Furnace 

Fabric FIlter 

Upgrade

Carbon 

Injection

Tap Hood 

Upgrade

Casting 

Capture & 

Control

Building 

Ventilation

Product 

Sizing Fabric 

Filter 

Upgrade

Facility

PM, Metal 

HAP Hg, PAH, HCHO

PM, Metal 

HAP

PM, Metal 

HAP

PM, Metal 

HAP

PM, Metal 

HAP

$1,413,952 $1,512,930

Felman $756,465

Annual Cost of Control Technology ($)

Eramet
Control Option

PM Emission 

Reduction 

(TPY)

PM2.5 

Emission 

Reduction1 

(TPY)

HAP 

Emission 

Reduction 

(TPY)

Capital Cost 

($)

Annual Cost 

($/Yr)

PM Cost 

Effectiveness 

($/Ton)

PM2.5 Cost 

Effectiveness 

($/Ton)

HAP Cost 

Effectiveness 

($/lb) Affected Facilities

Replace Furnace Fabric Filter2

24.6 10.1 2.95 $13,237,000 $1,543,603 $62,761 $153,075 $261 Eramet

Install ACI for Hg and PAH N/A N/A 3.55 $1,673,836 $1,413,952 N/A N/A $199 Eramet

Improve Tapping Capture 63.2 25.9 6.86 $314,922 $81,792 $1,294 $3,155 $6 Eramet, Felman

Casting Capture & Control 100 40.9 22.9 $4,979,039 $1,592,762 $15,949 $38,900 $35 Eramet, Felman

Install Building Ventilation 626 257 80.4 $9,439,500 $2,269,394 $3,623 $8,838 $14 Eramet, Felman

Improve Product Sizing Baghouse 11.4 4.65 4.66 $59,017 $14,394 $1,268 $3,092 $2 Eramet

1

 PM2.5 estimated to be approximately 41% of total PM.

2

 The emission reductions and annual cost for fabric filter replacement are based on the incremental difference between operation of a scrubber and a fabric filter. The 

cost effectiveness values were calculated using the incremental annual cost and the incremental emission reductions between the scrubber and the fabric filter.
Facility Total Capital Cost Total Annual Cost

Eramet $7,966,836 $2,926,882

Felman $3,146,500 $756,465

Total $11,113,336 $3,683,347
Building Ventilation Fabric Filter for Particulate Matter (PM) and Metal Hazardous Air Pollutant (HAP) Cost Effectiveness for Proposed MACT Floor & Beyond-the-Floor

Facility Emission Point

Current PM 

Emissions 

(Tons/yr)

Current HAP 

Emissions 

(Tons/yr)

Building 

Ventilation FF 

Capital Cost 

(FF + Ducts) ($)1

Building 

Ventilation 

Annual Cost (FF 

+ Ducts) ($/yr)2 

Proposed PM 

Emissions 

(Tons/yr)3

Proposed HAP 

Emissions 

(Tons/yr)3

PM Emission 

Reduction 

(Tons/yr)

HAP Emission 

Reduction 

(Tons/yr)

PM Cost 

Effectiveness 

($/Ton)

PM2.5 Cost 

Effectiveness 

($/Ton)

HAP Cost 

Effectiveness 

($/Ton)

HAP Cost 

Effectiveness 

($/lb)

Eramet EAF#1&12 Bldg Evacuation BH 300 96.1 $6,293,000 $1,512,930 72.4 35.5 228 60.6 $6,647 $13,294 $24,972 $12

Felman Building Evacuation Baghouse 468 38.1 $3,146,500 $756,465 69.1 18.2 399 19.8 $1,897 $3,795 $38,133 $19

1

 Capital cost for Fabric filter & associated ductwork calculated using equipment-only costs provided by vendor, with additional costs and annual costs estimated via EPA cost estimation manual. 28,219 14

2

 Annual cost calculated using 7% interest and a 20-year equipment life.

3

 The proposed PM and Metal HAP emissions were calculated assuming 95% capture (due to the hood upgrade) and 99% control for PM Metals, 15% for Hg, and 50% for Organic HAP.

CRF (20 years, 7% interest) 0.094392926

CEPCI (1998) 389.5

CEPCI (2010) 539.1

Facility Emission Point Pollutant Current (TPY) Proposed (TPY) Reduction (TPY)

Eramet EAF#1&12 Bldg Evacuation BH Total PM 299.9880349 72.37724318 227.6107917

Hydrochloric Acid 6.925092468 6.925092468 0

Hydrogen Fluoride 2.469091729 2.469091729 0

Formaldehyde 5.988936083 5.988936083 0

Metal HAP 78.61004707 18.44331525 60.16673182

PAH 2.061434477 1.643780927 0.41765355

Total HAP 96.05460182 35.47021646 60.58438537

Felman Building Evacuation Baghouse Total PM 467.8336501 69.12655692 398.7070932

Hydrochloric Acid 6.324869101 6.324869101 0

Hydrogen Fluoride 6.957356012 6.957356012 0

Formaldehyde 0.706531885 0.706531885 0

Metal HAP 23.83953234 4.014731188 19.82480115

PAH 0.229586516 0.216931829 0.012654687

Total HAP 38.05787586 18.22042001 19.83745584

Total Metal HAP 79.99153297

Total HAP 80.42184121

Total PM 626.3178849
Summary of ACI Capital and Annual Costs for Eramet

Cost Parameter Eramet EAF 1 

Cost ($2010)

Eramet EAF 12 

Cost ($2010)

Total Cost 

($2010)

Polishing Baghouse Capital Cost1

$1,442,224 N/A $1,442,224

Activated Carbon Injection Capital Cost2

$122,854 $108,759 $231,613

Total Capital Cost $1,565,078 $108,759 $1,673,836

Polishing Baghouse Annual Cost1

$525,655 N/A $525,655

Activated Carbon Injection Annual Cost2 (Hazardous) $308,964 $579,333 $888,297

Total Annual Cost (Hazardous) $834,619 $579,333 $1,413,952

Mercury Emission Rate (Ton/yr) 0.156 0.0785 0.235

PAH Emission Rate (Tons/yr) 1.84 0.927 2.77

Formaldehyde Emission Rate (Tons/yr) 0.363 0.183 0.546

Mercury/PAH Emission Reduction w/ ACI 2.12 1.07 3.19

Hazardous

Mercury/PAH/Formaldehyde Cost Effectiveness ($/Ton) $393,113 $541,610 $442,863

Mercury/PAH/Formaldehyde Cost Effectiveness ($/lb) $197 $271 $221

1

 Baghouse cost estimated using the EPA Control Cost Manual for a shaker baghouse w/ polyethylene bags,

and assuming a air-to-cloth ratio of 6.0 for a polishing baghouse w/ ACI.

2

 ACI costs developed using algorithms from Sargent & Lundy, IPM Model - Revisions to Cost and Performance

for APC Technologies, Mercury Control Cost Development Methodology Final, March 2011.

Note: The baghouse capital cost for EAF 12 includes a 20% cost for a exhaust gas heating system to increase

the temperature of the exhaust gas after the venturi scrubber and prior to ACI injection.
Hg PAH

$6,699,608 $567,784

$3,350 $284
Replacement of Eramet Scrubber with Negative Pressure Baghouse: Fabric Filter for Particulate Matter (PM) and Metal Hazardous Air Pollutant (HAP) Cost Effectiveness for Proposed MACT Floor & Beyond-the-Floor

Facility Emission Point

Current PM Emissions 

(Tons/yr)

Current Metal 

HAP 

Emissions 

(Tons/yr)

 Capital Cost 

($)1

Annual Cost 

($/yr)2 

Current 

Annual Cost 

($/Yr)3

Proposed PM 

Emissions 

(Tons/yr)4

Proposed 

Metal HAP 

Emissions 

(Tons/yr)3

Incremental 

PM Emission 

Reduction 

(Tons/yr)

Incremental 

Metal HAP 

Emission 

Reduction 

(Tons/yr)

Incremental 

Capital Cost 

($)

Incremental 

Annual Cost 

($/yr)

Incremental 

PM Cost 

Effectiveness 

($/Ton)

Incremental 

HAP Cost 

Effectiveness 

($/lb)

Eramet EAF #12 24.72 9.7609 $13,237,000 $2,543,603 $1,000,000 0.12 6.8082 24.60 2.9527 $13,237,000 $1,543,603 $62,761 $261

1

 Capital cost for Fabric filter calculated using equipment-only costs provided by vendor, with additional costs and annual costs estimated via EPA cost estimation manual.

2

 Annual cost calculated using 7% interest and a 20-year equipment life.

3

 From Facility ICR Response, where available.

4

 The proposed PM and Metal HAP emissions were calculated assuming 95% capture (due to the hood upgrade) and 99% control for PM Metals, 15% for Hg, and 50% for Organic HAP.

CRF (20 years, 7% interest) 0.094392926

CEPCI (1998) 389.5

CEPCI (2010) 539.1

Facility Emission Point Pollutant Current (TPY) Proposed (TPY)

Eramet EAF #12 PM Filterable 24.71952384 0.124505833

Arsenic 0.00537518 0.000784987

Chromium 0.003924933 0.016603689

Lead 0.083018443 1.731495806

Manganese 8.657479031 0.015667593

Mercury 0.078337963 0.004288449

Nickel 0.004288449 0.000240261

Chromium (VI) 0.001201303 4.943904768

Naphthalene 0.157961097 0.008222632

POM 72002 0.686453037 0.077735662

POM 75002 0.006086732 0.000883419

POM 76002 0.050864916 0.005505647

POM 77002 0.025867031 0.002834644

Total HAP 9.760858114 6.808167557
Crusher Baghouse Particulate Matter (PM) and Metal Hazardous Air Pollutant (HAP) Cost Effectiveness for Proposed MACT Floor

Facility

Emission 

Point

A/C Ratio 

(acfm/ft2)

Gas Flowrate 

(acfm)

Current PM 

Emissions 

(Tons/yr)

Current Metal 

HAP 

Emissions 

(Tons/yr)

Current Filter 

Bags Capital 

Cost ($)1

Current Filter 

Bags Annual 

Cost ($/yr)2

Proposed PM 

Emissions 

(Tons/yr)3

Proposed 

Metal HAP 

Emissions 

(Tons/yr)3,4

Proposed 

Filter Bags 

Capital Cost 

($)5

Proposed 

Filter Bags 

Annual Cost 

($/yr)2

Incremental 

PM Emission 

Reduction 

(Tons/yr)

Incremental 

Metal HAP 

Emission 

Reduction 

(Tons/yr)

Incremental 

Capital Cost 

($)

Incremental 

Annual Cost 

($/yr)

Incremental 

PM Cost 

Effectiveness 

($/Ton)

Incremental 

HAP Cost 

Effectiveness 

($/lb)

Eramet C2P BH1 2.5 43,868 5.43 2.23 $15,058 $3,672 1.65 0.6765 $34,730 $8,470 3.78 1.5543 $19,672 $4,798 $1,268 $2

Eramet C2P BH2 2.5 43,868 5.43 2.23 $15,058 $3,672 1.65 0.6765 $34,730 $8,470 3.78 1.5543 $19,672 $4,798 $1,268 $2

Eramet C2P BH3 2.5 43,868 5.43 2.23 $15,058 $3,672 1.65 0.6765 $34,730 $8,470 3.78 1.5543 $19,672 $4,798 $1,268 $2

1

 Current capital cost calculated using the 16-oz polyester bag cost of 0.62 $/ft2 and escalated to 2010 dollars using the Chemical Engineering Plant Cost Index.

