Appendix A-1: Equations Used to Estimate Capital and Annual Costs of a Multiclone

Parameters/Costs Equation

A. Parameters

1. Exhaust Gas Flow Rate, acfm (AQ) calculated per boiler, see Section 2.0 of the memo.

5. Capital recovery factor = [i x (1 + i)a

] / [(1 + i)a - 1], where i = interest rate, a = equipment life

 a. Equipment CRF, 20-yr life, 7% interest

15. Cost index

 a. 2008 545.4

 b. 2002 395.6

B. Total Capital Investment

TCI ($) = 3.5 x AQ x (545.4/395.6)

where AQ> 1,060

C. Annual Operating Costs, $/yr

O&M Costs = 8.5 x AQ x (545.4/395.6)

where AQ> 1,060

D. Annualized Costs

=O&M Costs + TCI x CRF

Source:

1. U.S. Environmental Protection Agency. Air Pollution Control Technology Fact Sheet. EPA-452/F-03-005. http://www.epa.gov/ttn/catc/dir1/fcyclon.pdf
Appendix A-2: Summary of Energy Audit Costs by SIC Code

SIC Code Description

Energy Audit 

Cost at 7%

01 Agricultural Production - Crops 854

02 Agricultural Production--Livestock 854

07 Agricultural Services 854

09 Fishing, Hunting, And Trapping 854

14 Nonmetallic Minerals, Except Fuels 854

16 Heavy Construction, Ex. Building 854

17 Special Trade Contractors 854

20 Food And Kindred Products 854

23 Apparel And Other Textile Products 854

24 Lumber And Wood Products 18292

26 Paper And Allied Products 18292

40 Railroad Transportation 854

41 Local And Interurban Passenger Transit 854

42 Trucking And Warehousing 854

43 U.S. Postal Service 854

44 Water Transportation 854

45 Transportation By Air, Water Transportation Services 854

47 Transportation Services 854

48 Communication 854

50 Wholesale Trade--Durable Goods 854

51 Wholesale Trade--Nondurable Goods 854

52 Building Materials & Garden Supplies 854

53 General Merchandise Stores 854

54 Food Stores 854

55 Automotive Dealers & Service Stations 854

56 Apparel And Accessory Stores 854

57 Furniture And Homefurnishings Stores 854

58 Eating And Drinking Places 854

59 Miscellaneous Retail 854

60 Depository Institutions 854

64 Insurance Agents, Brokers, & Service 854

65 Real Estate 854

70 Hotels And Other Lodging Places 854

72 Personal Services, Membership-Basis Organization Hotels 854

73 Business Services 854

75 Auto Repair, Services, And Parking 854

76

Miscellaneous Repair Services, Automotive Services, except 

Repair 854

79 Amusement & Recreation Services, Video Tape Rental 854

80 Health Services 854

81 Legal Services 854

82 Educational Services 854

83 Social Services 854

84 Museums, Botanical, Zoological Gardens 854

86 Membership Organizations 854

87 Engineering & Management Services 854

91 to 98 Government-Owned Buildings (State, Local, and Federal) 854

Unknown Unknown 854
Appendix A-3: Summary of Testing Costs at Area Source Boilers

