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# OAR Box 

# 1313 Prepped by LaTeia Shed



### Document

Number: 

# 59 ) ll-B-3 3
Docket Number: 

# A-88-0 2

Printed 6/12/20089:03:29AM

Sheet 59of 99P. 2

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# i 3 MA R

MEMORANDU

M SUBJECT : Capita l an dAnnualize dCost s fo r Contro l Technique s Use d Wit hChromiu

m Electroplatin g (ES D Projec t No . 85/2A ) FROM : Andre w

M . Smit h,.?'**•-^ Industria l Studie s Branch , ES D (MD-13 ) TO : Do nGillett e

Standard s Developmen t Branch , ES D (MD-13 ) Attache di s a tabl e tha t list s regulator y alternative s currentl y bein g considere dfo r the propose delectroplatin g MESHAP . Als o attache d ar e eigh t table s wit hcapita l andannualize dcost s fo r eac hcontro l techniqu e associate dwit hthe regulator y alternatives . No t include d ar e estimate s o f annualize dcost s fo r replacin g a hexavalen t chromiu m proces s wit ha trivalen t chromiu m process . Thes e estimate s shoul db e availabl e i.

nApril . Th e regulator y

alternative s ar e no t expecte dt o change . Th e cos t estimates , however , wil l b e change di nMarc hinrespons e t o anticipate d change s i nsom

e o f the mode l plan t parameter s an dt o includ e chromi c aci drecover y

credit s i nth e annualize dcos t estimates . I f yo u hav e an

y questions , pleas e cal l m e a t X539 8 o r Rand y Strai t o f MR I a t 467-5215 . 2 Attachment s cc : Ji mCrowder , IS B Gai l Lacy , SD B Rand yStrait , MR I A l Vervaert , IS BP. 3

TABL E 1 . CONTRO L TECHNIQUE S UPO N WHIC H TH E REGULATOR YALTERNATIV E COS TIMPACT S AR E BASE D Typ e o f operation / Regulator yAlternativ e (RA ) Contro l techniqu e Har d chromiu m platin g R AI (n o action )

R AI I
R AI I I
Oecorativ e chromiu m platin g R A I (n o action )

R A I la

R A li b

R A II I
Chromi c aci danodizin g R A I (n o action )

R A

R A M b Existin g (baseline ) leve l o f contro l • 2 5 percen t o f operation s uncontrolle d • 1 0 percen t o f operation s controlle db y mis t eliminator s wit h singl e set s o f blade s tha t reduc e uncontrolle demission s b y 8 5 percen t • 6 5 percen t o f operation s controlle db y singl e packed-be d scrubber s tha t reduc e uncontrolle demission s b y 9 5 percen t Mis t eliminator s (singl e set s o f blades ) that.reduc e uncon trolle demission s oy 8 5 percen t Singl e packed-be dscruDber s tha t reduc e uncontrolle demission s b y 9 5 percen t

Existin g (baseline ) leve l o f contro l • 1 0 percen t o f operation s uncontrolle d • 4 0 percen t o f operation s controlle db y chemica l fum e suppressant s tha t reduc e uncontrolle demission s b y 9 0 percen t • 5 0 percen t o f operation s controlle db y singl e packed-be d scrubber s tha t reduc e uncontrolle demission s b y 9 5 percen t Chemica l fume suppressant s applie di naccordanc e wit h monitorin g an drecordkeepin g requirement s tha t woul densur e tha t vendo r recommendation s o nus e ar e followed . Uncontrolle demission s reduce db y 9 5 percen t Singl e packed-be dscrubber s tha t reduc e uncontrolle demission s b y 9 5 percen t Trivalen t chromium

platin g processe s tha t reduc e hexavalen t chromium

emission s by

10 0 percen t

Existin g (baseline ) leve l o f contro l • 5 0 percen t o f operation s uncontrolle d • 2 5 percen t o f operation s controlle db y chemica l fum e suppressant s tha t reduc e uncontrolle demission s b y 9 0 percen t • 2 5 percen t o f operation s controlle db y packed-be dscrubber s tha t reduc e uncontrolle demission s b y 9 5 percen t Chemica l fume suppressant s applie di naccordanc e wit h monitorin g an d recordkeepin g requirement s tha t woul densur e tha t vendo r recommendation s o nus e ar e followed . Uncontrolle demission s reduce db y 9 5 percen t Singl e packed-be dscrubber s tha t reduc e uncontrolle demission s b y 9 5 percen tP. 4