2

 Annual cost calculated using 7% interest and a 5-year equipment life.

3

 The proposed PM and Metal HAP emissions were calculated assuming an effective PM limit of 0.002 gr/dscf @ 2% CO2 for Simcala, Globe WV, and Globe TN.

4

 For Globe Selma and Globe Beverly, the effective PM limit used to calculate the PM and Metal HAP emissions was 0.001 gr/dscf @ 2% CO2.

5

 Proposed capital cost calculated using the 16-oz Fiberglass bag cost of 1.01 $/ft2 and escalated to 2010 dollars using the Chemical Engineering Plant Cost Index.

CRF (5 years, 7% interest) 0.243890694

CEPCI (1998) 389.5

CEPCI (2010) 539.1
Mercury (Hg), Dioxin/Furan (CDD/CDF), Polycyclic Aromatic Hydrocarbons (PAH), and Formaldehyde (HCHO) Cost Effectiveness for Proposed MACT Floor

Facility Emission Point

Exhaust Gas 

Flow Rate 

(acfm)

Current Hg 

Emissions 

(Tons/yr)

Current 

CDD/CDF 

Emissions 

(Tons/yr)

Current PAH 

Emissions 

(Tons/yr)

Current HCHO 

Emissions 

(Tons/yr)

Control 

Option

Carbon 

Injection1,2

Capital Cost 

($)

Carbon 

Injection1,2

Annual Cost 

($)

Eramet

Furnace #1 

Baghouse 

Outlet

245,000 0.156 2.64E-07 1.84 0.363 ACI $1,565,078 $834,619

Eramet

Furnace #12 

Scrubber 

Outlet

184,000 0.079 1.33E-07 0.927 0.183 ACI $108,759 $579,333

1

 Costs for Carbon Injection + polishing baghouse to remove carbon. Baghouse cost estimated using the EPA Control Cost Manual for a shaker baghouse w/ polyethylene bags,

and assuming a air-to-cloth ratio of 6.0 for a polishing baghouse w/ ACI.

Appendix F, January 2011.

2

 Sargent & Lundy, IPM Model - Revisions to Cost and Performance for APC Technologies, Mercury Control Cost Development Methodology Final,

March 2011

CRF (20 years, 7% interest) 0.094392926

CEPCI (1998) 389.5

CEPCI (2010) 539.1
Eramet Cost Effectiveness By Pollutant

Total HAP 

Cost 

Effectiveness 

($/Ton)

Total HAP 

Cost 

Effectiveness 

($/lb)

HG Cost 

Eff 

($/lb)

PAH Cost 

Eff 

($/lb)

Total HG 

Cost Eff 

($/lb)

Total PAH 

Cost Eff 

($/lb)

$393,113 $197

$2,972 $252 $3,341 $284

$541,322 $271

$4,067 $347

ouse w/ polyethylene bags,
Tap Hood Upgrade Particulate Matter (PM) and Metal Hazardous Air Pollutant (HAP) Cost Effectiveness for Proposed MACT Floor & Beyond-the-Floor

Facility Emission Point

Current PM Emissions 

(Tons/yr)

Current Metal 

HAP 

Emissions 

(Tons/yr)

Hood Upgrade 

Capital Cost 

(Hood + Ducts) 

($)1

Hood Upgrade 

Annual Cost 

(Hood + 

Ducts) ($/yr)2 

Proposed PM 

Emissions 

(Tons/yr)3

Proposed 

Metal HAP 

Emissions 

(Tons/yr)3

Incremental 

PM Emission 

Reduction 

(Tons/yr)

Incremental 

Metal HAP 

Emission 

Reduction 

(Tons/yr)

Incremental 

Capital Cost 

($)

Incremental 

Annual Cost 

($/yr)

Incremental 

PM Cost 

Effectiveness 

($/Ton)

Incremental 

HAP Cost 

Effectiveness 

($/lb)

Eramet EAF #1 Tapping 33.21 4.5436 $78,731 $20,448 9.90 1.3642 23.30 3.1793 $78,731 $20,448 $878 $3

Eramet EAF #12 Tapping 30.92 11.0726 $78,731 $20,448 26.02 9.3185 4.90 1.7541 $78,731 $20,448 $4,175 $6

Felman EAF #2 Tapping 127.50 7.0356 $78,731 $20,448 107.30 5.9211 20.20 1.1146 $78,731 $20,448 $1,012 $9

Felman EAF #5 Tapping 97.24 5.3659 $78,731 $20,448 82.41 4.5544 14.83 0.8116 $78,731 $20,448 $1,379 $13

1

 Upgrade capital cost for hood & associated ductwork calculated using EPA Cost-air spreadsheets and escalated to 2010 dollars using the Chemical Engineering Plant Cost Index.

2

 Annual cost calculated using 7% interest and a 20-year equipment life.

3

 The proposed PM and Metal HAP emissions were calculated assuming 95% capture (due to the hood upgrade) and 99% control for PM Metals, 15% for Hg, and 50% for Organic HAP.

4

 Shop casting emissions are based on total emissions from the entire shop. Costs are calculated for each product line in the shop, and totaled.

CRF (20 years, 7% interest) 0.094392926

CEPCI (1998) 389.5

CEPCI (2010) 539.1

Facility Emission Point Pollutant Current (TPY) Proposed (TPY)

Eramet EAF #1 Tapping PM Filterable 33.20514521 9.903288923

Arsenic 0.007220351 0.002153438

Chromium 0.005272268 0.001572431

Lead 0.111516688 0.033259363

Manganese 4.38603987 1.308117154

Mercury 0.001237994 0.000369226

Nickel 0.005760571 0.001718065

Chromium (VI) 0.001613681 0.000481273

Naphthalene 0.004243707 0.001265667

POM 72002 0.018441919 0.013643295

POM 75002 0.000163523 0.000120974

POM 76002 0.001366513 0.001010943

POM 77002 0.000694931 0.000514109

Total HAP 4.543572018 1.36422594

Eramet EAF #12 Tapping PM Filterable 30.91853756 26.02055141

Arsenic 0.006723136 0.005658084

Chromium 0.004909204 0.004131508

Lead 0.103837309 0.087387834

Manganese 10.82854962 9.113135822

Mercury 0.005763711 0.004850648

Nickel 0.00536388 0.004514157

Chromium (VI) 0.001502558 0.001264529

Naphthalene 0.019757363 0.016627484

POM 72002 0.085859761 0.072258214

POM 75002 0.000761313 0.000640709

POM 76002 0.006362051 0.005354202

POM 77002 0.003235381 0.002722845

Total HAP 11.07262529 9.318546036

Felman EAF #2 Tapping PM Filterable 127.4997237 107.3017477

Arsenic 0.026867432 0.022611205

Chromium 0.047358361 0.039856046

Lead 1.992362325 1.676740571

Manganese 4.008436364 3.373436544

Mercury 0.001611795 0.001356461

Nickel 0.940700293 0.791678465

Chromium (VI) 0.00971293 0.008174248

Naphthalene 2.11071E-05 1.77634E-05

POM 72002 0.003297725 0.002775313

POM 75002 0.000139039 0.000117013

POM 76002 0.003982491 0.003351601

POM 77002 0.001132202 0.000952844

Total HAP 7.035622066 5.921068075

Felman EAF #5 Tapping PM Filterable 97.24142415 82.41102632

Arsenic 0.020491239 0.017392025

Chromium 0.03611925 0.030656365

Lead 1.519533881 1.289710742

Manganese 3.057152199 2.594770726

Mercury 0.001229283 0.001043359

Nickel 0.717452819 0.608941084

Chromium (VI) 0.007407853 0.006287446

Naphthalene 1.6098E-05 1.36632E-05

POM 72002 0.002515107 0.002134708

POM 75002 0.000106043 9.00041E-05

POM 76002 0.003037364 0.002577976

POM 77002 0.000863508 0.000732906

Total HAP 5.365924644 4.554351003
Casting Capture & Control Particulate Matter (PM) and Metal Hazardous Air Pollutant (HAP) Cost Effectiveness for Proposed MACT Floor & Beyond-the-Floor

Facility Emission Point

Current PM Emissions 

(Tons/yr)

Current Metal 

HAP Emissions 

(Tons/yr)

Casting 

Capture 

Capital Cost 

(Hood + 

Ducts) ($)1

Casting 

Capture 

Annual Cost 

(Hood + 

Ducts) ($/yr)2 

Casting 

Baghouse 

Capital Cost 

($)1

Casting 

Baghouse 

Annual Cost 

($)2

Proposed PM 

Emissions 

(Tons/yr)3

Proposed 

Metal HAP 

Emissions 

(Tons/yr)3

Incremental 

PM Emission 

Reduction 

(Tons/yr)

Incremental 

Metal HAP 

Emission 

Reduction 

(Tons/yr)

Incremental 

Capital Cost 

($)

Incremental 

Annual Cost 

($/yr)

Incremental 

PM Cost 

Effectiveness 

($/Ton)

Incremental 

HAP Cost 

Effectiveness 

($/lb)

Eramet EAF #1 Casting 62.96 22.3479 $222,469 $20,999 $1,437,211 $509,921 9.44 3.3522 53.52 18.9957 $1,659,680 $530,921 $9,921 $14

Eramet EAF #12 Casting 12.67 4.5374 $222,469 $20,999 $1,437,211 $509,921 1.90 0.6806 10.77 3.8568 $1,659,680 $530,921 $49,299 $69

Felman EAF #2 Casting 41.86 0.0249 $222,469 $20,999 $1,437,211 $509,921 6.28 0.0037 35.58 0.0212 $1,659,680 $530,921 $14,921 $12,531

1

 Upgrade capital cost for hood & associated ductwork calculated using EPA Cost-air spreadsheets and escalated to 2010 dollars using the Chemical Engineering Plant Cost Index.

2

 Annual cost calculated using 7% interest and a 20-year equipment life.

3

 The proposed PM and Metal HAP emissions were calculated assuming 85% capture (due to the added casting hoods) and 99% control for PM Metals, 15% for Hg, and 50% for Organic HAP.

4

 Globe Beverly #1 Shop casting emissions are calculated based on total production from the entire shop. Costs are calculated for each product line in the shop, and totaled.

