# TECHNICAL MEMORANDUM

TO: Jodi Howard, US EPA/OAQPS/SPPD/RCG

FROM: Eastern Research Group, Inc.

DATE: February 9, 2012

SUBJECT: Revised Costs and Emission Reductions for Major Sources in the Polyvinyl Chloride and Copolymers (PVC) Production Source Category

1.0 Introduction

The U.S. Environmental Protection Agency (EPA), under sect ion 112 of the Clean Air Act (CAA), is required to establish national emissions standards for Hazardous Air Pollutants (NESHAP) emitted from polyvinyl chloride and copolymer (PV C) production facilities. The complete set of regulated hazardous air pollutants (HAP) is listed in CAA section 112(b). The CAA requires EPA to determine the maximum achievable cont rol technology (MACT) for each category of sources. To do so, EPA must first determine the minimum stringency “floor” requirements. Separate memoranda document the MACT floo r and Beyond-the-Floor analyses for the production facilities 1 

# . The purpose of this memorandum is to present the nation wide costs and emission reductions for existing major sources to com ply with MACT.

1.1 Selection of Controls Needed to Meet MACT Floor Limit s A significant portion of the total cost for industry co mpliance comes from the cost of installing new pollution control devices or improving existing pollution control devices for facilities not currently meeting the MACT limits. Vari ous control technologies were considered for each facility depending upon which limits that facilit y needed to meet and how much emissions improvement or HAP reduction would be needed to me et the limits.

1.2 Compliance Costs

For each emission point, costs were estimated for exis ting production facilities for (A) the emission controls used to comply with the MACT floor l imits; and (B) the monitoring, testing, recordkeeping, and reporting activities used to demonstrate co mpliance. All costs were calculated as 2010 dollars.

1.3 Emission Control Costs

The costs for various types of control equipment were estimated depending on the emission point. For all cost analyses, an annual operati ng time of 8,400 hours (assuming 336 hours or 2 weeks of downtime) was assumed, where applica ble. A 20 year life was assumed for any installed equipment. Capital recovery factors (C RF) were calculated using a 7 percent discount rate. All PVC production facilities were assum ed to have adequate space to install

1

# additional emissions control equipment without shutting do wn the production facility for an

extended period. It was also assumed that connecting any pr ocess piping or ductwork could be performed during scheduled downtime for maintenance, thereby m inimizing expected downtime.

1.4 Testing, Monitoring, and Recordkeeping Costs

The initial costs and total annual costs (TAC) for testi ng, monitoring, recordkeeping and reporting were estimated for process vents, stripped resin, wastewater, equipment leaks, storage vessels, heat exchange systems, and other emission so urces. For total initial costs, the CRF, where applicable, was again calculated using a 7 percent dis count rate.

1.5 Emission Reductions

Emission reductions for each emission point were estima ted as a result of facilities meeting the MACT floor limits. Emission reductions wer e calculated by subtracting the emissions of facilities at the MACT floor from the facility baseline emissions. The calculation of baseline emissions is described in a separate memorandum 2 

# . If a facility is currently meeting a MACT floor, then emissions reductions for that facility , at that emission point were assumed to be zero.

2.0 Process Vents

2.1 Selection of Controls Needed to Meet MACT Floor Limit s

One control device to reduce emission concentrations fro m each subcategory of PVC process vents was considered. An existing control device m ay reduce one of the pollutants to below the MACT floor, but additional control may be requ ired to reduce emissions of other pollutants from that same process vent. The cost of a refrigerated condenser system installed before the thermal oxidizer was estimated to reduce viny l chloride (VC), hydrogen chloride (HCl), chlorinated dibenzodioxins and chlorinated dibenzof urans (CDD/CDF) and total organic HAP from facilities in each process vent subcategory. T otal organic HAP accounts for VC CDD/CDF, but does not include HCl or any other non-organic compounds. For facilities using a vent gas absorption system (VGA), the cost of install ing a refrigerated condenser on the VGA exhaust was estimated since the VGA does not reduce the emission concentrations to the MACT floor levels. A refrigerated condenser is expected to reduc e VC and total organic HAP emissions directly by reducing the amount of HAP being routed to, or exh aust from, the control device. For facilities requiring a reduction in HCl or CDD/CDF emiss ions, it was assumed that condensing and removing VC from the control system inlet stream wou ld reduce some of the HCl and/or CDD/CDF emissions in the control system exhaust strea m as the amount of chloride ions available for HCl and/or CDD/CDF formation during combust ion would be reduced.

2.2 Compliance Cost Methodology and Results

The cost of adding a refrigerated condenser for control o f VC, HCl, CDD/CDF and total organic HAP emissions from process vents was estimated. The cost algorithm for installing a refrigerated condenser is presented in Attachment A and is based on algorithms in the OAQPS Air Pollution Control Cost Manual 3 

# . The condenser input calculations for VC, HCl, CDD/CDF and total organic HAP reduction are presented in Attachment B. The refrigerated condenser total capital investment (TCI) costs range from approximately $ 47,000 to $777,000, and TAC range

2

# from approximately $103 thousand per year to $355 thousand per year . Although a refrigerated

condenser is expected to recover additional VC, no recove ry credit has been estimated for recovered materials as the extent of additional proces sing and conditioning is unknown. Sources for specific cost data are documented in Attachment A.

