p. 1



# OAR Box 1313 Prepped by LaTeia Shed



### Document

Number: 

# 90 ) ll-B-6 4
Docket Number: 

# A-88-0 2

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

Sheet 90 of 99P. 2 

# MR I 1^ 1 A-88-02 MIDWES TRESEARC H INSTITUT E 8H-e>-Cr M Suit e 35 0 40 1 Harriso n Oak

s Boulevard Cary , Nort h Carolin a 2751 3 Telephon e (919 ) 467-521 5 Facsimil e (919 ) 467-806 0

Date : Apri l 20 , 198 9

(Finalize dMa y

9 , 1989 ) Subject : Updat e o f Trivalen t Chromiu m Proces s Capita l Cos t Dat a fo r th e Decorativ e Chromiu

m Electroplatin g Mode l Plant s Chromiu m Electroplatin g NESHA P EPA Contrac t 68-02-3817 ; ES D Projec t 85/02 a MR I Projec t 7717- K From : Robi nBarke r ^
To : Andre w

M . Smit h ESD/ISB/SS S (MD-13 ) Unite dState s Environmenta l Protectio nAgenc y Researc hTriangl e Park , N.C . 2771 1 Th e trivalen t chromiu m capita l cos t estimate s documente d1 nanMR I memorandu

m date dApri l 18 , 1988 , hav e bee nupdate dfrom Octobe r 198 6 dollar s t o Novembe r 198 8 dollars . I naddition , th e contingenc y fe e wa s increase dfro

m 3 percen t o f th e purchase dequipmen t cos t t o 2 0 percen t t o allow fo r additiona l expense s incurre ddurin g a proces s modification . Cost s wer e updatin g usin g th e Chemica l Engineerin g (CE ) plan t index , fro m th e Februar y

198 9 issu e o f Chemica l Engineering . Th e mos t recen t fina l C E plan t inde xwa s fo r Novembe r 1988 , therefore , i t wa s chose na s th e basi s fo r th e update dcosts . Th e rati o o f th e C E Plan t Indice s [Novembe r 198 8 (347.8 ) + Octobe r 198 6 (319.3)] , equa l t o 1.09 , wa s use dt o updat e costs . Th e revise dcapita l cos t o f th e trivalen t chromiu m proces s conversio n fo r eac hmode l tank i s presente di nTabl e 1 . Th e representativ e capita l cos t o f th e trivalen t chromiu m proces s conversio nfo r existin g facilitie s i s presente di nTabl e 2 . Th e incrementa l capita l cos t o f installin g th e trivalen t chromiu

m proces s rathe r tha nth e hexavalen t chromium proces s a t ne w facilitie s i s presente di nTabl e 3 . A compariso no f mode l plan t cost s t o actua l reporte dfacilit y cost s i s presente di nTabl e 4 .

/ •P. 3

TABL E 1 . CAPITAL COS T O F CONVERTINGHEXAVALEN T CHROMIUM PROCES S T O TRIVALEN T CHROMIUM

PROCES S FOREAC H MODE L TAN K ELECTROPLATINGFACILITIE S

Componen t Mode l tan k 4 2 ft ' 7 2 ft '
Startup(tank conversion ) Initia l trivalen t chromium solutio npurchas e Initia l passivatio nsolution , purchase 3 ' Wast e disposa l cost . o | hexavalen t chromiu m solution 15 ' Subtota l Purchase dequipmen t cost s Ampere-hou r controlle r Tank line r Replacemen t anode s an d hanger s Anod e boxes 0 » Chiller*- ? Filter d ' Subtota l x Taxe s an

d freight* 2 ' TOTAL f 9 Installation/modification' ' Indirec t costs** ' 10,90 0 27,30 0 50 0 1,30 0 3,70 0 8,20 0 15,10 0