CRF (20 years, 7% interest) 0.094392926

CEPCI (1998) 389.5

CEPCI (2010) 539.1

Facility Emission Point Pollutant Current (TPY) Proposed (TPY)

Eramet EAF #1 Casting PM Filterable 62.96 9.444

Arsenic 0.013690447 0.002053567

Chromium 0.009996704 0.001499506

Lead 0.168492417 0.025273863

Manganese 22.05037942 3.307556913

Mercury 0.011736753 0.001760513

Nickel 0.010922571 0.001638386

Chromium (VI) 0.003059688 0.000458953

Naphthalene 0.040232291 0.006034844

POM 72002 0.035184173 0.005277626

POM 75002 0.000311976 4.67963E-05

POM 76002 0.002607083 0.000391062

POM 77002 0.001325816 0.000198872

Total HAP 22.34793934 3.352190901

Eramet EAF #12 Casting PM Filterable 12.67 1.9005

Arsenic 0.00275505 0.000413258

Chromium 0.002011726 0.000301759

Lead 0.04255113 0.006382669

Manganese 4.437393699 0.665609055

Mercury 0.002361891 0.000354284

Nickel 0.002198046 0.000329707

Chromium (VI) 0.000615728 9.23592E-05

Naphthalene 0.008096301 0.001214445

POM 72002 0.035184173 0.005277626

POM 75002 0.000311976 4.67963E-05

POM 76002 0.002607083 0.000391062

POM 77002 0.001325816 0.000198872

Total HAP 4.537412617 0.680611893

Felman EAF #2 Casting PM Filterable 41.86 6.279

Arsenic 8.82097E-05 1.32314E-05

Chromium 0.000155484 2.33227E-05

Lead 0.006541213 0.000981182

Manganese 0.013160275 0.001974041

Mercury 0.000449799 6.74699E-05

Nickel 0.003088455 0.000463268

Chromium (VI) 3.1889E-05 4.78334E-06

Naphthalene 3.46489E-06 5.19733E-07

POM 72002 0.000541345 8.12018E-05

POM 75002 2.28243E-05 3.42365E-06

POM 76002 0.000653755 9.80632E-05

POM 77002 0.000185859 2.78789E-05

Total HAP 0.024922574 0.003738386
Summary of ACI Capital and Annual Costs for Eramet

Cost Parameter Eramet EAF 1 

Cost ($2010)

Eramet EAF 12 

Cost ($2010)

Total Cost 

($2010)

Polishing Baghouse Capital Cost1

$1,442,224 N/A $1,442,224

Activated Carbon Injection Capital Cost2

$122,854 $108,759 $231,613

Total Capital Cost $1,565,078 $108,759 $1,673,836

Polishing Baghouse Annual Cost1

$525,655 N/A $525,655

Activated Carbon Injection Annual Cost2 (Non-Hazardous) $263,014 $504,435 $767,449

Total Annual Cost (Non-Hazardous) $788,669 $504,435 $1,293,104

Mercury Emission Rate (Ton/yr) 0.156 0.0785 0.2345

PAH Emission Rate (Tons/yr) 1.84 0.927 2.77

Formaldehyde Emission Rate (Tons/yr) 0.363 0.183 0.55

Mercury/PAH/Formaldehyde Emission Reduction w/ ACI 2.12 1.07 3.19

Non-Hazardous

Mercury/PAH/Formaldehyde Cost Effectiveness ($/Ton) $371,471 $471,589 $405,013

Mercury/PAH/Formaldehyde Cost Effectiveness ($/lb) $186 $236 $203

1

 Baghouse cost estimated using the EPA Control Cost Manual for a shaker baghouse w/ polyethylene bags,

and assuming a air-to-cloth ratio of 6.0 for a polishing baghouse w/ ACI.

2

 ACI costs developed using algorithms from Sargent & Lundy, IPM Model - Revisions to Cost and Performance

for APC Technologies, Mercury Control Cost Development Methodology Final, March 2011.

Note: The baghouse capital cost for EAF 12 includes a 20% cost for a exhaust gas heating system to increase

the temperature of the exhaust gas after the venturi scrubber and prior to ACI injection.
TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

Eramet Polishing Furnace

COST BASE DATE: Second Quarter 1998 [2]

CEPCI (2010) 539.1

CEPCI (1998) 389.5

 INPUT PARAMETERS:

-- Inlet stream flowrate (acfm): 245295.5

-- Inlet stream temperature (oF): 220.6666667

-- Inlet stream temperature, adjusted--pulse jet only (oF): 220.6666667

-- Dust type: Activated Carbon

-- Inlet dust loading (gr/ft3): 0.014 Assumes 2lb/Mmacf

-- Dust mass median diameter (microns): 7

-- Filtration time (min): 10

-- Dust specific resistance (in.H2O/fpm/lb/ft2): 15

-- G/C ratio factors (shaker & reverse-air):

A: 2

B: 0.9

C: 1.2

-- G/C ratio factors (pulse-jet):

 Material: 9

Application: 0.8

-- G/C ratio factors (cartridge filters): A:

B:

C:

D:

E:

-- Cleaning pressure, psig (pulse-jet only): 100

-- Fraction of bags cleaned (shaker & rev-air): 0.1

-- Insulation required? ('yes'=1;'no'=0): 0

-- Stainless steel required? ('yes'=1;'no'=0): 0

-- Bag material: Fiberglass

-- Fabric effective residual drag (in. H2O/fpm): 1.1

-- Bag prices ($/ft2): (from table below, for bag material selected above only) [4]

Cleaning Mech. Bag Diam. (in.) Price ($/ft2)

------------------------------------------------------------------------------------------------------------------------

Pulse jet--BBR 4.5 to 5.125 0.75

6 to 8 0.67

Pulse jet--cart. 4.875 0

6.125 0

Shaker--strap 5 0.63

Shaker--loop 5 0.61

Reverse air w/o rings 8 0.44

11.5 0.44

-- Cost of auxiliary equipment (ductwork, fan, stack, etc.), ($): 89500

DESIGN PARAMETERS

-- Gas-to-cloth ratio (acfm/ft2 cloth area):

Shaker: 6 Sargent & Lundy, IPM Model - Revisions 
Reverse-air: 6 Sargent & Lundy, IPM Model - Revisions 

Pulse-jet: 6 Sargent & Lundy, IPM Model - Revisions 

Cartridge: 0

-- Net cloth area required (ft2):

Shaker: 40882.58333

Reverse-air: 40882.58333

Pulse-jet: 40882.58333

Cartridge: #DIV/0!

-- Gross cloth area required (ft2):

Shaker: 45992.90625

Reverse-air: 45992.90625

Pulse-jet: 40882.58333

Cartridge: #DIV/0!

-- Area per bag--reverse-air (ft2) (8-in. x 24-ft): 50.2656

-- Number of bags--reverse air: 915

-- Area per bag--shaker (ft2) (5-in x 8-ft): 10.472

-- Number of bags--shaker 4392

-- Area per bag--pulse jet (ft2): Small (4.5-in. x 8-ft) 9.4248

Large (5.125-in. x 10-ft) 13.41725

-- Number of bags/cages (pulse-jet only): Small bags 4338

Large bags 3048

-- Area per bag--cartridge (ft2): 153

-- Number of bags--cartridge: #DIV/0!

-- Bag pressure drop (in. w.c.):

Shaker: 6.6108

Reverse-air: 6.6108

Pulse-jet: 1.839131028

Cartridge: 0

-- Baghouse shell pressure drop (in. w.c.): 3

-- Ductwork pressure drop (in. w.c.): 4

CAPITAL COSTS

Equipment Costs ($):

Item: Cost ($):

 Shaker Rev-air P-J (mod) P-J (com) P-J (cartridge)

---------------------------------------------------------------------------------------------------------------------------------------------------

Baghouse 249,386 250,355 376,782 295,149 0

Bags--small 28,056 20,237 30,662 30,662 0

 " --large 27,391 27,391

Insulation 0 0 0 0 0

Stainless 0 0 0 0 0

Cages-small [5] 0 0 25,957 25,957 0

 " -large 0 0 33,637 33,637 0

Auxiliaries 89,500 89,500 89,500 89,500 0

------------------------------------------------------------------------------------------------------------------------------------------------

Total--small[5a] 366,942 360,092 522,901 441,268 0

 " --large: 527,310 445,677

PEC($)-base: 432,992 424,909 617,023 520,696 0

 ' ' -esc.: 664,619 652,212 947,097 799,241 0

TCI ($): 1,442,224 1,415,301 2,055,201 1,734,353 0

 ($/acfm): 5.88 5.77 8.38 7.07 0.00

==================================================================================================

ANNUAL COST INPUTS:
Operating factor (hr/yr): 8640

Operating labor rate ($/hr): 17.26

Maintenance labor rate ($/hr): 17.74

Operating labor factor (hr/sh): 2

Maintenance labor factor (hr/sh): 1

Electricity price ($/kWhr): 0.0671

Compressed air ($/1000 scf): 0.25

Dust disposal ($/ton): 25

Annual interest rate (fraction): 0.07

Control system life (years): 20

Capital recovery factor: 0.094392926

Bag life (years): 2

Capital recovery factor (bags): 0.553091787

Taxes, insurance, admin. factor: 0.04

 ANNUAL COSTS ($/yr):

 Item Shaker Reverse-air P-J (modular) P-J (common) P-J (cartridge)

---------------------------------------------------------------------------------------------------------------------------------------------------

Oper. labor 37,282 37,282 37,282 37,282 0

Supv. labor 5,592 5,592 5,592 5,592 0

Maint. labor 19,159 19,159 19,159 19,159 0

Maint. matl. 19,159 19,159 19,159 19,159 0

Electricity 170,322 771,103 227,517 227,517 0

Compr. air 0 0 63,581 63,581 0

Bag repl. 34,271 15,679 45,171 45,171 0

Dust dispos. 3,179 3,179 3,179 3,179 0

Overhead 48,715 48,715 48,715 48,715 0

Tax,ins.,adm 57,689 56,612 82,208 69,374 0

Cap. recov. 130,287 130,918 186,287 156,002 0

---------------------------------------------------------------------------------------------------------------------------------------------------

Total Annual 525,655 1,107,400 737,851 694,731 0

($/ton):[6] 4,134 8,709 5,802 5,463 0

ANNUAL COST WEIGHTING FACTORS:

 Item Shaker Reverse-air P-J (mod) P-J (com) P-J (cartridge)

---------------------------------------------------------------------------------------------------------------------------------------------------

Oper. labor 0.070924071 0.033665895 0.05052729 0.053663359 0

Supv. labor 0.010638611 0.005049884 0.007579093 0.008049504 0

Maint. labor 0.036448234 0.017301071 0.025966226 0.027577867 0

Maint. matl. 0.036448234 0.017301071 0.025966226 0.027577867 0

Overhead 0.09267549 0.043990753 0.066023301 0.070121158 0

---------------------------------------------------------------------------------------------------------------------------------------------------

S/T labor: 0.247134639 0.117308675 0.176062135 0.186989755 0

Compr. air 0 0 0.086169989 0.091518288 0

Bag repl. 0.065196628 0.014158769 0.061219772 0.06501949 0

Dust dispos. 0.006047748 0.002870716 0.004308499 0.004575914 0

Electricity 0.324017972 0.696318735 0.308351063 0.327489438 0

Tax,ins.,adm 0.10974677 0.051121589 0.111415555 0.099857521 0

Cap. recov. 0.247856243 0.118221516 0.252472986 0.224549594 0

---------------------------------------------------------------------------------------------------------------------------------------------------

S/T capital: 0.357603013 0.169343105 0.363888541 0.324407115 0

---------------------------------------------------------------------------------------------------------------------------------------------------
Total: 1 1 1 1 0

==================================================================================================

RELATIONSHIP BETWEEN GROSS AND NET CLOTH AREA

Net Cloth Area >/= (ft2): Gross/Net Area Ratio:

------------------------------------------------------------------------------------------------------------------------

1 2

4001 1.5

12001 1.25

24001 1.17

36001 1.125

48001 1.11

60001 1.1

72001 1.09

84001 1.08

96001 1.07

108001 1.06

132001 1.05

180001 1.04

[1] Parameters and other input data needed for this program can be found

in Chapter 5 (December 1998 revision) of the 'OAQPS Control Cost Manual'(5th edition).