2.3 Testing, Monitoring, and Recordkeeping Costs

The initial cost of emissions tests at process vents f or VC, HCl, CDD/CDF and total organic HAP were calculated and annualized. The costs of performing emissions tests at process vents every 5 years for VC, CDD/CDF, and total organic H AP were calculated. Cost estimates for US EPA Method 18, Method 26, Method 23, and Method 25A fo r VC, HCl, CDD/CDF, and THC respectively were performed.

The cost algorithm used to estimate TAC of testing on a facility basis is presented in Attachment C. Testing costs on a facility basis for pr ocess vents are presented in Table 1. The industry TAC for process vent testing was estimated at appr oximately $188,000 per year.

Although facilities will determine traverse points (Meth od 1), stack velocity (Method 2), stack gas oxygen content (Method 3 or ANSI/ASME PTC 19.10-1981 ), and stack gas moisture content (Method 4), it was assumed that the cost of t hese methods was included in the estimate for HCl, CDD/CDF, THC, and VC. Although facilities may potentially use a CEMS to demonstrate compliance, any costs to install, maintain , or demonstrate compliance using a CEMS have not been estimated.

Recordkeeping and reporting costs were estimated for proces s vents. An industry wide initial cost of $70,600 and an industry wide total annual cost of $33,100 were calculated based on the algorithms presented in Attachment D. Recordkeeping a nd reporting costs on a facility basis for process vents are presented in Table 2.

3

# Table 1. Summary of Control Equipment Costs for Process Ve nts

Company/Facility Condenser Total Control Costs for Process Vents

TCI ($) Annualized Capital

Cost ($/yr) Annual Costs

($/yr) TCI ($) TAC ($/yr)

Dow - Midland - - - - -

Formosa - Baton Rouge 584,150 55,140 209,045 584,15 0 264,185

Formosa - Point Comfort 435,451 41,104 156,028 435, 451 197,131

Formosa - Delaware 54,595 5,153 101,501 54,595 106, 655

Georgia Gulf - Aberdeen 48,450 4,573 100,026 48,450 104,599

Georgia Gulf - Plaquemine - - - - -

OxyVinyls - Pasadena 777,040 73,347 281,841 777,040 355,188

OxyVinyls - Pedricktown - - - - -

PolyOne - Henry 59,229 5,591 100,068 59,229 105,659

PolyOne - Pedricktown 47,498 4,483 99,437 47,498 10 3,921

Shintech - Freeport - - - - -

Shintech - Plaquemine - - - - -

Shintech - Addis - - - - -

Westlake - Calvert City 584,150 55,140 209,045 584, 150 264,185

Westlake - Geismar - - - - -

Total* 2,590,563 244,531 1,256,991 2,590,563 1,501, 522 

## *Totals may not add exactly due to rounding.

4

# Table 2. Summary of Testing, Recordkeeping, and Monitoring Cost s for Process Vents

Company/Facility Performance Testing Cost Recordkeeping and Reporting Cost Total Monitoring, Reporting, and Recordkeeping Costs for Process Vents

Total Initial Costs ($) Annualized

Initial Cost ($/yr) Annual

Cost ($/yr) Total Initial

Costs ($) Annual

Cost ($/yr) Total

Initial Costs ($) TAC

($/yr)

Dow-Midland 51,198 4,833 8,640 4,706 2,204 55,904 1 5,677 Formosa-Baton Rouge 51,198 4,833 8,640 4,706 2,204 55,904 15,677 Formosa-Point Comfort 51,198 4,833 8,640 4,706 2,20 4 55,904 15,677 Formosa -Delaware 51,198 4,833 8,640 4,706 2,204 55 ,904 15,677 Georgia Gulf-Aberdeen 51,198 4,833 8,640 4,706 2,20 4 55,904 15,677 Georgia Gulf -Plaquemine 51,198 4,833 8,640 4,706 2 ,204 55,904 15,677 OxyVinyls-Pasadena 51,198 4,833 8,640 4,706 2,204 5 5,904 15,677 OxyVinyls -Pedricktown - - - 4,706 2,204 4,706 2,20 4 PolyOne-Henry 51,198 4,833 8,640 4,706 2,204 55,904 15,677 PolyOne-Pedricktown 51,198 4,833 8,640 4,706 2,204 55,904 15,677 Shintech-Freeport 51,198 4,833 8,640 4,706 2,204 55 ,904 15,677 Shintech-Plaquemine 51,198 4,833 8,640 4,706 2,204 55,904 15,677 Shintech -Addis 51,198 4,833 8,640 4,706 2,204 55,9 04 15,677 Westlake -Calvert City 51,198 4,833 8,640 4,706 2,2 04 55,904 15,677 Westlake -Geismar 51,198 4,833 8,640 4,706 2,204 55 ,904 15,677 Total* 716,772 67,662 120,960 70,591 33,055 787,363 221,677 

## *Totals may not add exactly due to rounding.



# 2.4 Emission Reduction Methodology and Results

The average HAP concentration values used to calculate b aseline annual emissions 2 

# for every process vent at each facility were compared with the MACT floor emissions limits. Percentages to quantify the amount of improvement needed f or the facility to meet the limits were calculated. Table 3 and 4 contains the baseline HAP concentration values used for each facility and the percentage improvement required to meet th e MACT floor emissions limits for PVC-only and PVC-combined process vents, respectively. Reduc tions of VC, HCl, CDD/CDF and total organic HAP for process vents were estimated a t each facility as a result of all facilities complying with the MACT floor standard. Reductions were es timated at 1.02E-01 tons per year of VC, 21 tons per year of HCl, 1.87E-08 tons per year of C DD/CDF, and 1.93 tons per year of total organic HAP.