TABL E 2 . CAPITA L COST S O F MIS T ELIMINATOR S ANDPACKED-BE D SCRUBBER S FO

RHAR DCHROMIU

M PLATINGMOOE L PLANT S (Octobe r 198 6 Dollars )

Mode l plan t siz e Smal l Purchase dequipmen t Installatio n Startu p. Tota l capita l cos t Mediu m Chevron-blad e mis t eliminato r wit ha singl e se t o f blade s

17,94 0 14,71 0 18 0 32,80 0 Singl e packed be dscrubbe r

31,74 0 18,84 0 32 0 50,90 0

Purchase dequipmen t Installatio n Startup 4 Tota l capita l cos t Larg e Purchase dequipmen t Installatio n

- Startup * . Tota l capita l cos t 26,63 0 19,13 0 27 0 46,00 0

77,51 0 53,31 0 78 0 131,60 0 45,49 0 24,26 0 45 0 70,20 0

133,40 0 70,67 0 1,33 0 205,40 0 ^Startu pcost s ar e base don1 percen t o f th e purchase dequipmen t cost . "Tota l capita l cos t i s th e su m o f purchase dequipment , installation , an d startupcosts . Cost s wer e rounde dt o th e neares t $100 .



### 3TABL E 3 . ANNUALIZE DCOST S O F MIS T ELIMINATOR S AN O PACKED-BE D SCRUBBER S FORHAR DCHROMIUM PLATINGMODE L PLANT S (Octobe r 198 6 Dollars )

Mode l plan t siz e Smal l Utilities * . Labo r an dmaterial s Indirec t costs c Capita l recover y Annualize dcos t Mediu m Utilities * Labo r an dmaterial s Indirec t costs c Capita l recover y Annualize dcos t 

### Larg e Utilities * Labo r an dmaterial s Indirec t costs 0 Capita l recover y Annualize dcos t Chevron-blad e mis t eliminato r wit ha Singl e packed singl e se t o f blade s bedscrubbe r

0 60 0 70 0 1,20 0 1,60 0 2,40 0 3,80 0 6,00 0 6,10 0 10,20 0

0 1,30 0 1,30 0 2,40 0 2,30 0 3,60 0 5,40 0 8,20 0 9,00 0 15,50 0

10 0 25,30 0 9,40 0 17,00 0 8,60 0 13,80 0 15,40 0 24,00 0 33,50 0 80,10 0

a Uti1it y cost s fo r mis t eliminator s wer e rounde dt o zer o becaus e utilit y cost s wer e les s tha n$50/yr . ^Include s operator , supervisor , an dmaintenanc e labo r an dmaterials . Include s overhead , propert y tax , insurance , an

dadministration . P. 5

^P. 6

TABL E 4 . CAPITAL COST S O F PACKED-BE DSCRUBBER S FORDECORATIV E

CHROMIUM PLATINGMODE L PLANT S (Octobe r 198 6 Dollars )

Mode l plan t siz e Singl e packed be dscrubbe r Smal l Purchase dequipmen t Installatio n Startu p. Tota l capita l cost 0 Mediu m Purchase dequipmen t Installatio n Startup * . Tota l capita l cos t Larg e Purchase dequipmen t Installation " Startu p,

- Tota l capita l cost 0 *Startu pcost s ar e base do n1 percen t o f th e purchase dequipmen t cost . Tota l capita l cos t i s th e su m o f rchase dequipment , installation , an d startu pcosts . Th e cost s wer e rounde dt o th e neares t $100 . 17,94 0 15,60 0 18 0 33,70 0