Chapter 5 is found at: HTTP://WWW.EPA.GOV/TTN/CATC/PRODUCTS.HTML#CCCINFO.

[2] Base equipment costs reflect this date.

[3] VAPCCI = Vatavuk Air Pollution Control Cost Index (for fabric

filters) corresponding to year and quarter shown. Base equipment cost,

purchased equipment cost, and total capital investment have been

escalated to this date via the VAPCCI.

[4] These prices pertain to the bag material entered above. If this

bag material is not available for a baghouse type, enter '0'. 

(See 'Manual,' Chapter 5, Table 5.8.)

[5] Cage prices calculated from "500-cage lots" cost equations. (See Table 5.8.)

[5a] Total equipment cost for "small" and "large" bags and cages cases, respectively. 

[6] Total annual cost ($/yr) divided by total particulate captured

(tons/yr). If PM10, PM2.5, or other fractions are desired, divide by ratio

of PM10, PM2.5, etc., to total PM.

BAG PRICES (2nd quarter 1998 $/ft2) FOR SELECTED MATERIALS

[excerpted from Table 5.8, Chapter 5]

*********************************************************************************************************************

Cleaning Mech. Bag Diam. (in.) Polyethylene Polypropylene Nomex Homo-acrylic

------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

Pulse jet--TR 4.5 to 5.125 0.75 0.81 2.17 1.24

6 to 8 0.67 0.72 1.95 1.15
Pulse jet-BBR 4.5 to 5.125 0.53 0.53 1.84 0.95

6 to 8 0.5 0.6 1.77 0.98

Pulse jet-cart. 4.875 2.95 NA 6.12 NA

6.125 1.53 NA 4.67 NA

Shaker-strap5 0.63 0.88 1.61 1.03

Shaker-loop5 0.61 1.01 1.53 1.04

Rev. air w/rings8 0.63 1.52 1.35 NA

11.5 0.62 NA 1.43 NA

Rev. air w/o "8 0.44 NA 1.39 NA

11.5 0.44 NA 1.17 NA
ACFM Stack Temp

246462 209

243330 228

246074 225

246478 209

lb/Mmacf 243350 228

246079 225

Lundy, IPM Model - Revisions to Cost and Performance for APC Technologies, Mercury Control Cost Development Methodology Final, March 2011
Lundy, IPM Model - Revisions to Cost and Performance for APC Technologies, Mercury Control Cost Development Methodology Final, March 2011

Lundy, IPM Model - Revisions to Cost and Performance for APC Technologies, Mercury Control Cost Development Methodology Final, March 2011

************************************************************** ********************************************************************* *******************

Fiberglas Cotton Teflon P84 Ryton Nextel

------------------------------------------------------------------ ------------------------------------------------------------------------

1.92 NA 12.21 4.06 2.87 20.66

1.6 NA 9.7 3.85 2.62 NA
1.69 NA 12.92 3.6 2.42 16.67

1.55 NA9 3.51 2.3 NA

NA NA NA NA NA NA

NA NA NA NA NA NA

NA 0.7 NA NA NA NA

NA 0.59 NA NA NA NA

1.14 NA NA NA NA NA

1.01 NA NA NA NA NA

0.95 NA NA NA NA NA

0.75 NA NA NA NA NA
ology Final, March 2011
ology Final, March 2011

ology Final, March 2011

**********
Activated Carbon Injection Model Costs1,2,3,4

Eramet EAF 1 Eramet EAF 12

Parameters

Control Device Fabric Filter Venturi Scrubber

Annual Operating Hours, hr/yr (H) 8760 8760

Exhaust Gas Flow Rate, acfm (Qa) 245,296 183,671

Exhaust Gas Flow Rate, dscfm (Q) 185,258 151,206

Operating Labor Rate, $/hr (LR) $17.26 $17.26 Bureau of Labor Statistics, National Compensation Survey (Metal Furnace and Kilns)

Activated Carbon Cost, $/lb (ACC) $0.75 $1.00 Carbon cost for FF from IPM,2 carbon cost for scrubber from email from Albemarle3 

Dust Disposal Cost, $/Ton (DDC, Non-Hazardous) $40.00 $40.00 Cost from EPA

Dust Disposal Cost, $/Ton (DDC, Hazardous) $400.00 $400.00 Cost from EPA

Capital Recovery Factor (CRF) 0.094392926 0.094392926 CRF calculated assuming 20-year equipment life and 7% interest

CEPCI, 2010 539.1 539.1

CEPCI, 2008 575.4 575.4

CEPCI, 1991 361.3 361.3

ACI Adjustment Factor (AF) 0.9 0.9 Calculated control efficiency

ACI Injection Rate (lb/MMacf) 2.0

ACI Injection Rate (lb/hr) 50.0 Estimated carbon injection rate based on email from Albemarle4

Total Capital Investment, $ (TCI) $122,854 $108,759 Calculated using algorithm 4,500 x (Q/1,976)0.6 x (1.2 retrofit factor) x CEPCI Adj.

Direct Annual Cost, $/yr (DAC)

Operating Labor $4,725 $4,725 Calculated using (0.25 hr/8-hr shift) x H x LR

Supervisory Labor $709 $709 Calculated using 0.15 x Operating Labor

Maintenance $24,571 $21,752 Calculated using 0.2 x TCI

Activated Carbon $193,391 $438,000

Dust Disposal (Non-Hazardous) $5,106 $8,322 Calculated using ACI injection rate, 99% capture efficiency for FF and 95% capture efficiency for scrubber, and non-hazardous disposal cost

Dust Disposal (Hazardous) $51,055 $83,220 Calculated using ACI injection rate, 99% capture efficiency for FF and 95% capture efficiency for scrubber, and hazardous disposal cost

Indirect Annual Cost, $/yr (IAC)

Overhead $18,003 $16,311 Calculated using 0.6 x (Labor + Maintenance)

Property Tax, Insurance, & Admin $4,914 $4,350 Calculated using 0.04 x TCI

Capital Recovery $11,597 $10,266 Calculated using CRF x TCI

Total Annual Cost (Non-Hazardous) $263,014 $504,435 Sum of DAC + IAC

Total Annual Cost (Hazardous) $308,964 $579,333 Sum of DAC + IAC

1

 Memorandum from Amanda Singleton and Susan McClutchey, ERG to Jim Eddinger, EPA, Revised Methodology for Estimating Control Costs for

Industrial, Commercial, Institutional Boilers and Process Heaters National Emissions Standards for Hazardous Air Pollutants - Major Source,

Appendix F, January 2011.

2

 Sargent & Lundy, IPM Model - Revisions to Cost and Performance for APC Technologies, Mercury Control Cost Development Methodology Final,

March 2011

3

 Email from Daryl Lipscomb, Albemarle to Bradley Nelson, EC/R, 8/30/2011

4

 Email from Daryl Lipscomb, Albemarle to Bradley Nelson, EC/R, 8/26/2011
TOTAL ANNUAL COST SPREADSHEET PROGRAM--CASTING STRAIGHT DUCTWORK + CAPTURE HOODS [1]

DUCTS: COST BASE DATE: CEPCI 1993 [2] 359.2

HOOD: COST BASE DATE: CEPCI 1988 [2] 342.5

COST ESCALATION: CEPCI 2010 [3] 539.1

INPUT PARAMETERS

Ductwork:

-- Inlet stream flowrate (acfm): 60,000

-- Duct velocity (ft/min): [4] 4,750

-- Duct length (ft): [5] 400

-- Material of construction: [6] Sheet-galv CS

-- Insulation thickness (in.): (text input) [7] 0

-- Duct design: [8] Circular-longitudinal

-- Cost equation parameters: [9]

 a: 2.03

 b: 0.784

-- Cost equation form: [10] 1

-- Control system installation factor: [11] 1.5

 (if no system, enter '0')

-- Fan-motor combined efficiency (fraction): 0.6

DESIGN PARAMETERS

-- Duct diameter (in.): 48

-- Pressure drop (in. w.c.): [12] 2

Hoods:

-- Hood Length (ft) [13] 30

CAPITAL COSTS

Ductwork Cost ($)--base: $16,921

Ductwork Cost ($)--escalated: $25,395

Hood Cost ($)--base (4 hoods): $71,112

Hood Cost ($)--escalated: $111,931

Purchased Equipment Cost ($): $148,312

Total Capital Investment ($): [14] $222,469

ANNUAL COST INPUTS

Operating factor (hours/year): 2190

Electricity price ($/kWhr): 0.067

Annual interest rate (fractional): 0.07

Ductwork economic life (years): 20

Capital recovery factor (system): 0.094392926

Taxes, insurance, admin. factor: 0.04

Labor, $/hr [15] 17.42

ANNUAL COSTS

Item Cost ($/yr) Wt.Fact.

Electricity $3,010 0.085481992

Taxes, insurance, administrative $8,899 0.252687696

Capital recovery $20,999 0.596298274

Labor [15] $1,442 0.040957523

Overhead [16] $865 0.024574514

Total Annual Cost $35,216 1

Notes:

[1] Data used to develop this program were taken from 'OAQPS Control Cost Manual', 5th edition, Chapter 10. Prices are for CIRCULAR straight ductwork, only.

[2] Chemical Engineering Plant Cost Index CEPCI for base year. Base costs reflect this date.

[3] Chemical Engineering Plant Cost Index CEPCI for year shown. Equipment cost has been escalated to this date via this CEPCI.

[4] See 'Manual,' pp. 10-30 to 10-33.

[5] Duct length is a site-specific parameter that can vary from < 10 to > 1000 ft.

[6] Choices available are: carbon steel sheet (galv. CS sh.), stainless steel sheet (304 SS sh.), coated carbon steel plate (coat. CS pl.), 304 stainless steel plate (304 SS pl.), polyvinyl chloride (PVC), and fiber-reinforced plastic (FRP)

[7] Choices are: 0, 1, and 3.

