion efficiency.

If any responses to the following questions are not known, please indicate UK (unknown) or NA (not available). 

Follow instructions in section D5 of the survey overview document to populate this table.

Instruction:

Provide for all entries. This should match NEI Site 

ID used in other portions of your survey response.

Line IDs should match those used in other portions 

of your survey response. Enter Pulping line ID for 

pulp mill equipment, Bleaching line ID for bleach 

plant equipment, or Emission Unit ID of paper 

machine with which paper mill equipment are 

affiliated. If equipment is shared between 2 lines 

(e.g., chemical recovery equipment serving 2 

pulping lines) then indicate both Line IDs separated 

by an underscore "_." See subpart S definitions of 

"pulping line" and "bleaching line" if needed.

Enter a description of process or equipment change for which information is being 

provided

Survey overview reference:

Field: NEI Site ID

Line ID (Pulping line ID, Bleaching line ID, or 

paper machine Emission Unit ID) Process or equipment change description

Example entry: 99999 Kraft1 Changing from a DCE to NDCE recovery furnace

99999 Kraft1 Changing from a wet to a dry bottom ESP

99999 Kraft1 Adding fields to an existing ESP 

99999 Kraft1 Installation of quarterary air ports in the recovery furnace to improve combustion efficiency

99999 Kraft1 Replacing a recovery furnace with a black liquor gasification system 

Equip change costs EPA-HQ-OAR-2007-0544-DRAFT-0006.xls 10 of 12
Do any of the responses (individual cells) you entered in this tab contain CBI? Yes/No

Do you consider the entire contents of this spreadsheet tab to be CBI?Yes/No

 If yes, be sure to shade the CBI-containing cells red and submit this spreadsheet according to the section C1 of the survey overview document.

Enter Emission Unit ID(s) 

affected by the process or 

equipment change

Enter APCD_ID 

affected by the 

process or 

equipment change

Was the process or 

equipment change 

implemented on existing 

emission units and/or 

APCD in the process 

line? Select yes/no

Was the APCD installed 

at the same time the 

emission unit was newly 

installed? Select yes/no

Enter the year (e.g., 2006). This will be 

used as the base year for scaling of costs to 

current levels.

Enter number of days of lost pulp production required to 

implement the process or equipment change. 

If the change occurred during scheduled downtime that 

would have occurred regardless of the process or 

equipment change, then do not include the scheduled 

downtime. Only the days of lost production that can be 

specifically attributed to the process or equipment 

change are of interest.

Please distinguish between one-time 

capital and annual operating costs where 

appropriate. If a breakdown of the 

specific capital or annual cost items is 

available, please provide as a separate 

attachment. 

Enter the total capital cost associated 

with the process or equipment change in 

this cell.

Emission Unit ID APCD_ID

Retrofit to existing 

equipment in an 

existing process line? 

Change implemented 

in a new process line?

Year of process or equipment change 

(XXXX)

Number of days process shut down in order to 

make the change (days of lost production) Total capital cost, $

RF2 yes no 2001 20 19,664,100

RF1 ESP1 yes no 2001 3 3,266,300

RF1 ESP1 yes no 2001 3 5,372,400

RF1 yes no 2001 3 624,140

RF2 yes no 2001 90 150,000,000

Equip change costs EPA-HQ-OAR-2007-0544-DRAFT-0006.xls 11 of 12
Provide changes in annual operating costs (if estimated). 

Otherwise, leave blank.

Include annual operating costs that are an increase to prior 

operating costs (e.g., additional operating costs due to 

addition of ESP fields). 

If the process or equipment change resulted in decreased 

annual operating costs, then indicate the cost decrease as a 

negative number.

Describe the air pollutants affected and emissions reduction achieved. 

indicate the basis for emissions reduction reported (e.g., air emissions 

testing before and after modification). You may provide this information 

as a separate attachment to your response if it does not fit here.

Total annual operating cost, $/yr Emission reduction achieved (if quantified)

187,350 gaseous organic HAP - 80%

88,000 Methanol - 48%

214,000 PM -66%

39,800 NOx - 20%

(16,340,100) HAP-98%; PM-92%

Equip change costs EPA-HQ-OAR-2007-0544-DRAFT-0006.xls 12 of 12