### 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 $756,465 Felman **Annual Cost of Control Technology ($)**

Eramet

## Control Option **PM Emission Reduction**  **(TPY) PM** **2.5**



## Emission **Reduction 1**  

## (TPY) **HAP**

**Emission Reduction**  **(TPY) Capital Cost** 

**($) Annual Cost** 

**($/Yr) PM Cost** 

**Effectiveness ($/Ton)**  **PM 2.5** 

## 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

## PM 2.5

## 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

1Current 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.

2Annual cost calculated using 7% interest and a 5-year equipment life.

3The 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.

4For 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.

5Proposed 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** 

**Injection 1,2**  

# Capital Cost **($) Carbon** 

**Injection 1,2**  

# 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

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,**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

1Upgrade capital cost for hood & associated ductwork calculated using EPA Cost-air spreadsheets and escalated to 2010 dollars using the Chemical Engineering Plant Cost Index.
2Annual cost calculated using 7% interest and a 20-year equipment life.
3The 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.
4Shop 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

1Upgrade capital cost for hood & associated ductwork calculated using EPA Cost-air spreadsheets and escalated to 2010 dollars using the Chemical Engineering Plant Cost Index.

2Annual cost calculated using 7% interest and a 20-year equipment life.
3The 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.

4Globe 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 to Cost and Performance for APC Technologies, Mercury Control Cost Development Methodology Final, March 2011

# Reverse-air: 6 Sargent & Lundy, IPM Model - Revisions to Cost and Performance for APC Technologies, Mercury Control Cost Development Methodology Final, March 2011 Pulse-jet: 6 Sargent & Lundy, IPM Model - Revisions to Cost and Performance for APC Technologies, Mercury Control Cost Development Methodology Final, March 2011 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-strap 5 0.63 0.88 1.61 1.03 Shaker-loop 5 0.61 1.01 1.53 1.04 Rev. air w/rings 8 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 Assumes 2lb/Mmacf 243350 228 246079 225

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

# Sargent & Lundy, IPM Model - Revisions to Cost and Performance for APC Technologies, Mercury Control Cost Development Methodology Final, March 2011 Sargent & 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 NA 9 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

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

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

# *******************

### Activated Carbon Injection Model Costs**1,2,3,4**



### 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.

# TOTA**L A NNUA** **L COST SPREA DSHEET - TA** **P HOOD UPGRA DE** 
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 A nnual 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 this date via this CEPCI. [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. Chelsea, Michigan, Lewis Book Publishers. 1990. Pp. 92 [5] Assume 117% of purchase costs. [6] 17.42 /hr; 4 hr/month ; 15% supervision factor, from Bureau of Labor Statistics National Compensation survey, 2009, for Metal Furnace & Kiln Operators [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

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

Hood cost equation = 39.0 (Length)^1.8 from Vatavuk, W.M., Estimating Costs of Air Pollution Control. Chelsea, Michigan, Lewis Book Publishers. 1990. Pp. 92
/hr; 4 hr/month ; 15% supervision factor, from Bureau of Labor Statistics National Compensation survey, 2009, for Metal Furnace & Kiln Operators

capital amortization cost, based on a 20-year equipment life and a 7% interest rate, and cost for administration, insurance, and property taxes applied to the total capital 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 PA RAMETERS:** 

-- Inlet streamflowrate (acfm): 60,000 -- Inlet streamtemperature (oF): 138 -- Inlet streamtemperature, 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 (m in): 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 from1990 $ to 1998 $ for equivalence with other base costs in the spreadsheet.

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.): 4.00CAPITAL 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 ($/kWhr): 0.0670 Electricity cost fromhttp://w ww.eia.doe.gov/cneaf/electricity/epm/table5_6_a.html for US industry, January 2011. Com pressed air ($/1000 scf): 0.25 Dust disposal ($/ton): 25 Annual interest rate (fraction): 0.07 Control systemlife (years): 20 Capital recovery factor: 0.0944 Bag life (years): 2 Capital recovery factor (bags): 0.5531 Taxes, insurance, adm in. factor: 0.04
ANNUAL COSTS ($/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 Com pr. 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 Com pr. 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 1.050180001 1.040[1] Parameters and other input data needed for this programcan be found

in Chapter 5 (Decem ber 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] Chem ical 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 fromTable 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 PA RAMETERS:** 

-- Inlet streamflowrate (acfm): 150,000 -- Inlet streamtemperature (oF): 275 -- Inlet streamtemperature, adjusted--pulse jet only (oF): 275 -- Dust type: Fugitive Em issions fromFerroalloys processes -- Inlet dust loading (gr/ft3): 0.0022 Fromvendor 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 (m in): 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 Fromvendor 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 fromvendor estimate.
-- Gas-to-cloth ratio (acfm/ft2 cloth area): Pulse-jet: 2.96 Fromvendor estimate -- Net cloth area required (ft2): Pulse-jet: 50736 Fromvendor estimate -- Gross cloth area required (ft2): Pulse-jet: 50736 Fromvendor 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.): 4.00CAPITAL 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($)-base: ' ' -esc.: 1,450,000 Fromvendor estimate TCI ($): 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 ($/kWhr): 0.0670 Electricity cost fromhttp://w ww.eia.doe.gov/cneaf/electricity/epm/table5_6_a.html for US industry, January 2011. Com pressed air ($/1000 scf): 0.25 Dust disposal ($/ton): 25 Annual interest rate (fraction): 0.07 Control systemlife (years): 20 Capital recovery factor: 0.0944 Bag life (years): 2 Capital recovery factor (bags): 0.5531 Taxes, insurance, adm in. factor: 0.04
ANNUAL COSTS ($/yr): Item P-J (modular)

------------------------------------------------------------------------------------------------------------------------------------------------ Oper. labor 37,627 Supv. labor 5,644 Maint. labor 18,814 Maint. matl. 18,814 Electricity 124,221 Com pr. 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 Com pr. 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 1.050180001 1.040[1] Parameters and other input data needed for this programcan be found

in Chapter 5 (Decem ber 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] Chem ical 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 fromTable 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 PA RAMETERS:** 

-- Inlet streamflowrate (acfm): 180,000 from Vendor Estimate -- Inlet streamtemperature (oF): 500 from Vendor Estimate -- Inlet streamtemperature, 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 (m in): 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 from1990 $ to 1998 $ for equivalence with other base costs in the spreadsheet.

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.): 4.00CAPITAL 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 ($/kWhr): 0.0670 Electricity cost fromhttp://w ww.eia.doe.gov/cneaf/electricity/epm/table5_6_a.html for US industry, January 2011. Com pressed air ($/1000 scf): 0.25 Dust disposal ($/ton): 25 Annual interest rate (fraction): 0.07 Control systemlife (years): 20 Capital recovery factor: 0.0944 Bag life (years): 2 Capital recovery factor (bags): 0.5531 Taxes, insurance, adm in. factor: 0.04
ANNUAL COSTS ($/yr): Item Reverse-air

------------------------------------------------------------------------------------------------------------------------------------------------ Oper. labor 37,627 Supv. labor 5,644 Maint. labor 18,814 Maint. matl. 18,814 Electricity 451,552 Com pr. 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 Com pr. 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 1.050180001 1.040[1] Parameters and other input data needed for this programcan be found

in Chapter 5 (Decem ber 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] Chem ical 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 fromTable 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