[8] Choices are: circular spiral (circ.-spiral) and circular longitudinal (circ.-long.)

[9] Equation type and parameters depend on duct material of construction. Parameters reflect 2nd quarter 1993 costs. See 'Manual,' pp. 10-44 to 10-49.

[10] Choices are: power function (1) and exponential (2).

[11] Installation factor depends on control device ductwork is supporting. This factor, when multiplied by Purchased Equipment Cost, yields Total Capital Investment (TCI). If ductwork is installed alone, factor is 1.25 to 1.50. (Default = 1.50.) See 'Manual'.

[12] Pressure drop applies ONLY to circular, spiral-wound galvanized duct with 10 joints per 100 feet. For pressure drop data for other duct types, see 'Manual,' Chapter 10.

[13] Equation for steel hoods from Vatavuk, W.M., Estimating Costs of Air Pollution Control. Chelsea, Michigan, Lewis Book Publishers. 1990. Pp. 92

[14] Product of installation factor and Purchased Equipment Cost. Costs are presented both in terms of 2nd quarter '93 and above escalation date. Latter costs are based on Producer Price Index PCU 3444#1 ('Air-conditioning ducts and stove pipe')

[15] Labor of 17.42/hr ; 6 hr/month ; 15% supervision factor, from Bureau of Labor Statistics National Compensation survey, 2009, for Metal Furnace & Kiln Operators

[16] 60% of Labopr costs

Additional Assumptions:

Single cast hood is approx 20' high by 30' wide. Casting station is made up of 4 pouring stations each with a cast hood. 

Cast hoods are all connected to the same duct, and louvered off so that only one at a time draws air.

Assumes that casting is performed 12 times daily, for 30 minutes, 365 days/yr

Electricity cost from http://www.eia.doe.gov/cneaf/electricity/epm/table5_6_a.html for US industry, January 2011.

Guideline duct diameter of 48" taken from representative test report.
TOTAL ANNUAL COST SPREADSHEET - TAP HOOD UPGRADE

HOOD: COST BASE DATE: CEPCI 1988 [1] 342.5

COST ESCALATION: CEPCI 2010 [2] 539.1

Diameter of taphole, ft 2

Length of rectangular hood, ft, [3] 17

Width of rectangular hood, ft 10

Temperature difference between hot 2,430

 source and ambient air, deg F

Ventilation rate, acfm 59,538

Total purchase cost, [4] 6,395

Installation costs, [5] 7,483

Total Capital Costs $ 13,878

Retrofit Adjustment (25%) $ 17,348

Total Capital Costs, Escalated [1,2] $ 27,305.57

Annual operating costs (2009 Labor Rate)

Direct and overhead

Labor, [6] $ 962

Electricity, [7] $ -

Overhead, [8] $ 577

Total direct $ 1,539

Indirect, [9] $ 3,670

Total Annual Costs $ 5,208

[1] Chemical Engineering Plant Cost Index CEPCI for base year. Base costs reflect this date.

[2] Chemical Engineering Plant Cost Index CEPCI for year shown. Equipment cost has been escalated to t

[3] Length and width were chosen to form a rectangular hood similar in size

to those seen on site visits, and to reflect an acfm of close to 60,000.

[4] Hood cost equation = 39.0 (Length)^1.8 from Vatavuk, W.M., Estimating Costs of Air Pollution Control. 

[5] Assume 117% of purchase costs.

[6] 17.42 /hr; 4 hr/month ; 15% supervision factor, from Bureau of Labor Statistics National Compensatio

[7] Assume no additional electrical costs

[8] 60% of labor costs

[9] 9.4% capital amortization cost, based on a 20-year equipment life and a 7% interest rate, and

4.0% cost for administration, insurance, and property taxes applied to the total capital costs
been escalated to this date via this CEPCI.

r Pollution Control. Chelsea, Michigan, Lewis Book Publishers. 1990. Pp. 92

tional Compensation survey, 2009, for Metal Furnace & Kiln Operators

est rate, and

pital costs
TOTAL ANNUAL COST SPREADSHEET PROGRAM--STRAIGHT DUCTWORK for Tapping[1]

DUCTS: COST BASE DATE: CEPCI 1993 [2] 359.2

COST ESCALATION: CEPCI 2010 [3] 539.1

INPUT PARAMETERS

Ductwork:

-- Inlet stream flowrate (acfm): 60,000

-- Duct velocity (ft/min): [4] 4,750

-- Duct length (ft): [5] 400

-- Material of construction: [6] Sheet-galv CS

-- Insulation thickness (in.): (text input) [7] 0

-- Duct design: [8] Circular-longitudinal

-- Cost equation parameters: [9]

 a: 2.03

 b: 0.784

-- Cost equation form: [10] 1

-- Control system installation factor: [11] 1.5

 (if no system, enter '0')

-- Fan-motor combined efficiency (fraction): 0.6

DESIGN PARAMETERS

-- Duct diameter (in.): 48

-- Pressure drop (in. w.c.): [12] 2

CAPITAL COSTS

Ductwork Cost ($)--base: $16,921

Ductwork Cost ($)--escalated: $25,395

Purchased Equipment Cost ($): $27,427

Retrofit Adjustment (25%) $34,283

Total Capital Investment ($): [14] $51,425

ANNUAL COST INPUTS

Operating factor (hours/year): 4380

Electricity price ($/kWhr): 0.067

Annual interest rate (fractional): 0.07

Ductwork economic life (years): 20

Capital recovery factor (system): 0.094392926

Taxes, insurance, admin. factor: 0.04

Labor, $/hr [15] 17.42

ANNUAL COSTS

Item Cost ($/yr) Wt.Fact.

Electricity $6,021 0.395069441

Taxes, insurance, administrative $2,057 0.134976414

Capital recovery $4,854 0.318520465

Labor [15] $1,442 0.09464605

Overhead [16] $865 0.05678763

Total Annual Cost $15,240 1

Notes:

[1] Data used to develop this program were taken from 'OAQPS Control Cost Manual', 5th edition, Chapter 10. Prices are for CIRCULAR straight ductwork, only.

[2] Chemical Engineering Plant Cost Index CEPCI for base year. Base costs reflect this date.

[3] Chemical Engineering Plant Cost Index CEPCI for year shown. Equipment cost has been escalated to this date via this CEPCI.

[4] See 'Manual,' pp. 10-30 to 10-33.

[5] Duct length is a site-specific parameter that can vary from < 10 to > 1000 ft.

[6] Choices available are: carbon steel sheet (galv. CS sh.), stainless steel sheet (304 SS sh.), coated carbon steel plate (coat. CS pl.), 304 stainless steel plate (304 SS pl.), polyvinyl chloride (PVC), and fiber-reinforced plastic (FRP)

[7] Choices are: 0, 1, and 3.

[8] Choices are: circular spiral (circ.-spiral) and circular longitudinal (circ.-long.)

[9] Equation type and parameters depend on duct material of construction. Parameters reflect 2nd quarter 1993 costs. See 'Manual,' pp. 10-44 to 10-49.

[10] Choices are: power function (1) and exponential (2).

[11] Installation factor depends on control device ductwork is supporting. This factor, when multiplied by Purchased Equipment Cost, yields Total Capital Investment (TCI). If ductwork is installed alone, factor is 1.25 to 1.50. (Default = 1.50.) See 'Manual'.

[12] Pressure drop applies ONLY to circular, spiral-wound galvanized duct with 10 joints per 100 feet. For pressure drop data for other duct types, see 'Manual,' Chapter 10.

[13] Equation for steel hoods from Vatavuk, W.M., Estimating Costs of Air Pollution Control. Chelsea, Michigan, Lewis Book Publishers. 1990. Pp. 92

[14] Product of installation factor and Purchased Equipment Cost. Costs are presented both in terms of 2nd quarter '93 and above escalation date. Latter costs are based on Producer Price Index PCU 3444#1 ('Air-conditioning ducts and stove pipe')

[15] Labor of 17.42/hr ; 6 hr/month ; 15% supervision factor, from Bureau of Labor Statistics National Compensation survey, 2009, for Metal Furnace & Kiln Operators

[16] 60% of Labopr costs

Additional Assumptions:

Assumes that Tapping is performed 12 times daily, for 60 minutes, 365 days/yr

Electricity cost from http://www.eia.doe.gov/cneaf/electricity/epm/table5_6_a.html for US industry, January 2011.

Guideline duct diameter of 48" taken from representative test report.
TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

COST BASE DATE: CEPCI 1998 [2] 389.5

COST ESCALATION: CEPCI 2010 [3] 539.1

 INPUT PARAMETERS:

-- Inlet stream flowrate (acfm): 60,000

-- Inlet stream temperature (oF): 138

-- Inlet stream temperature, adjusted--pulse jet only (oF): 138

-- Dust type: Metal Furnace Fume

-- Inlet dust loading (gr/ft3): 0.0371

-- Dust mass median diameter (microns): 2.5 max for range of 0-2.5, taken from EPA's SPECIATE database for ferroalloys facilities.

-- Filtration time (min): 45 Median of range cited in EPA control cost manual was used.

-- Dust specific resistance (in.H2O/fpm/lb/ft2): 15 Assumed, as per EPA cost manual.

-- G/C ratio factors (shaker & reverse-air):

A: 1.5

B: 0.8

C: 1.2

-- G/C ratio factors (pulse-jet):

 Material: 6.0

Application: 0.8

-- G/C ratio factors (cartridge filters): A: 1.3

B: 0.8

C: 0.85

D: 0.9

E: 1.125

-- Cleaning pressure, psig (pulse-jet only): 100

-- Fraction of bags cleaned (shaker & rev-air): 0.1

-- Insulation required? ('yes'=1;'no'=0): 0

-- Stainless steel required? ('yes'=1;'no'=0): 0

-- Bag material: Nomex Selected as representative based on Ferroalloys ICR responses.

-- Fabric effective residual drag (in. H2O/fpm): 0.9 Median of range cited in EPA control cost manual was used.