Emission reductions as a result of facilities meeting th e MACT floor were estimated by multiplying the percent improvement needed by the calculate d baseline annual emissions. It was assumed that if one of the four pollutant categories r equired reduction, all pollutants would be equally reduced. Reductions by facility for VC, HCl, chlorine (Cl 2 

# ), CDD/CDF and total organic HAP are presented in Table 5.

5Table 3. Percent Improvement Needed for PVC-Only ProcessVents to Meet MACT Floor Emission LimitsCompany/FacilityVCLimit: 6.0 ppmvdHClLimit: 78 ppmvdCDD/CDF (TEQ)Limit: 3.8E-02 ng/dscmTotal Organic HAPLimit: 56 ppmvdFacilityBaseline(ppmvd)PercentImprovementNeededFacilityBaseline(ppmvd)PercentImprovementNeededFacilityBaseline(ng/dscm)PercentImprovementNeededFacilityBaseline(ppmvd)PercentImprovementNeededFormosa – Delaware City 2.45E-01 - 121 35.7 2.70E-03 - 2.84 -Georgia Gulf – Aberdeen 2.00 - 157 50.2 4.72E-03 - 6.87 -OxyVinyls – Pasadena 9.71E-01 - 360 78.3 7.76E-03 - 17.8 -PolyOne – Henry 2.18 - 5.30E-01 - - - 9,724 99.4PolyOne – Pedricktown 2.66 - 1.32 - - - 25,173 99.8Shintech – Addis 2.43E-01 - 8.47E-02 - 1.73E-02 - 11.9 -Shintech - Freeport 5.00E-03-1.2E-01 - 1.16E-02-2.16E-01-VC – Vinyl chlorideHCl – Hydrogen chlorideCDD/CDF - Chlorinated dibenzodioxin and chlorinated dibenzofuranTEQ - Toxic EquivalencyHAP – Hazardous air pollutantppmvd – Parts per million on a dry volume basis correctedto 3 percent oxygenng/dscm – Nanograms per dry standard cubic meter corrected to 3 percent oxygen



### 6Table 4. Percent Improvement Needed for PVC-Combined Process Vents to Meet MACT Floor Emission LimitsCompany/FacilityVCLimit: 1.1 ppmvdHClLimit: 380 ppmvdCDD/CDF (TEQ)Limit: 5.1E-02 ng/dscmTotal Organic HAPLimit: 9.8 ppmvdFacilityBaseline(ppmvd)PercentImprovementNeededFacilityBaseline(ppmvd)PercentImprovementNeededFacilityBaseline(ng/dscm)PercentImprovementNeededFacilityBaseline(ppmvd)PercentImprovementNeededDow – Midland 4.51E-03 - NR - 1.68E-03 - 3.36E-01 -Formosa – Baton Rouge 1.28E-01 - 92.3 - 7.05E-02 27.6 2.02 -Formosa – Point Comfort 4.40E-01 - 92.3 - 3.10E-01 83.6 2.02 -Georgia Gulf – Plaquemine 2.35E-03 - 184 - 4.69E-02 - 1.71 -Shintech – Plaquemine 1.28E-01 - 92.3 - 1.95E-02 - 2.02 -Westlake – Calvert City 1.28E-01 - 92.3 - 7.05E-02 27.6 2.02 -Westlake - Geismar 7.31E-04-4.06E-01 - 2.91E-02-4.02-VC – Vinyl chlorideHCl – Hydrogen chlorideCDD/CDF - Chlorinated dibenzodioxin and chlorinated dibenzofuranTEQ - Toxic EquivalencyHAP – Hazardous air pollutantppmvd – Parts per million on a dry volume basis correctedto 3 percent oxygenng/dscm – Nanograms per dry standard cubic meter corrected to 3 percent oxygen



### 7

# Table 5. Process Vent Emission Reductions as a Result of E missions Limits

Company/Facility Emission Reduction ( Tons per Year )

VC HCl Cl 2 

## CDD/CDF Total Organic HAP
Dow – Midland - - - - - Formosa - Delaware City 1.74E-03 5.04E-01 1.04E

- 03 7.32E-12 1.78E-02

Formosa - Point Comfort 4.80E-02 5.87E+00 2.76E

- 01 1.29E-08 1.32E-01 Formosa - Baton Rouge 1.39E-02 5.84E+00 2.74E

- 01 2.91E-09 1.31E-01 Georgia Gulf - Plaquemine - - - - - Georgia Gulf - Aberdeen 1.14E-02 5.22E-01 2.51E

- 01 1.03E-11 3.82E-02 OxyVinyls – Pasadena 1.29E-02 2.78E+00 9.06E

- 02 3.92E-11 2.21E-01 PolyOne – Henry 1.11E-04 1.58E-05 1.96E

- 05 - 9.09E-01 PolyOne – Pedricktown 2.05E-05 5.93E-06 3.39E

- 04 - 3.54E-01 Shintech – Freeport - - - - - Shintech – Addis - - - - - Shintech - Plaquemine - - - - - Westlake - Calvert City 1.39E-02 5.84E+00 2.74E