Model Unit

Total Testing 

(TCI and 

TAC) PM Hg CO - Test

Distillate Unit 1 13600 8000 600 5000

Distillate Unit 2 13600 8000 600 5000

Distillate Unit 3 13600 8000 600 5000

Distillate Unit 4 13600 8000 600 5000

Distillate Unit 5 13600 8000 600 5000

Distillate Unit 6 13600 8000 600 5000

Distillate Unit 7 8600 8000 600 0

Residual Unit 1 13600 8000 600 5000

Residual Unit 2 13600 8000 600 5000

Residual Unit 3 13600 8000 600 5000

Residual Unit 4 13600 8000 600 5000

Residual Unit 5 13600 8000 600 5000

Residual Unit 6 13600 8000 600 5000

Residual Unit 7 8600 8000 600 0

Biomass Unit 1 15000 5000 5000 5000

Biomass Unit 2 15000 5000 5000 5000

Biomass Unit 3 15000 5000 5000 5000

Biomass Unit 4 15000 5000 5000 5000

Biomass Unit 5 15000 5000 5000 5000

Biomass Unit 6a 15000 5000 5000 5000

Biomass Unit 6b 15000 5000 5000 5000

Biomass Unit 7a 12000 6000 6000 0

Biomass Unit 7b 12000 6000 6000 0

Coal Unit 1 15000 5000 5000 5000

Coal Unit 2 15000 5000 5000 5000

Coal Unit 3 15000 5000 5000 5000

Coal Unit 4 15000 5000 5000 5000

Coal Unit 5 15000 5000 5000 5000

Coal Unit 6a 15000 5000 5000 5000

Coal Unit 6b 15000 5000 5000 5000

Notes:

Testing:

Testing Costs were estimated by ERG Air Laboratory Staff in March 2009 and assume that the testing 

contractor will make a single trip to the facility to conduct all necessary tests.

A basic range of testing costs was applied to various pollutants. Tests for PM (filterable) and CO could 

be completed with manual testing methods, and these manual methods were estimated to range from 

approximately $5,000 - $7,000. For the tests that involve more lab analysis (e.g., Hg), the testing costs 

were estimated to range from approximately $10,000 - $15,000. 

Although these cost ranges can be applied as is for cases where a single pollutant is being measured, 

estimating costs for facilities that need test data for more than one pollutant is more difficult and 

uncertain. For example, if a facility needs PM data and CO data, the test costs would not be twice the 

$5,000 - $7,000 range because some of the costs are associated with getting to the site and setting up 

the equipment. Such costs are one-time costs and would not be duplicated no matter how many 

pollutants are to be tested). Therefore, if a facility had more than one of the simpler tests to run (e.g., 

PM and CO, then the site-specific cost would start in the $5,000 - $7,000 with a few $1,000 added for 

subsequent pollutants. 

For units less than 100 mmBtu/hr, sources were expected to test for CO, and units greater than 100 

mmBtu/hr were expected to monitoring CO emissions with a CO CEMS so the testing costs for CO 

were subtracted from the total testing costs.

For liquid fuels, it was assumed that units would comply using a fuel analysis (or by receiving a certified 

fuel analysis from the fuel supplier for HCl and Hg), so the costs for these two tests for Hg and HCl 

were subtracted from the total testing costs. Fuel analysis was estimated to cost $600 per year, 

although some boilers my request that their fuel supplier submit fuel analysis documentation instead of 

conducting the analysis at the facility.
Analyzers BEFORE AFTER

 CO 0 1

 SO2 0 0

 NOX 0 0

 HCl 0 0

 Mercury (and CO2/O2) 0 0

 CO2 0 0

 O2 0 0

 THC 0 0

Summary of Costs

First Costs Labor Test ODCs Total

 Planning 4,835 0 352 5,187

 Select Equipment 20,313 0 3,067 23,380

 Support Facilities 0 0 19,065 19,065

 Purchase CEMS Hardware 0 0 61,070 61,070

 Install and Check CEMS 6,534 0 11,979 18,513

 Performance Specification Tests 3,907 11,230 503 15,640

 QA/QC Plan 4,679 14,546 692 19,917

40,269 25,777 96,727 162,773 TCI

Annual Costs

 Day-to-Day Activities 7,503 0 1,000 8,503

 Annual RATA 1,337 10,642 0 11,980

 PM Monitor RCA 0 0 0 0

 PM Monitor RRA 0 0 0 0

 Cylinder Gas Audits (ACA/SVA for PM) 2,034 0 1,069 3,103

 Recordkeeping and Reporting 1,822 0 160 1,982

 Annual QA & O&M Review and Update 3,399 0 1,161 4,560

 Capital Recovery (i=7%, monitor life = 10 years) 5,734 3,671 13,774 23,179

 Total w/o capital recovery 16,095 10,642 3,390 30,128

 Total with capital recovery 21,830 14,313 17,164 53,307 TAC

Source:

U.S. EPA CEMS Cost Model. 03/07/2007. http://www.epa.gov/ttn/emc/cem.html

Appendix A-4: Summary of CO CEMS
Appendix A-5: Other Monitoring Costs for Boilers

Parameters/Costs Equation

A. Parameters

1. Recording lime/carbon flow, min/4-

hr period

2. Annual operating hours, hr/yr (H)

3. Cost index

 a. 2008 575.4 575.4

 b. 2006 499.6 All costs 

are in 

$2006

 c. 1998

389.5

All costs 

are in 

$1997

 d. 1997

 e. 1993

 f. 1992

4. Operating labor wage rate, $/hr 

(LR)

$34.60

5. Capital recovery factor, 20-yr 

equipment life, 7% interest (CRF)

= [i x (1 + i)a] / [(1 + i)a - 1], where i = interest rate, a = equipment life 0.09439

B. Total Capital Investment, $ (TCI)

1. Planning $800

2. Select type of equipment $4,500

3. Provide support facilities $500

4. Purchased equipment cost (PEC) $14,100

5. Install and check equipment $4,800

6. Perf. spec. tests (certif.) $0

7. Prepare QA/QC plan $800

8. Total capital cost = Planning + selecting equipment + support facilities + PEC + installation + perf. spec. 

tests + QA/QC plan

$25,500 $43,137

C. Annual Costs, $/yr

1. Operating labor = (5 min to record lime/carbon flow/4-hr period) x (1 hr/60 min) x H x LR

2. Maintenance materials = 0.02 x TCI $1,477

3. Operation & maintenance = Day-to-day activities + annual RATA + CGA + annual QA + O&M review and update $6,000

$5,909

4. Recordkeeping and reporting = $1,000 x (525.4/386.5) $200 $1,477

5. Overhead = 0.6 x (labor + maintenance materials)

6. Property taxes, insurance, and 

administration

= 0.04 x TCI

$1,725

7. Capital recovery = CRF x TCI $3,500 $4,071

8. Total annual cost = Operating labor + maintenance materials + recordkeeping and reporting + overhead 

+ property taxes, insurance, and administration + capital recovery

$9,700 $14,661

Bag leak detector Opacity
Notes:

1. Monitoring costs have been rounded to the nearest $100 to be consistent with level of rounding in original costs.

2. Costs to be replaced include: (a) bag leak detector replacing opacity test; (b) CO CEMS replacing CO test and secondary chamber temperature monitor;

(c) HCl CEMS replacing HCl test, HCl sorbent monitor (dry scrubbers) and scrubber liquor pH monitor (wet scrubbers); (d) PM CEMS replacing PM and

opacity tests and and pressure drop monitor (wet scrubbers); (e) multi-metal/Hg CEMS replacing flue gas temperature monitor (wet scrubbers); (f) dioxin

sorbent trap biweekly monitoring replacing fabric filter inlet temperature monitor; and (g) Hg sorbent trap biweekly monitoring replacing flue gas temperature

monitor (wet scrubbers).

Sources:

1. Hospital/Medical/Infectious Waste Incinerators (HMIWI) [EPA-HQ-OAR-2006-0534] Testing and Monitoring Options and Costs Memo (IV-B-66).

2. E-mail from Dan Bivins, EPA, to Mary Johnson, EPA. July 28, 2006. Some Preliminary Thoughts on the HWI Monitoring.

3. Memorandum from Thomas Holloway, Midwest Research Institute, to Rick Copland, U.S. Environmental Protection Agency, Revised Testing and 

Monitoring Options and Costs for Medical Waste Incinerators (MWI’s) - Methodology and Assumptions. March 17, 1997.