-- Bag prices ($/ft2): (from table below, for bag material selected above only) [4]

Cleaning Mech. Bag Diam. (in.) Price ($/ft2)

---------------------------------------

Pulse jet--BBR 4.5 to 5.125 1.84

6 to 8 1.77

Pulse jet--cart. 4.875 6.12

6.125 4.67

Shaker--strap 5 1.61

Shaker--loop 5 1.53

Reverse air w/o rings 8 1.39

11.5 1.17

-- Cost of auxiliary equipment (ductwork, fan, stack, etc.), ($): $ 96,247 Fan cost only. Ductwork costs calculated elsewhere. Fan cost formula from CueCost spreadsheet, escalated in cell from 1990 $ to 1998 $ for equiv

DESIGN PARAMETERS

-- Gas-to-cloth ratio (acfm/ft2 cloth area):

Shaker: 1.44

Reverse-air: 1.44

Pulse-jet: 4.40

Cartridge: 0.90

-- Net cloth area required (ft2):

Shaker: 41667

Reverse-air: 41667

Pulse-jet: 13638

Cartridge: 67035

-- Gross cloth area required (ft2):

Shaker: 46875

Reverse-air: 46875

Pulse-jet: 13638

Cartridge: 67035

-- Area per bag--reverse-air (ft2) (8-in. x 24-ft): 50.3

-- Number of bags--reverse air: 933

-- Area per bag--shaker (ft2) (5-in x 8-ft): 10.5

-- Number of bags--shaker 4477

-- Area per bag--pulse jet (ft2): Small (4.5-in. x 8-ft) 9.42

Large (5.125-in. x 10-ft) 13.42

-- Number of bags/cages (pulse-jet only): Small bags 1448

Large bags 1017

-- Area per bag--cartridge (ft2): 153

-- Number of bags--cartridge: 439

-- Bag pressure drop (in. w.c.):

Shaker: 1.30

Reverse-air: 1.30

Pulse-jet: 1.41

Cartridge: 0.81

-- Baghouse shell pressure drop (in. w.c.): 3.00

-- Ductwork pressure drop (in. w.c.): 4.00
CAPITAL COSTS

Equipment Costs ($):

Item: Cost ($):

 Shaker Rev-air P-J (mod) P-J (com) P-J (cartridge)

------------------------------------------------------------------------------------------------------------------------------------------------

Baghouse 252,324 254,433 134,714 99,996 15,131

Bags--small 71,719 54,844 25,094 25,094 313,055

 " --large 24,139 24,139

Insulation 0 0 0 0 0

Stainless 0 0 0 0 0

Cages-small [5] 0 0 8,664 8,664 0

 " -large 0 0 11,223 11,223 0

Auxiliaries 96247 96247 96,247 96,247 96,247

------------------------------------------------------------------------------------------------------------------------------------------------

Total--small[5a] 420,290 405,524 264,720 230,002 424,434

 " --large: 266,324 231,606

PEC($)-base: 495,942 478,519 312,369 271,403 500,832

 ' ' -esc.: 787,607 662,309 432,345 375,643 693,192

TCI ($): 1,709,107 1,437,211 938,189 815,146 1,504,227

 ($/acfm): 28 24 16 14 25

==================================================================================

ANNUAL COST INPUTS:

Operating factor (hr/yr): 8640

Operating labor rate ($/hr): 17.42 Labor of 17.42/hr ; from Bureau of Labor Statistics National Compensation survey, 2009, for Metal Furnace & Kiln Operators

Maintenance labor rate ($/hr): 17.42 Labor of 17.42/hr ; from Bureau of Labor Statistics National Compensation survey, 2009, for Metal Furnace & Kiln Operators

Operating labor factor (hr/sh): 2

Maintenance labor factor (hr/sh): 1

Electricity price ($/kWhr): 0.0670 Electricity cost from http://www.eia.doe.gov/cneaf/electricity/epm/table5_6_a.html for US industry, January 2011.

Compressed air ($/1000 scf): 0.25

Dust disposal ($/ton): 25

Annual interest rate (fraction): 0.07

Control system life (years): 20

Capital recovery factor: 0.0944

Bag life (years): 2

Capital recovery factor (bags): 0.5531

Taxes, insurance, admin. factor: 0.04

 ANNUAL COSTS ($/yr):

 Item Shaker Reverse-air P-J (modular) P-J (common)P-J (cartridge)

------------------------------------------------------------------------------------------------------------------------------------------------

Oper. labor 37,627 37,627 37,627 37,627 37,627

Supv. labor 5,644 5,644 5,644 5,644 5,644

Maint. labor 18,814 18,814 18,814 18,814 18,814

Maint. matl. 18,814 18,814 18,814 18,814 18,814

Electricity 8,358 155,121 52,870 52,870 49,089

Compr. air 0 0 15,552 15,552 15,552

Bag repl. 61215 36,356 23,886 23,886 188,128

Dust dispos. 2061 2,061 2,061 2,061 2,061

Overhead 48,539 48,539 48,539 48,539 48,539

Tax,ins.,adm 68364 57,488 37,528 32,606 60,169

Cap. recov. 150880 129,458 84,482 72,868 109,882

------------------------------------------------------------------------------------------------------------------------------------------------ ------------------------------------------------

Total Annual 420,316 509,921 345,815 329,279 554,318

($/ton):[6] 5099 6186 4195 3995 6725

ANNUAL COST WEIGHTING FACTORS:

 Item Shaker Reverse-air P-J (mod) P-J (com) P-J (cartridge)

------------------------------------------------------------------------------------------------------------------------------------------------

Oper. labor 0.090 0.074 0.109 0.114 0.068

Supv. labor 0.013 0.011 0.016 0.017 0.010

Maint. labor 0.045 0.037 0.054 0.057 0.034

Maint. matl. 0.045 0.037 0.054 0.057 0.034

Overhead 0.115 0.095 0.140 0.147 0.088

------------------------------------------------------------------------------------------------------------------------------------------------

S/T labor: 0.308 0.254 0.374 0.393 0.234

Compr. air 0.000 0.000 0.045 0.047 0.028

Bag repl. 0.146 0.071 0.069 0.073 0.339

Dust dispos. 0.005 0.004 0.006 0.006 0.004

Electricity 0.020 0.304 0.153 0.161 0.089

Tax,ins.,adm 0.163 0.113 0.109 0.099 0.109

Cap. recov. 0.359 0.254 0.244 0.221 0.198

------------------------------------------------------------------------------------------------------------------------------------------------

S/T capital: 0.522 0.367 0.353 0.320 0.307

------------------------------------------------------------------------------------------------- ------------------------------------------------

Total: 1.000 1.000 1.000 1.000 1.000

==================================================================================

RELATIONSHIP BETWEEN GROSS AND NET CLOTH AREA

Net Cloth Area >/= (ft2): Gross/Net Area Ratio:

------------------------------------------------------------------------------------------------------------------------

1 2.000

4001 1.500

12001 1.250

24001 1.170

36001 1.125

48001 1.110

60001 1.100

72001 1.090

84001 1.080

96001 1.070

108001 1.060

132001 1.050
180001 1.040
[1] Parameters and other input data needed for this program can be found

in Chapter 5 (December 1998 revision) of the 'OAQPS Control Cost Manual'(5th edition).

Chapter 5 is found at: HTTP://WWW.EPA.GOV/TTN/CATC/PRODUCTS.HTML#CCCINFO.

[2] Base equipment costs reflect this date.

[3] Chemical Engineering Plant Cost Index CEPCI for year shown. Equipment cost has been escalated to this date via this CEPCI.

[4] These prices pertain to the bag material entered above. If this

bag material is not available for a baghouse type, enter '0'. 

(See 'Manual,' Chapter 5, Table 5.8.)

[5] Cage prices calculated from "500-cage lots" cost equations. (See Table 5.8.)

[5a] Total equipment cost for "small" and "large" bags and cages cases, respectively. 

[6] Total annual cost ($/yr) divided by total particulate captured

(tons/yr). If PM10, PM2.5, or other fractions are desired, divide by ratio

of PM10, PM2.5, etc., to total PM.

BAG PRICES (2nd quarter 1998 $/ft2) FOR SELECTED MATERIALS

[excerpted from Table 5.8, Chapter 5]

********************************************************************************************************************************************************** ********************************************************************* *******************

Cleaning Mech. Bag Diam. (in.) Polyethylene Polypropylene Nomex Homo-acrylic Fiberglas Cotton Teflon P84 Ryton Nextel

--------------------------------------- ------------------------------------------------------------------------

Pulse jet--TR 4.5 to 5.125 0.75 0.81 2.17 1.24 1.92 NA 12.21 4.06 2.87 20.66

6 to 8 0.67 0.72 1.95 1.15 1.60 NA 9.70 3.85 2.62 NA

Pulse jet-BBR 4.5 to 5.125 0.53 0.53 1.84 0.95 1.69 NA 12.92 3.60 2.42 16.67

6 to 8 0.50 0.60 1.77 0.98 1.55 NA 9.00 3.51 2.30 NA

Pulse jet-cart. 4.875 2.95 NA 6.12 NA NA NA NA NA NA NA

6.125 1.53 NA 4.67 NA NA NA NA NA NA NA

Shaker-strap 5 0.63 0.88 1.61 1.03 NA 0.70 NA NA NA NA

Shaker-loop 5 0.61 1.01 1.53 1.04 NA 0.59 NA NA NA NA

Rev. air w/rings 8 0.63 1.52 1.35 NA 1.14 NA NA NA NA NA

11.5 0.62 NA 1.43 NA 1.01 NA NA NA NA NA

Rev. air w/o " 8 0.44 NA 1.39 NA 0.95 NA NA NA NA NA

11.5 0.44 NA 1.17 NA 0.75 NA NA NA NA NA
TOTAL ANNUAL COST SPREADSHEET PROGRAM--STRAIGHT DUCTWORK for Tapping[1]

DUCTS: COST BASE DATE: CEPCI 1993 [2] 359.2

COST ESCALATION: CEPCI 1998 [3] 389.5 Escalated to 1998 for comparability with base numbers when input into fabric filter estimate

INPUT PARAMETERS

Ductwork:

-- Inlet stream flowrate (acfm): 150,000

-- Duct velocity (ft/min): [4] 3,800 From vendor quote

-- Duct length (ft): [5] 1000

-- Material of construction: [6] Sheet-galv CS

-- Insulation thickness (in.): (text input) [7] 0

-- Duct design: [8] Circular-longitudinal

-- Cost equation parameters: [9]

 a: 2.03

 b: 0.784

-- Cost equation form: [10] 1

-- Control system installation factor: [11] 0 None here, included in vendor quote

 (if no system, enter '0')

-- Fan-motor combined efficiency (fraction): 0.6

DESIGN PARAMETERS

-- Duct diameter (in.): 76 From vendor quote

-- Pressure drop (in. w.c.): [12] 2

CAPITAL COSTS

Ductwork Cost ($)--base: $60,542

Ductwork Cost ($)--escalated: $65,649

Purchased Equipment Cost ($): $70,900

Retrofit Adjustment (25%) $88,626

Total Capital Investment ($): [14] $132,938

ANNUAL COST INPUTS

Operating factor (hours/year): 4380

Electricity price ($/kWhr): 0.067

Annual interest rate (fractional): 0.07

Ductwork economic life (years): 20

Capital recovery factor (system): 0.094392926

Taxes, insurance, admin. factor: 0.04

Labor, $/hr [15] 17.42

ANNUAL COSTS

Item Cost ($/yr) Wt.Fact.

Electricity $14,681 0.421201787

Taxes, insurance, administrative $5,318 0.152563362

Capital recovery $12,548 0.360022552

Labor [15] $1,442 0.041382687

Overhead [16] $865 0.024829612

Total Annual Cost $34,855 1

Notes:

[1] Data used to develop this program were taken from 'OAQPS Control Cost Manual', 5th edition, Chapter 10. Prices are for CIRCULAR straight ductwork, only.