- 01 2.91E-09 1.31E-01

Westlake – Geismar - - - - - TOTAL* 1.02E-01 21.37 1.17 1.87E-08 1.93 *Totals may not add exactly due to roundingVC – Vinyl Chloride HCl – Hydrogen chloride Cl 2 

## - Chlorine CDD/CDF – Chlorinated dibenzodioxin and chlorinated dibenzofuran s HAP - Hazardous air pollutant



# 3.0 Stripped Resin

3.1 Selection of Controls Needed to Meet MACT Floor Limit s

Average HAP concentration values used to calculate base line annual emissions 2 

# originating from residual HAP remaining in stripped resin(s) were compared with the MACT floor limits for residual HAP in stripped resin(s) for each applicable subcategory. The percent improvement needed for a facility to meet the limits wa s then calculated. Tables 6 through 9 contain the baseline HAP concentration values used for each facility and the percentage improvement required to meet the residual HAP stripped resin limits.

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# Table 6. Stripped Resin Limits, Baseline Concentrations, and Required Facility Improvements – Dispersion Resin

Company/Facility VC Limit: 1,300 ppmw Total Non-VC Organic HAP Limit: 240 ppmw

Facility Baseline (ppmw) Percent

Improvement Needed Facility

Baseline (ppmw) Percent

Improvement Needed 

## Formosa – Delaware City 534 - 29.0 - PolyOne – Henry 381 - 26.3 - PolyOne – Pedricktown 144 - 64.7 -
VC – Vinyl chloride HAP – Hazardous air pollutant ppmw – parts per million by weight



# Table 7. Stripped Resin Limits, Baseline Concentrations, and Required Facility

Improvements – Suspension Resin

Company VC Limit: 37 ppmw Total Non-VC Organic HAP Limit: 670 ppmw

Facility Baseline (ppmw) Percent

Improvement Needed Facility

Baseline (ppmw) Percent

Improvement Needed

Formosa - Baton Rouge 5.39E-01 - 39.8 -

OxyVinyls - Deer Park 8.64E-01 - 12.1 -

PolyOne - Henry 8.79E-01 - 152 -

Formosa - Point Comfort 1.68 - 19.1 -

Shintech - Plaquemine 3.38 - 68.0 -
Shintech - Freeport 3.64 - 67.8 -

Georgia Gulf - Plaquemine 3.67 - 235 -

OxyVinyls - Pasadena 5.51 - 77.2 -

Shintech - Addis 6.11 - 68.3 -

OxyVinyls - Pedricktown 6.89 - 39.6 -

Westlake - Calvert City 13.6 - 248 -

Georgia Gulf - Aberdeen 18.6 - 226 -

Westlake - Geismar 68.7 46.3 1.09 -
VC – Vinyl chloride HAP – Hazardous air pollutant ppmw – parts per million by weight

9

# Table 8. Stripped Resin Limits, Baseline Concentrations, and Required Facility Improvements – Suspension Blending Resin

Company VC Limit: 140 ppmw Total Non-VC Organic HAP Limit: 500 ppmw

Facility Baseline (ppmw) Percent Improvement

Needed Facility Baseline

(ppmw) Percent Improvement

Needed

PolyOne – Henry 15.7 - 64.2 -
VC – Vinyl chloride HAP – Hazardous air pollutant ppmw – parts per million by weight



# Table 9. Stripped Resin Limits, Baseline Concentrations, and Required Facility

Improvements – Copolymer Resin

Company VC Limit: 790 ppmw Total Non-VC Organic HAP Limit: 1,900 ppmw

Facility Baseline (ppmw) Percent

Improvement Needed Facility

Baseline (ppmw) Percent

Improvement Needed

Dow – Midland 3.67E-01 - 1.86 -

Formosa – Delaware City 361 - 893 -
VC – Vinyl chloride HAP – Hazardous air pollutant ppmw – parts per million by weight



# 3.2 Compliance Cost Methodology and Results

The cost installing a new steam stripper was estimated ba sed on industry provided information. The algorithm for calculating the TCI and TAC is presented in Attachment E and is based on the cost algorithm for wastewater stripper stea m requirements used for the development of the Hazardous Organic National Emission Standards for H azardous Air Pollutants (HON) 4 

# . It was assumed that annual costs for operating the new stri pper would not increase in regards to the facility’s current operation. The annualized cost consis ts only of the annualized capital cost. Source specific cost data are noted in Attachment E.

Table 10 presents a summary of the TCI and TAC for resin s as a result of complying with the MACT floor.

10

# Table 10. Annual Cost of New Steam Stripper

Company/Facility TCI ($) TAC ($/yr)

Dow – Midland

- - Formosa - Baton Rouge

- - Formosa - Delaware City

- - Formosa - Point Comfort

- - Georgia Gulf – Aberdeen

- - Georgia Gulf – Plaquemine

- - OxyVinyls – Pasadena

- - OxyVinyls – Pedricktown

- - PolyOne – Henry

- - PolyOne – Pedricktown

- - Shintech – Addis

- - Shintech – Freeport

- - Shintech – Plaquemine

- - Westlake - Calvert City

- - Westlake – Geismar 10,000,000 943,929

TOTAL* 10,000,000 943,929 $/yr – dollars per year *Totals may not add exactly due to rounding



# 3.3 Testing, Monitoring, and Recordkeeping Costs

Industry wide initial testing costs for stripped resin wer e estimated at approximately $32,000. Industry wide annual testing costs for stripped resin we re estimated at approximately $130,000 per year. An average test cost of $301 was assumed for U S EPA Method 8260B. Since VC is currently analyzed “in-house” using Method 107, no additi onal cost for Method 107 was estimated. The cost algorithm is presented in Attachment F and facility specific costs are summarized in Table 11. Source specific cost data are noted in Attachment F.