### 1,60 0 2,20 0 3,30 0 7,80 0 9,30 0 7,60 0 31,80 0 2,50 0 34,30 0 6,90 0 10,60 0 36,80 0

1,60 0 3,60 0 8,70 0 7,80 0 14,20 0 10,90 0 46,80 0 3.70 0 ' 50,50 0 10,10 0 15,70 0
Tota l cos t 66,90 0 113,10 0

3 Passivatio nsolutio ni s require dfo r som e trivalen t chromiu

m processes . bWast e disposa l cost s includ e treatmen t an d transportation . Th e treatmen t cos t wa s estimate dt o b e $80.0 0 pe r 55-gallo ndru m an d th e transportatio n cos t wa s $845.0 0 pe r truckload . An y fractio no f a loadwa s coste dou t a s a ful l load . °Anod e boxe s ar e require dfo r al l double-cel l processes . •-•Optiona l equipment . e Taxe s an

d freigh t ar e estimate dt o be 3 an d 5 percen t o f th e bas e equipmen t cost , respectively , "installation/modificatio ncost s ar e base do n2 0 percen t o f purchase d equipmen t costs . ^Indirec t cost s includ e cost s associate dwit hengineerin g an d supervisio n (1 0 percent) , proces s startu p( 1 percent) , an d contingencie s (2 0 percent ) an dar e estimate dt o b e 3 1 percen t o f th e purchase dequipmen t cost . "Th e tota l capita l cos t i s no t solel y attributabl e t o ai r pollutio n contro l bu t als o t o proces s improvement .

^P. 4

TABL E 2 . CAPITAL COS T O F CONVERTINGHEXAVALEN T CHROMIU M PROCES S T O TRIVALEN T CHROMIU

M PROCES S FO REAC H MOOE L PLAN T

Componen t Mode l plan t siz e Smal l Mediu

m Larg e
Startu p(tan

k conversion) 3 Initia l trivalen t chromiu m solutio npurchas e Initia l passivatio nsolutio n purchas e Wast e disposa l cost 8 o f hexavalen t chromiu m solutio n Subtota l Purchase dequipmen t cos t Ampere-houi* * mete r Tan k line r Replacement^anode s an d hanger s Anod e boxe s Chiller 0 ? Filter 0 ' Subtota l l 0 Taxe s an

d freigh t ' TOTA L

J Q Installation/modificatio n ' Indirect 12 ' 1 0 10,90 0 

### 50 0 3,70 0 15,10 0

1,60 0 2,20 0 3,30 0 7,80 0 9,30 0 7,60 0 31,80 0 2,50 0 34,30 0 6,90 0 10,60 0 21,80 0

1,00 0 7,40 0 30,20 0

3,20 0 4,40 0 6,60 0 15,60 0 18,60 0 15,20 0 63,60 0 5,10 0 68,70 0 13,70 0 21,30 0 136,50 0

6,50 0 41,00 0 184,00 0

8,00 0 18,00 0 43,50 0

. 39,00 0 71,00 0 54,50 0 234,00 0 18,70 0 252,70 0 50,50 0 78,30 0
Tota l cos t 66,90 0 133,90 0 565,50 0

3 Startu p cost s includ e th e initia l makeu p o f th e trivalen t chromiu m solution , and th e disposa l cos t o f th e hexavalen t chromiumplatin g .solution
. Optiona l equipment
. c Taxe s and 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
. d Installation/modificatio n cost s ar e base d o n 2 0 percen t o f purchase d equipmen t costs
. e Indirec t cost s includ e cost s associate d wit h engineerin g an d supervisio n (1 0 percent) , proces s startup ( 1 percent) , an d contingencie s (2 0 percent) , an d ar e estimate d t o b e 3 1 percen t o f th e purchase d .equipmen t cost
. Th e tota l capita l cos t i s no t solel yattributabl e t o ai r pollutio n contro l bu t als o t o proces s improvement
.