[2] Chemical Engineering Plant Cost Index CEPCI for base year. Base costs reflect this date.

[3] Chemical Engineering Plant Cost Index CEPCI for year shown. Equipment cost has been escalated to this date via this CEPCI.

[4] See 'Manual,' pp. 10-30 to 10-33.

[5] Duct length is a site-specific parameter that can vary from < 10 to > 1000 ft.

[6] Choices available are: carbon steel sheet (galv. CS sh.), stainless steel sheet (304 SS sh.), coated carbon steel plate (coat. CS pl.), 304 stainless steel plate (304 SS pl.), polyvinyl chloride (PVC), and fiber-reinforced plastic (FRP)

[7] Choices are: 0, 1, and 3.

[8] Choices are: circular spiral (circ.-spiral) and circular longitudinal (circ.-long.)

[9] Equation type and parameters depend on duct material of construction. Parameters reflect 2nd quarter 1993 costs. See 'Manual,' pp. 10-44 to 10-49.

[10] Choices are: power function (1) and exponential (2).

[11] Installation factor depends on control device ductwork is supporting. This factor, when multiplied by Purchased Equipment Cost, yields Total Capital Investment (TCI). If ductwork is installed alone, factor is 1.25 to 1.50. (Default = 1.50.) See 'Manual'.

[12] Pressure drop applies ONLY to circular, spiral-wound galvanized duct with 10 joints per 100 feet. For pressure drop data for other duct types, see 'Manual,' Chapter 10.

[13] Equation for steel hoods from Vatavuk, W.M., Estimating Costs of Air Pollution Control. Chelsea, Michigan, Lewis Book Publishers. 1990. Pp. 92

[14] Product of installation factor and Purchased Equipment Cost. Costs are presented both in terms of 2nd quarter '93 and above escalation date. Latter costs are based on Producer Price Index PCU 3444#1 ('Air-conditioning ducts and stove pipe')

[15] Labor of 17.42/hr ; 6 hr/month ; 15% supervision factor, from Bureau of Labor Statistics National Compensation survey, 2009, for Metal Furnace & Kiln Operators

[16] 60% of Labopr costs

Additional Assumptions:

Assumes that Tapping is performed 12 times daily, for 60 minutes, 365 days/yr

Electricity cost from http://www.eia.doe.gov/cneaf/electricity/epm/table5_6_a.html for US industry, January 2011.

Guideline duct diameter of 48" taken from representative test report.
TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

COST BASE DATE: CEPCI 1998 [2] 389.5

COST ESCALATION: CEPCI 2010 [3] 539.1

 INPUT PARAMETERS:

-- Inlet stream flowrate (acfm): 150,000

-- Inlet stream temperature (oF): 275

-- Inlet stream temperature, adjusted--pulse jet only (oF): 275

-- Dust type: Fugitive Emissions from Ferroalloys processes

-- Inlet dust loading (gr/ft3): 0.0022 From vendor estimate

-- Dust mass median diameter (microns): 2.5 max for range of 0-2.5, taken from EPA's SPECIATE database for ferroalloys facilities.

-- Filtration time (min): 45 Median of range cited in EPA control cost manual was used.

-- Dust specific resistance (in.H2O/fpm/lb/ft2): 15 Assumed, as per EPA cost manual.

-- G/C ratio factors (shaker & reverse-air):

A: 1.5

B: 0.8

C: 1.2

-- G/C ratio factors (pulse-jet):

 Material: 6.0

Application: 0.8

-- G/C ratio factors (cartridge filters): A: 1.3

B: 0.8

C: 0.85

D: 0.9

E: 1.125

-- Cleaning pressure, psig (pulse-jet only): 100

-- Fraction of bags cleaned (shaker & rev-air): 0.1

-- Insulation required? ('yes'=1;'no'=0): 0

-- Stainless steel required? ('yes'=1;'no'=0): 0

-- Bag material: Polyester From vendor estimate

-- Fabric effective residual drag (in. H2O/fpm): 0.9 Median of range cited in EPA control cost manual was used.

-- Bag prices ($/ft2): (from table below, for bag material selected above only) [4]

Cleaning Mech. Bag Diam. (in.) Price ($/ft2)

---------------------------------------

Pulse jet--BBR 4.5 to 5.125 0.53

6 to 8 0.50

Pulse jet--cart. 4.875 2.95

6.125 1.53

-- Cost of auxiliary equipment (ductwork, fan, stack, etc.), ($): $ 132,938 Ductwork Only. Other costs in vendor estimate. Escalated to 1998 $ via CEPCI when calculated.

DESIGN PARAMETERS Only used for annual cost estimation. Capital cost from vendor estimate.

-- Gas-to-cloth ratio (acfm/ft2 cloth area):

Pulse-jet: 2.96 From vendor estimate

-- Net cloth area required (ft2):

Pulse-jet: 50736 From vendor estimate

-- Gross cloth area required (ft2):

Pulse-jet: 50736 From vendor estimate

-- Area per bag--pulse jet (ft2): Small (4.5-in. x 8-ft) 9.42

Large (5.125-in. x 10-ft) 13.42

-- Number of bags/cages (pulse-jet only): Small bags 5384

Large bags 3782

-- Bag pressure drop (in. w.c.):

Pulse-jet: 0.90

-- Baghouse shell pressure drop (in. w.c.): 3.00

-- Ductwork pressure drop (in. w.c.): 4.00
CAPITAL COSTS

Equipment Costs ($):

Item: Cost ($):

 P-J (mod)

------------------------------------------------------------------------------------------------------------------------------------------------

Baghouse 464,329

Bags--small 26,890

 " --large 25,368

Insulation 0

Stainless 0

Cages-small [5] 32,216

 " -large 41,737

Auxiliaries 132,938

------------------------------------------------------------------------------------------------------------------------------------------------

Total--small[5a] 656,374

 " --large: 664,372

PEC($)-base:

 ' ' -esc.: 1,450,000 From vendor estimate

TCI ($): 3,146,500

 ($/acfm): 21

==================================================================================

ANNUAL COST INPUTS:

Operating factor (hr/yr): 8640

Operating labor rate ($/hr): 17.42 Labor of 17.42/hr ; from Bureau of Labor Statistics National Compensation survey, 2009, for Metal Furnace & Kiln Operators

Maintenance labor rate ($/hr): 17.42 Labor of 17.42/hr ; from Bureau of Labor Statistics National Compensation survey, 2009, for Metal Furnace & Kiln Operators

Operating labor factor (hr/sh): 2

Maintenance labor factor (hr/sh): 1

Electricity price ($/kWhr): 0.0670 Electricity cost from http://www.eia.doe.gov/cneaf/electricity/epm/table5_6_a.html for US industry, January 2011.

Compressed air ($/1000 scf): 0.25

Dust disposal ($/ton): 25

Annual interest rate (fraction): 0.07

Control system life (years): 20

Capital recovery factor: 0.0944

Bag life (years): 2

Capital recovery factor (bags): 0.5531

Taxes, insurance, admin. factor: 0.04

 ANNUAL COSTS ($/yr):

 Item P-J (modular)

------------------------------------------------------------------------------------------------------------------------------------------------

Oper. labor 37,627

Supv. labor 5,644

Maint. labor 18,814

Maint. matl. 18,814

Electricity 124,221

Compr. air 38,880

Bag repl. 49,139

Dust dispos. 305

Overhead 48,539

Tax,ins.,adm 125,860

Cap. recov. 288,621

------------------------------------------------------------------------------------------------------------------------------------------------

Total Annual 756,465

($/ton):[6] 61907

ANNUAL COST WEIGHTING FACTORS:

 Item P-J (mod)

------------------------------------------------------------------------------------------------------------------------------------------------

Oper. labor 0.050

Supv. labor 0.007

Maint. labor 0.025

Maint. matl. 0.025

Overhead 0.064

------------------------------------------------------------------------------------------------------------------------------------------------

S/T labor: 0.171

Compr. air 0.051

Bag repl. 0.065

Dust dispos. 0.000

Electricity 0.164

Tax,ins.,adm 0.166

Cap. recov. 0.382

------------------------------------------------------------------------------------------------------------------------------------------------

S/T capital: 0.548

-------------------------------------------------------------------------------------------------

Total: 1.000

==================================================================================

RELATIONSHIP BETWEEN GROSS AND NET CLOTH AREA

Net Cloth Area >/= (ft2): Gross/Net Area Ratio:

------------------------------------------------------------------------------------------------------------------------

1 2.000

4001 1.500

12001 1.250

24001 1.170

36001 1.125

48001 1.110

60001 1.100

72001 1.090

84001 1.080

96001 1.070

108001 1.060

132001 1.050
180001 1.040
[1] Parameters and other input data needed for this program can be found

in Chapter 5 (December 1998 revision) of the 'OAQPS Control Cost Manual'(5th edition).

Chapter 5 is found at: HTTP://WWW.EPA.GOV/TTN/CATC/PRODUCTS.HTML#CCCINFO.

[2] Base equipment costs reflect this date.

[3] Chemical Engineering Plant Cost Index CEPCI for year shown. Equipment cost has been escalated to this date via this CEPCI.

[4] These prices pertain to the bag material entered above. If this

bag material is not available for a baghouse type, enter '0'. 

(See 'Manual,' Chapter 5, Table 5.8.)

[5] Cage prices calculated from "500-cage lots" cost equations. (See Table 5.8.)

[5a] Total equipment cost for "small" and "large" bags and cages cases, respectively. 

[6] Total annual cost ($/yr) divided by total particulate captured

(tons/yr). If PM10, PM2.5, or other fractions are desired, divide by ratio

of PM10, PM2.5, etc., to total PM.

BAG PRICES (2nd quarter 1998 $/ft2) FOR SELECTED MATERIALS

[excerpted from Table 5.8, Chapter 5]

********************************************************************************************************************************************************** ********************************************************************* *******************

Cleaning Mech. Bag Diam. (in.) Polyester Polypropylene Nomex Homo-acrylic Fiberglas Cotton Teflon P84 Ryton Nextel

--------------------------------------- ------------------------------------------------------------------------

Pulse jet--TR 4.5 to 5.125 0.75 0.81 2.17 1.24 1.92 NA 12.21 4.06 2.87 20.66

6 to 8 0.67 0.72 1.95 1.15 1.60 NA 9.70 3.85 2.62 NA

Pulse jet-BBR 4.5 to 5.125 0.53 0.53 1.84 0.95 1.69 NA 12.92 3.60 2.42 16.67

6 to 8 0.50 0.60 1.77 0.98 1.55 NA 9.00 3.51 2.30 NA

Pulse jet-cart. 4.875 2.95 NA 6.12 NA NA NA NA NA NA NA

6.125 1.53 NA 4.67 NA NA NA NA NA NA NA

Shaker-strap 5 0.63 0.88 1.61 1.03 NA 0.70 NA NA NA NA

Shaker-loop 5 0.61 1.01 1.53 1.04 NA 0.59 NA NA NA NA

Rev. air w/rings 8 0.63 1.52 1.35 NA 1.14 NA NA NA NA NA

11.5 0.62 NA 1.43 NA 1.01 NA NA NA NA NA

Rev. air w/o " 8 0.44 NA 1.39 NA 0.95 NA NA NA NA NA

11.5 0.44 NA 1.17 NA 0.75 NA NA NA NA NA
TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

COST BASE DATE: CEPCI 1998 [2] 389.5

COST ESCALATION: CEPCI 2010 [3] 539.1

 INPUT PARAMETERS:

-- Inlet stream flowrate (acfm): 180,000 from Vendor Estimate

-- Inlet stream temperature (oF): 500 from Vendor Estimate

-- Inlet stream temperature, adjusted--pulse jet only (oF): 275

-- Dust type: Metal Furnace Fume

-- Inlet dust loading (gr/ft3): 0.7700 from Vendor Estimate

-- Dust mass median diameter (microns): 2.5 max for range of 0-2.5, taken from EPA's SPECIATE database for ferroalloys facilities.