Recordkeeping and reporting costs were estimated for strippe d resins. An industry wide initial cost of $42,000 and an industry wide total annual cost of $55,000 were calculated based on the algorithms presented in Attachment D.

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# Table 11. Annual Costs of Stripped Resin Testing, Monitoring, and Recordkeeping

Company/Facility Testing and Monitoring Recordkeeping and Reporting Testing, Monitoring, Recordkeeping and Reporting
Total Initial Cost ($) Total Annual

Cost ($/yr) Total Initial

Cost ($) Total Annual

Cost ($/yr) Total Initial

Cost ($) Total Annual

Cost ($/yr)

Dow - Midland 1,803 7,212 2,799 3,664 4,602 10,876

Formosa - Baton Rouge 1,803 7,212 2,799 3,664 4,602 10,876

Formosa - Delaware City a 3,606 14,424 2,799 3,664 6,405 18,088

Formosa - Point Comfort 1,803 7,212 2,799 3,664 4,602 10,876

Georgia Gulf - Aberdeen 1,803 7,212 2,799 3,664 4,602 10,876

Georgia Gulf - Plaquemine 1,803 7,212 2,799 3,664 4,602 10,876

OxyVinyls - Pasadena 1,803 7,212 2,799 3,664 4,602 10,876

OxyVinyls - Pedricktown 1,803 7,212 2,799 3,664 4,602 10,876

PolyOne – Henry a 5,409 21,636 2,799 3,664 8,208 25,300

PolyOne - Pedricktown 1,803 7,212 2,799 3,664 4,602 10,876

Shintech - Addis 1,803 7,212 2,799 3,664 4,602 10,876

Shintech - Freeport 1,803 7,212 2,799 3,664 4,602 10,876

Shintech - Plaquemine 1,803 7,212 2,799 3,664 4,602 10,876

Westlake - Calvert City 1,803 7,212 2,799 3,664 4,602 10,876

Westlake - Geismar 1,803 7,212 2,799 3,664 4,602 10,876

TOTAL* 32,454 129,816 41,983 54,962 74,437 184,776
$/yr – dollars per year

a Facility is required to test multiple types of re sin. *Totals may not add exactly due to rounding



# 3.4 Emission Reduction Methodology and Results

Annual emissions reductions of VC and total non-VC organic H AP were calculated as a result of meeting the MACT floor limit for residual H AP contained in the stripped resin. VC reductions were estimated at approximately 8 tons per year.

VC and total non-VC organic HAP MACT floor emission rat es were estimated using the procedure described in a separate memorandum 2 

# , except that the baseline concentrations for VC and total non-VC organic HAP were replaced with the MACT floor limit concentration values. Emissions reductions were then calculated by subtracting the MACT floor emission rate from the baseline emission rate. Reductions by facility for VC a nd total non-VC organic HAP are presented in Table 12.

12

# Table 12. Estimated Emission Reductions for Stripped Resin

Company/Facility Emission Reduction (Tons per Year)

VC Total Non

VC Organic HAP
Dow – Midland - - Formosa - Baton Rouge - - Formosa - Delaware City - -
Formosa - Point Comfort - - Georgia Gulf - Aberdeen - - Georgia Gulf - Plaquemine - - OxyVinyls - Pasadena - - OxyVinyls - Pedricktown - - PolyOne – Henry - - PolyOne - Pedricktown - -

Shintech – Addis - - Shintech – Freeport - - Shintech - Plaquemine - - Westlake - Calvert City - -

Westlake – Geismar 8 -

TOTAL 8 - VC – Vinyl chloride HAP – Hazardous air pollutant *Totals may not add exactly due to rounding



# 4.0 Storage Vessels

4.1 Selection of Controls Needed to Meet MACT Floor Limit s, Costs, and Emission Reductions

Current industry work practices, as discussed in previous memoranda 1 

# , constitute the MACT Floor for storage vessels; therefore, costs ass ociated with improvement of emissions from storage, unloading, and transfer were not calculated . No additional emissions reductions from storage vessels would result from facilities com plying with the MACT floor.

4.2 Testing, Monitoring and Recordkeeping Costs

Recordkeeping and reporting costs were estimated for stora ge vessels and are presented in Table 13. An industry wide initial cost of $16,530 and an indust ry wide total annual cost of $23,309 were calculated based on the algorithms presented in At tachment D.