53,82 0 46,80 0 54 0 101,20 0

65,62 0 49,34 0 66 0 115,60 0TABL E 5 . ANNUALIZE DCOST S O F FUM E SUPPRESSANT S ANDPACKED-BE DSCRUBBER S FO RDECORATIV E CHROMIUM PLATIN GMODE L PLANT S (Octobe r 198 6 Dollars ) P. 7

Mode l plan t siz e Fum e suppressan t (permanent ) Singl e

packed-be d scrubbe r Smal l Utilitie s Labo r an dmaterial s Indirec t cost s Capita l recover y Annualize dcos t NA? l,100 c N A NA
_ 

### ITIOO " 30 0

l,000 c 1,70 0 3,90 0 6,90 0 Medium Utilitie s Labo r an dmaterial s Indirec t cost s Capita l recover y Annualize dcos t NA , 6,300 c N A NA
_ 6,30 0 1,60 0

6,000 c 6,10 0 11.80 0 25,50 0 Larg e Utilitie s Labo r an dmaterial s Indirec t cost s Capita l recover y Annualize dcos t *N A = no t applicable . NA , 22,900 c N A NA
_ 22,90 0 8,90 0 9,400 c 7,80 0 13,50 0 39,60 0
Include s materia l cost s o f makeu pan dmaintenanc e addition s only , cost s ar e no t include dbecaus e labo r associate dwit hprovidin g maintenanc e addition s i s negligible . ^Include s operator , supervisor , an dmaintenanc e labo r an dmaterials . Include s overhead , propert y tax , insurance , an

dadministration . Labo rP. 8

TABL E 6
. CAPITA L COS T O F REPLACIN G AHEXAVALEN T CHROMIU M PROCES S WIT H ATRIVALEN T CHROMIU M PROCES S A T EXISTIN G DECORATIV E

CHROMIU M ELECTROPLATIN G FACILITIE S (Octobe r 198 6 Dollars )

_- • Componen t
Startu p (tank conversion) * Initia l trivalen t chromium solutio n purchas e Wast e disposa l cos t o f hexavalen t chromiu msolutio n Subtota l Purchase d equipmen t Ammete r Tan k line r Replacemen t anode s an d hanger s Filte r Subtota l
. Taxe s and freigh t TOTA L Installation/modification 0 Indirec t Tota l cos t Smal l

10,00 0 3,40 0 13,40 0

20 0 2,00 0 3,00 0 7,00 0 12,20 0 1,00 0 13,20 0 

### 60 0 1,80 0 29,00 0 Mode l plan t siz e

Mediu m

30,00 0 10,20 0 40,20 0

60 0 6,00 0 9,00 0 21,00 0 36,60 0 2,90 0 39,50 0 1,80 0 5,50 0 87,00 0 

### Larg e

125,00 0 37,50 0 162,50 0

1,00 0 16,50 0 40,00 0 50,00 0 107,50 0 8,60 0 116,10 0 3,00 0 16,00 0 297,60 0 *Startu p cost s includ e th e initia l makeu p o f th e trivalen t chromium platin g solutio n and th e disposa l cos t o f th e hexavalen t chromiumplatin g solution
. Taxe s an

d freigh t ar e estimate d t o b e 3 an d 5 percen t o f th e bas e equipmen t cost , respectively
. ^Include s ne wequipmen t installatio n and tan k cleanin g costs . Indirec t cost s includ e cost s associate d wit h engineerin g and supervision , proces s startup , and contingencie s an d ar e estimate d t o b e 1 4 percen t o f th e purchase d equipmen t cost .