-- Filtration time (min): 45 Median of range cited in EPA control cost manual was used.

-- Dust specific resistance (in.H2O/fpm/lb/ft2): 15 Assumed, as per EPA cost manual.

-- G/C ratio factors (shaker & reverse-air):

A: 1.5

B: 0.8

C: 1.2

-- G/C ratio factors (pulse-jet):

 Material: 6.0

Application: 0.8

-- G/C ratio factors (cartridge filters): A: 1.3

B: 0.8

C: 0.85

D: 0.9

E: 1.125

-- Cleaning pressure, psig (pulse-jet only): 100

-- Fraction of bags cleaned (shaker & rev-air): 0.1

-- Insulation required? ('yes'=1;'no'=0): 0

-- Stainless steel required? ('yes'=1;'no'=0): 0

-- Bag material: Fiberglass from Vendor Estimate

-- Fabric effective residual drag (in. H2O/fpm): 0.9 Median of range cited in EPA control cost manual was used.

-- Bag prices ($/ft2): (from table below, for bag material selected above only) [4]

Cleaning Mech. Bag Diam. (in.) Price ($/ft2)

---------------------------------------

Pulse jet--BBR 4.5 to 5.125 1.69

6 to 8 1.55

Pulse jet--cart. 4.875 NA

6.125 NA

Shaker--strap 5 NA

Shaker--loop 5 NA

Reverse air w/o rings 8 0.95

11.5 0.75

-- Cost of auxiliary equipment (ductwork, fan, stack, etc.), ($): $ 189,988 Fan cost only. Ductwork costs calculated elsewhere. Fan cost formula from CueCost spreadsheet, escalated in cell from 1990 $ to 1998 $ for equiv

DESIGN PARAMETERS

-- Gas-to-cloth ratio (acfm/ft2 cloth area):

Shaker: 1.44

Reverse-air: 1.50 from Vendor Estimate

Pulse-jet: 3.12

Cartridge: 0.90

-- Net cloth area required (ft2):

Shaker: 125000

Reverse-air: 120000

Pulse-jet: 57690

Cartridge: 201106

-- Gross cloth area required (ft2):

Shaker: 132500

Reverse-air: 127200

Pulse-jet: 57690

Cartridge: 201106

-- Area per bag--reverse-air (ft2) (8-in. x 24-ft): 50.3

-- Number of bags--reverse air: 2531

-- Area per bag--shaker (ft2) (5-in x 8-ft): 10.5

-- Number of bags--shaker 12653

-- Area per bag--pulse jet (ft2): Small (4.5-in. x 8-ft) 9.42

Large (5.125-in. x 10-ft) 13.42

-- Number of bags/cages (pulse-jet only): Small bags 6122

Large bags 4300

-- Area per bag--cartridge (ft2): 153

-- Number of bags--cartridge: 1315

-- Bag pressure drop (in. w.c.):

Shaker: 1.45

Reverse-air: 1.52

Pulse-jet: 1.67

Cartridge: 0.87

-- Baghouse shell pressure drop (in. w.c.): 3.00

-- Ductwork pressure drop (in. w.c.): 4.00
CAPITAL COSTS

Equipment Costs ($):

Item: Cost ($):

 Rev-air

------------------------------------------------------------------------------------------------------------------------------------------------

Baghouse 625,776

Bags--small 95,400

 " --large

Insulation 0

Stainless 0

Cages-small [5] 0

 " -large 0

Auxiliaries 189988

------------------------------------------------------------------------------------------------------------------------------------------------

Total--small[5a] 911,164

 " --large:

PEC($)-base:

 ' ' -esc.: 6,100,000 from Vendor Estimate

TCI ($): 13,237,000

 ($/acfm): 74

==================================================================================

ANNUAL COST INPUTS:

Operating factor (hr/yr): 8640

Operating labor rate ($/hr): 17.42 Labor of 17.42/hr ; from Bureau of Labor Statistics National Compensation survey, 2009, for Metal Furnace & Kiln Operators

Maintenance labor rate ($/hr): 17.42 Labor of 17.42/hr ; from Bureau of Labor Statistics National Compensation survey, 2009, for Metal Furnace & Kiln Operators

Operating labor factor (hr/sh): 2

Maintenance labor factor (hr/sh): 1

Electricity price ($/kWhr): 0.0670 Electricity cost from http://www.eia.doe.gov/cneaf/electricity/epm/table5_6_a.html for US industry, January 2011.

Compressed air ($/1000 scf): 0.25

Dust disposal ($/ton): 25

Annual interest rate (fraction): 0.07

Control system life (years): 20

Capital recovery factor: 0.0944

Bag life (years): 2

Capital recovery factor (bags): 0.5531

Taxes, insurance, admin. factor: 0.04

 ANNUAL COSTS ($/yr):

 Item Reverse-air

------------------------------------------------------------------------------------------------------------------------------------------------

Oper. labor 37,627

Supv. labor 5,644

Maint. labor 18,814

Maint. matl. 18,814

Electricity 451,552

Compr. air 0

Bag repl. 66,740

Dust dispos. 128,304

Overhead 48,539

Tax,ins.,adm 529,480

Cap. recov. 1,238,089

------------------------------------------------------------------------------------------------------------------------------------------------

Total Annual 2,543,603

($/ton):[6] 496

ANNUAL COST WEIGHTING FACTORS:

 Item Shaker Reverse-air P-J (mod) P-J (com) P-J (cartridge)

------------------------------------------------------------------------------------------------------------------------------------------------

Oper. labor 0.000 0.015 #DIV/0! #DIV/0! 0.000

Supv. labor 0.000 0.002 #DIV/0! #DIV/0! 0.000

Maint. labor 0.000 0.007 #DIV/0! #DIV/0! 0.000

Maint. matl. 0.000 0.007 #DIV/0! #DIV/0! 0.000

Overhead 0.000 0.019 #DIV/0! #DIV/0! 0.000

------------------------------------------------------------------------------------------------------------------------------------------------

S/T labor: 0.000 0.051 #DIV/0! #DIV/0! 0.000

Compr. air 0.000 0.000 #DIV/0! #DIV/0! 0.000

Bag repl. 0.000 0.026 #DIV/0! #DIV/0! 0.000

Dust dispos. 0.000 0.050 #DIV/0! #DIV/0! 0.000

Electricity 0.000 0.178 #DIV/0! #DIV/0! 0.000

Tax,ins.,adm 0.000 0.208 #DIV/0! #DIV/0! 0.000

Cap. recov. 0.000 0.487 #DIV/0! #DIV/0! 0.000

------------------------------------------------------------------------------------------------------------------------------------------------

S/T capital: 0.000 0.695 #DIV/0! #DIV/0! 0.000

------------------------------------------------------------------------------------------------- ------------------------------------------------

Total: 0.000 1.000 #DIV/0! #DIV/0! 0.000

==================================================================================

RELATIONSHIP BETWEEN GROSS AND NET CLOTH AREA

Net Cloth Area >/= (ft2): Gross/Net Area Ratio:

------------------------------------------------------------------------------------------------------------------------

1 2.000

4001 1.500

12001 1.250

24001 1.170

36001 1.125

48001 1.110

60001 1.100

72001 1.090

84001 1.080

96001 1.070

108001 1.060

132001 1.050
180001 1.040
[1] Parameters and other input data needed for this program can be found

in Chapter 5 (December 1998 revision) of the 'OAQPS Control Cost Manual'(5th edition).

Chapter 5 is found at: HTTP://WWW.EPA.GOV/TTN/CATC/PRODUCTS.HTML#CCCINFO.

[2] Base equipment costs reflect this date.

[3] Chemical Engineering Plant Cost Index CEPCI for year shown. Equipment cost has been escalated to this date via this CEPCI.

[4] These prices pertain to the bag material entered above. If this

bag material is not available for a baghouse type, enter '0'. 

(See 'Manual,' Chapter 5, Table 5.8.)

[5] Cage prices calculated from "500-cage lots" cost equations. (See Table 5.8.)

[5a] Total equipment cost for "small" and "large" bags and cages cases, respectively. 

[6] Total annual cost ($/yr) divided by total particulate captured

(tons/yr). If PM10, PM2.5, or other fractions are desired, divide by ratio

of PM10, PM2.5, etc., to total PM.

BAG PRICES (2nd quarter 1998 $/ft2) FOR SELECTED MATERIALS

[excerpted from Table 5.8, Chapter 5]

********************************************************************************************************************************************************** ********************************************************************* *******************

Cleaning Mech. Bag Diam. (in.) Polyester Polypropylene Nomex Homo-acrylic Fiberglas Cotton Teflon P84 Ryton Nextel

--------------------------------------- ------------------------------------------------------------------------

Pulse jet--TR 4.5 to 5.125 0.75 0.81 2.17 1.24 1.92 NA 12.21 4.06 2.87 20.66

6 to 8 0.67 0.72 1.95 1.15 1.60 NA 9.70 3.85 2.62 NA

Pulse jet-BBR 4.5 to 5.125 0.53 0.53 1.84 0.95 1.69 NA 12.92 3.60 2.42 16.67

6 to 8 0.50 0.60 1.77 0.98 1.55 NA 9.00 3.51 2.30 NA

Pulse jet-cart. 4.875 2.95 NA 6.12 NA NA NA NA NA NA NA

6.125 1.53 NA 4.67 NA NA NA NA NA NA NA

Shaker-strap 5 0.63 0.88 1.61 1.03 NA 0.70 NA NA NA NA

Shaker-loop 5 0.61 1.01 1.53 1.04 NA 0.59 NA NA NA NA

Rev. air w/rings 8 0.63 1.52 1.35 NA 1.14 NA NA NA NA NA

11.5 0.62 NA 1.43 NA 1.01 NA NA NA NA NA

Rev. air w/o " 8 0.44 NA 1.39 NA 0.95 NA NA NA NA NA

11.5 0.44 NA 1.17 NA 0.75 NA NA NA NA NA