13

# Table 13. Summary of Recordkeeping and Reporting Costs for St orage Vessels

Company/Facility Recordkeeping and Reporting

Total Initial Cost ($) Total

Annual Cost ($/yr)

Dow - Midland 1,102 1,554

Formosa - Baton Rouge 1,102 1,554

Formosa - Delaware City 1,102 1,554

Formosa - Point Comfort 1,102 1,554

Georgia Gulf - Aberdeen 1,102 1,554
Georgia Gulf - Plaquemine 1,102 1,554

OxyVinyls - Pasadena 1,102 1,554

OxyVinyls - Pedricktown 1,102 1,554

PolyOne - Henry 1,102 1,554

PolyOne - Pedricktown 1,102 1,554

Shintech - Addis 1,102 1,554

Shintech - Freeport 1,102 1,554

Shintech - Plaquemine 1,102 1,554

Westlake - Calvert City 1,102 1,554

Westlake - Geismar 1,102 1,554

TOTAL* 16,530 23,309 $/yr – Dollars per year *Totals may not add exactly due to rounding



# 5.0 Heat Exchange Systems

5.1 Selection of Controls Needed to Meet MACT Floor Limit s

The MACT floor for heat exchange systems is comprised o f a leak action level more stringent that 40 CFR Part 61, subpart F, and an equipment leak program. It was assumed that a more stringent testing and monitoring program would eliminat e all baseline emissions.

5.2 Compliance Cost Methodology and Results

It was assumed that no additional control equipment wil l be necessary to meet the MACT floor; therefore, no additional control equipment cost estimation was performed. The cost estimation for additional sampling, monitoring, and repair i s described in Section 5.3.

5.3 Testing, Monitoring, and Recordkeeping Costs

The cost of a more stringent testing, monitoring, and re pair program for heat exchangers using was estimated using the following assumptions; all f acilities would elected to perform sampling and analysis using method 107; therefore not additional cost for sampling and

14

# monitoring was estimated. It was assumed that each cool ing tower would require 1 repair event

per year at $4,300 per event. Detailed cost information on a per facility basis is presented in Table 5-1. Attachment G contains the analysis used to esti mate the costs presented in Table 14. The total annual cost for heat exchange system sampling and analysis, along with repair events was estimated at approximately $99,000 per year. For simplicit y, the cost of additional testing and monitoring as a result of delay or repair was not esti mated.

Table 14. Summary of Testing, Monitoring, Recordkeeping and Rep orting Costs for Heat Exchange Systems

Company/Facility Costs to Repair Number

of Cooling
Towers Repairs Costs to Repair Recordkeeping and

Reporting Total Initial Costs ($/yr) Total

Annual Costs ($/yr)($/eventtower) (event/yr) ($/yr) Total Initial Cost ($) Total

Annual Cost ($/yr)

Dow - Midland 4,300 1 1 4,300 3,103 3,555 3,103 7,8 55

Formosa - Baton Rouge 4,300 1 1 4,300 3,103 3,555 3 ,103 7,855

Formosa - Delaware City 4,300 2 1 8,600 3,103 3,555 3,103 12,155

Formosa - Point Comfort 4,300 1 1 4,300 3,103 3,555 3,103 7,855

Georgia Gulf - Aberdeen 4,300 3 1 12,900 3,103 3,55 5 3,103 16,455

Georgia Gulf - Plaquemine 4,300 4 1 17,200 3,103 3, 555 3,103 20,755

OxyVinyls - Pasadena 4,300 2 1 8,600 3,103 3,555 3, 103 12,155

OxyVinyls - Pedricktown 4,300 1 1 4,300 3,103 3,555 3,103 7,855

PolyOne - Henry 4,300 1 1 4,300 3,103 3,555 3,103 7 ,855

PolyOne - Pedricktown 4,300 2 1 8,600 3,103 3,555 3 ,103 12,155

Shintech - Addis 4,300 1 1 4,300 3,103 3,555 3,103 7,855

Shintech - Freeport 4,300 1 1 4,300 3,103 3,555 3,1 03 7,855

Shintech - Plaquemine 4,300 1 1 4,300 3,103 3,555 3 ,103 7,855

Westlake - Calvert City 4,300 1 1 4,300 3,103 3,555 3,103 7,855

Westlake - Geismar 4,300 1 1 4,300 3,103 3,555 3,10 3 7,855

TOTAL* - 23 - 98,900 46,545 53,325 46,545 152,225
$/yr – Dollars per year $/yr-tower – Dollars per year per cooling tower $/event-tower – Dollars per repair event per coolin g tower event/yr – event per year *Totals may not add exactly due to rounding



# 5.4 Emission Reduction Methodology and Results

Emission reductions from heat exchangers were estimate d by calculating the difference in emissions between the facilities’ reported, or estima ted, cooling water VC concentration and the MACT floor leak action level for facilities complying w ith Method 107. Emission reductions of 101 tons per year of vinyl chloride and total organic HAP were estimated for heat exchangers. Table 15 presents a summary of heat exchange system emiss ion reductions on a facility basis.

15

# Table 15. Estimated Emission Reductions from Heat Exchange S ystems

Company/Facility Emission Reduction (Tons per Year)

VC Total Organic

HAP
Dow - Midland 41.1 41.1 Formosa - Baton Rouge - - Formosa - Delaware City 2.20 2.20
Formosa - Point Comfort 38.8 38.8 Georgia Gulf - Aberdeen - - Georgia Gulf - Plaquemine - - OxyVinyls - Pasadena - - OxyVinyls - Pedricktown 2.01 2.01 PolyOne - Henry 9.54 9.54 PolyOne - Pedricktown 9.18E-01 9.18E-01
Shintech - Addis 1.10E-01 1.10E-01 Shintech - Freeport 8.81E-02 8.81E-02 Shintech - Plaquemine 1.06E-01 1.06E-01 Westlake - Calvert City 5.63 5.63
Westlake - Geismar - -

TOTAL* 101 101 VC – Vinyl chloride *Totals may not add exactly due to rounding



# 6.0 Equipment Leaks

6.1 Selection of Controls Needed to Meet MACT Floor Limit s

The MACT floor level of control for equipment leaks c onsists of 40 CFR part 61 subpart V. All facilities currently comply with subpart V or a more stringent equipment leak detection and repair (LDAR) program; therefore, no additional costs o f complying with a LDAR program were calculated. The cost of each facility installing electronic monitoring to detect releases of pressure relief devices (PRD) was calculated. Further desc riptions of these cost estimations are listed in Section 6.2 and 6.3.