### ^BP. 5

TABL E 3 . INCREMENTA

L CAPITA

L COS T ASSOCIATE D WIT H INSTALLIN GA TRIVALENT CHROMIU M PROCES S INSTEA

D OF A HEXAVALEN T CHROMIU

M PROCES S A T NE

W PLANT S
Componen t Mode l plan t siz e

Startup(platin

g tank[s] ) cost 3 ' Initia l passivatio nsolution " Subtota l Purchase dequipmen t cos t Ampere-hou r controlle r Anod e boxes/* ' i t

;a; i Chillerrs Filte r Subtota l 1 0 Taxe s an dfreight e ' TOTAL f 9 Installation' Indirec t costs 9 ' Smal l 2,80 0 

### 500 3,30 0
1,60 0 7,80 0 9,30 0 7,60 0 26,30 0 2,10 0 28,40 0 4,30 0 8,80 0 

### Mediu

m 5,50 0 1,00 0 6,50 0
3,20 0 15,60 0 18,60 0 15,20 0 52,60 0 4,20 0 56,80 0 8,50 0 17,60 0 

### Larg e

27,50 0 6,50 0 34,00 0
8,00 0 39,00 0 71,00 0 54,50 0 172,50 0 13,80 0 186,30 0 27,90 0 57,80 0
Tota l cos t Wastewate r treatmen t cos t savings' 1 ' 1 1 44,80 0 -W^OO 1 89,40 0

-29,400 J 306,00 0

-41,400 J Ne t cost k25,20 0 60,00 0 264,60 0



# 5 ? 3 Startu pcos t fo r ne

w plant s woul donl y

consis t o f the incrementa l cos t o f th e trivalen t chromiu m bathsolutio nove r th e hexavalen t chromiu m bat h solution . Th e cos t differentia l betwee nth e trivalen t chromiu m platin g solutionan

dth e hexavalen t platin g solutioni s $1.6 0 pe r gallo no f plating solutionfo r the smal l ant- i mediu m mode l plant s an

d$1.2 0 pe r allonfo r th e larg e mode l plant .

. assivationsolutio ni s requiredfo r som e trivalen t chromiu

m processes . jAnod e boxe s ar e require dfo r al l double-cel l processes . °0ptiona l equipment . e Taxe s an

dfreigh t ar e estimatedt o b e 3 an d5 percen t o f th e bas e f equipmen t cost , respectively . Installationcost s ar e base don1 5 percen t o f the purchase dequipmen t costs . •^Indirect cost s includ e cost s associate dwit hengineering an dsupervisio n (1 0 percent) , proces s startu p( 1 percent) , an

dcontingencie s (2 0 percent) , an

dar e base

don3 1 percen t o f the purchase dequipmen t h costs . "Represent s th e capita l cos t o f a hexavalen t chromiu m reductio nuni t fo r •th e wastewate r volum

e associatedwit heachmode l plant . ^Batchprocess . ^Continuou s process . Th e tota l capita l cos t i s no t solel y attributabl e t o ai r pollutio n contro l bu t als o t o proces s improvement .



# fP. 6

TABL E 4 . COMPARISON

O F PLANT CAPITA L COS T DATA AN D MODE L PLAN T CAPITAL COS T DATA 3
Plan t Tota l capita l cost , $
Plan t dat a Plan t 1 (small) 5 71,80 0 Plan t 2 (small) 0 . 32,90 0 Plan t 3 (medium) 0 138,60 0 Mode l plan t dat a Smal l 66,90 0 Mediu m 133,90 0 Larg e 565,50 0

3 Cos t dat a ar e presente dinNovembe r 198 8 dollars . Proces s wa s installe dinNovembe r 1987 . Th e C E Plan t Index fo r 198 7 wa s 323.8 . Rati o o f C E Plan t Indice s wa s 1.07 . °Proces s wa s installe din1984 . The C E Plan t Indexfo r 198 4 .was 322.7 . Rati o o f C E Plan t Indice s wa s 1.08 . d Proces s wa s installe di n1981 . Th e C E Plan t Indexfo r 198 1 wa s 297.0 . Rati o o f C E Plan t Indice s wa s 1.17 .



## jr