/TABL E 7 . INCREMENTAL CAPITAL COS T OF INSTALLIN GA TRIVALEN T CHROMIU

M PROCES S INSTEA

D O F A HEXAVALEN T CHROMIU

M PROCES S A T NE

W DECORATIVE CHROMIU M ELECTROPLATINGFACILITIE S (Octobe r 198 6 Dollars ) P. 9

Componen t Smal l Mode l plan t siz e Mediu m Larg e Startup * Purchase dequipmen t Ammete r Filte r Subtota l , Taxe s an

dfreigh t TOTAL 

### Installation 0 

### Indirec t 2,80 0

20 0 7,00 0 7,20 0 60 0 8,30 0

60 0 21,00 0 21,60 0 I t 70 0 27,50 0

1,00 0 50,00 0 51,50 0 4,10 0 7,80 0 

### 10 0 1,10 0 23,30 0



### 40 0 3,30 0 55,60 0



### 60 0 7,80 0 Tota l capita l cos t 11,20 0 8,30 0

Ne t capita l cos t (6,200 ) 8,30 0 91,50 0 Wastewate r treatmen t cos t savings e f (18,000) g (27,000) h(38,000) ' 53,50 0 *Startu p cos t fo r ne wplant s woul d onl yconsis t o f th e incrementa l cos t o f th e trivalen t chromiu m bat h solutio n ove r th e hexavalen t chromiumbat h solution
. Th e incrementa l cos t o f th e trivalen t ove r th e hexavalen t chromiu mplatin g solutio n i s $1.6 0 pe r gallo n o f platin g solutio n fo r th e smal l and mediu mmode l plant s and $1.2 0 pe r gallo n fo r th e larg e mode l plant
. Taxe s and freigh t ar e estimate d t o b e 3 and 5 percen t o f th e bas e equipmen t cost , respectively
. installatio n cost s ar e th e cost s associate d wit h installatio n o f th e ne w equipmen t and ar e base d o n 1 6 labor-hour s a t $8.0 0 pe r hou r fo r eac h mode l tank
. Cost s wer e rounde d t o th e neares t $100
. Indirec t cost s includ e cost s associate d wit h engineerin g an d supervision , proces s startup , and contingencie s and ar e base d o n 1 4 percen t o f th e purchase d equipmen t costs . Represent s th e capita l cos t o f a hexavalen t chromiu mreductio n uni t fo r f th e wastewate r volum e associate d wit h eac h mode l plant
. Parenthese s indicat e negativ e values
. jJBatc h process . Continuou s process .P.1 0

TABL E 8 . CAPITA L COST S O F PACKED-BE DSCRUBBER S FORCHROMI C ACI DANOOIZINGMODE L PLANT S

(Octobe r 198 6 Dollars ) Singl e packed Mode l plan t siz e bedscrubbe r Smal l Purchase dequipmen t 17,94 0 Installatio n15,60 0 Startup * . 18 0 Tota l capita l cost 0 33,70 0 Larg e Purchase dequipmen t 48,82 0 Installatio n23,95 0 Startup * . 49 0 Tota l capita- l cost 0 73,30 0 *Startupcost s ar e 1 percen t o f th e purchase dequipmen t cost . Tota l capita l cos t i s th e su m o f th e purchase dequipment , installation , an dstartupcosts . Th e cost s wer e rounde dt o neares t $100 .



# 9p.1 1

TABL E 9 . ANNUALIZE DCOST S O F PACKED-BE DSCRUBBER S FO RCHROMI C ACI DANODIZIN GMOOE L PLANT S (Octobe r 198 6 Dollars ) Singl e packed Mode l plan t siz e be dscrubbe r Smal l Utilitie s 30 0 Labo r an dmaterials * 1,00 0 Indirec t costs 0 1,70 0 Capita l recover y

3,90 0 Tota l annualize dcos t 6,90 0 Larg e Utilitie s 3,20 0 Labo r andmaterial s 4,80 0 Indirec t costs 0 4,50 0 Capita l recover y

8,60 0 Annualize dcos t 21,10 0 *Inc1ude s operator , supervisor , an dmaintenanc e labo r an dmaterials . Include s overhead , propert y tax , insurance , an

dadministration .

/£>