6.2 Compliance Cost Methodology and Results

All facilities currently comply with the MACT floor LDAR program. The cost estimation for pressure relief device monitoring systems is described in Section 6.3, Testing, Monitoring, and Recordkeeping Costs for Equipment Leaks.

6.3 Testing, Monitoring, and Recordkeeping Costs

The TCI and TAC of installing a PRD monitoring system at each facility were
calculated 5 

# . The TCI was estimated at approximately $2.8 million and t he TAC was estimated at approximately $403,000. Source specific cost data are documented i n Attachment H.

16

# Recordkeeping and reporting costs were estimated for equipm ent leaks. An industry wide

initial cost of $34,500 and an industry wide total annual cost of $65,700 were calculated based on the algorithms presented in Attachment D. Table 16 summa rizes the TCI and TAC required for each facility to install and operating a PRD monitori ng in addition to recordkeeping and reporting costs.

Table 16. Summary of Testing and Monitoring Costs for Equipme nt Leaks

Company/Facility Cost of PRV Reduction Monitoring System Recordkeeping and Reporting Total Testing, Monitoring, Recordkeeping and Reporting Costs

TCI ($) TAC

($/yr) Total Initial

Cost ($) Total Annual

Cost ($/yr) Total Initial

Cost ($) TAC ($/yr)

Dow - Midland 188,913 26,897 2,999 4,382 191,212 31 ,279

Formosa - Baton Rouge 188,913 26,897 2,999 4,382 19 1,212 31,279

Formosa - Delaware City 188,913 26,897 2,999 4,382 191,212 31,279

Formosa - Point Comfort 188,913 26,897 2,999 4,382 191,212 31,279

Georgia Gulf - Aberdeen 188,913 26,897 2,999 4,382 191,212 31,279

Georgia Gulf - Plaquemine 188,913 26,897 2,999 4,38 2 191,212 31,279

OxyVinyls - Pasadena 188,913 26,897 2,999 4,382 191 ,212 31,279

OxyVinyls - Pedricktown 188,913 26,897 2,999 4,382 191,212 31,279

PolyOne - Henry 188,913 26,897 2,999 4,382 191,212 31,279

PolyOne - Pedricktown 188,913 26,897 2,999 4,382 19 1,212 31,279

Shintech - Addis 188,913 26,897 2,999 4,382 191,212 31,279

Shintech - Freeport 188,913 26,897 2,999 4,382 191, 212 31,279

Shintech - Plaquemine 188,913 26,897 2,999 4,382 19 1,212 31,279

Westlake - Calvert City 188,913 26,897 2,999 4,382 191,212 31,279

Westlake - Geismar 188,913 26,897 2,999 4,382 191,2 12 31,279

TOTAL* 2,833,695 403,455 34,478 65,730 2,868,173 46 9,185

TCI – Total capital investment TAC – Total annualized cost $/yr – Dollars per year *Totals may not add exactly due to rounding



# 6.4 Emission Reduction Methodology and Results

All facilities currently comply with the MACT floor LDAR program for equipment leaks. Additionally, installation of an electronic PRD monitor ing system is not expected to result in any emission reductions. Therefore, no emission reductions were calculated for facilities meeting the MACT floor for equipment leaks.

7.0 Other Emission Sources

7.1 Selection of Controls Needed to Meet MACT Floor Limit s

17

# The MACT floor level of control for other emission s ources consists of numeric emission

limits for reactor opening losses and component openings a s required by 40 CFR Part 61, subpart
F.

7.2 Testing, Monitoring, and Recordkeeping Costs

All facilities currently meet the numeric emission l imits required by 40 CFR Part 61, subpart F; therefore, no additional compliance or test ing and monitoring costs were calculated.

Recordkeeping and reporting costs were estimated other emis sion sources and are presented in Table 17. An industry wide initial cost of $16,500 a nd an industry wide total annual cost of $23,300 were calculated based on the algorithms presen ted in Attachment D.

Table 17. Summary of Recordkeeping and Reporting Costs for Ot her Emission Sources

Company/Facility Recordkeeping and Reporting

Total Initial Cost ($) Total

Annual Cost ($/yr)

Dow - Midland 1,102 1,554

Formosa - Baton Rouge 1,102 1,554

Formosa - Delaware City 1,102 1,554

Formosa - Point Comfort 1,102 1,554

Georgia Gulf - Aberdeen 1,102 1,554

Georgia Gulf - Plaquemine 1,102 1,554
OxyVinyls - Pasadena 1,102 1,554

OxyVinyls - Pedricktown 1,102 1,554

PolyOne - Henry 1,102 1,554

PolyOne - Pedricktown 1,102 1,554

Shintech - Addis 1,102 1,554

Shintech - Freeport 1,102 1,554

Shintech - Plaquemine 1,102 1,554

Westlake - Calvert City 1,102 1,554

Westlake - Geismar 1,102 1,554

TOTAL* 16,530 23,309 $/yr – Dollars per year *Totals may not add exactly due to rounding

18

# 7.3 Emission Reduction Methodology and Results

The MACT floor for other emissions sources consists o f numeric emission limits for reactor opening losses and component openings, as well as w ork practices to reduce emission from other emission sources. It was assumed that emis sion reductions as a result of the MACT floor would be negligible.

8.0 Wastewater

8.1 Selection of Controls Needed to Meet MACT Floor Limit s

The MACT floor level of control for wastewater cons ists of numeric concentration limits for process wastewater streams before being exposed to th e atmosphere and work practices for controlling emissions from maintenance wastewater.

8.2 Compliance Cost Methodology and Results

All facilities currently meet the numeric concentrat ion limits for process wastewater streams before being exposed to the atmosphere. It was assumed that facilities would not incur additional costs for perform work practices that consti tute the MACT floor for maintenance wastewater. Therefore, no additional control equipment costs were calculated for wastewater.

8.3 Testing, Monitoring, and Recordkeeping Costs

The industry wide wastewater total initial testing cost was estimated at approximately $28,000 per year. As previously stated, an average test cost o f $301 was assumed for US EPA
Method 8260B. It was assumed that the cost of Method 107 was included with the cost of Method 8260B. The cost algorithm and facility specific costs are presented in Attachment I where source specific cost data are also documented. Table 18 presents the wastewater annual testing, monitoring, recordkeeping and reporting costs on a f acility basis.

Table 18. Summary of Testing, Monitoring, Recordkeeping and Rep orting Costs for
Wastewater

Company/Facility Testing and Monitoring Recordkeeping and Reporting Total Testing, Monitoring Recordkeeping and Reporting
Total Initial Cost ($) Total

Annual Cost ($/yr) Total Initial

Cost ($) Total

Annual Cost ($/yr) Total

Initial Cost ($) Total

Annual Cost ($/yr)
Dow - Midland 1,962 7,358 3,125 3,708 5,087 11,066
Formosa - Baton Rouge 981 6,377 3,125 3,708 4,106 10,085
Formosa - Delaware City 1,962 7,358 3,125 3,708 5,087 11,066
Formosa - Point Comfort 1,962 7,358 3,125 3,708 5,087 11,066
Georgia Gulf - Aberdeen 981 6,377 3,125 3,708 4,106 10,085
Georgia Gulf - Plaquemine 1,962 7,358 3,125 3,708 5,087 11,066
OxyVinyls - Pasadena 3,924 9,320 3,125 3,708 7,049 13,028

19

## Company/Facility Testing and Monitoring Recordkeeping and Reporting Total Testing, Monitoring Recordkeeping and Reporting
Total Initial Cost ($) Total

Annual Cost ($/yr) Total Initial

Cost ($) Total

Annual Cost ($/yr) Total

Initial Cost ($) Total

Annual Cost ($/yr) OxyVinyls - Pedricktown 1,962 7,358 3,125 3,708 5,087 11,066
PolyOne - Henry 3,434 8,829 3,125 3,708 6,559 12,537
PolyOne - Pedricktown 1,962 7,358 3,125 3,708 5,087 11,066
Shintech - Addis 1,962 7,358 3,125 3,708 5,087 11,066
Shintech - Freeport 981 6,377 3,125 3,708 4,106 10,085
Shintech - Plaquemine 1,472 6,867 3,125 3,708 4,597 10,575
Westlake - Calvert City 981 6,377 3,125 3,708 4,106 10,085

Westlake - Geismar 1,472 6,867 3,125 3,708 4,597 10,575
TOTAL* 27,959 108,891 46,879 55,614 74,835 164,511 $/yr – Dollars per year *Totals may not add exactly due to rounding



# 8.4 Generation Reduction Methodology and Results

All facilities currently comply with the MACT floor wastewater concentration limits; therefore, no generation reduction was calculated for w astewater.

9.0 Summary and Results for the Industry

9.1 Costs

The total initial cost for all existing PVC production fac ilities to meet the MACT floor emission limits is estimated at approximately $16.5 million . The TAC for controls for all units is about $2.8 million. The total initial costs for testing, m onitoring, recordkeeping and reporting was estimated at approximately $1.1 million and the TAC was estimated at approximately $737,000. Table 19 summarizes the TCI and TAC of the emission limits for each facility. Table 20 summarizes the same costs on an emission point basis . Table 21 summarizes the same costs on an emission point and facility basis.

20

# Table 19. Summary of Control Equipment and Testing and Monitor ing Costs by Facility

Company/Facility MACT Floor Costs

Control Equipment Costs Testing, Monitoring, and Recordkeeping Total Emission Limits Costs

Total Initial Costs ($) TAC

($/yr) Total Initial

Costs ($) TAC

($/yr) Total

Initial Costs ($) TAC

($/yr)

Dow – Midland 188,913 26,897 73,199 52,962 262,112 79,859
Formosa - Baton Rouge 773,063 291,082 72,218 51,981 845,281 343,063

Formosa

- Delaware City 243,508 133,552 75,002 64,474 318,510 198,026

Formosa

- Point Comfort 624,364 224,028 73,199 52,962 697,563 276,990

Georgia Gulf

– Aberdeen 237,363 131,496 72,218 60,581 309,581 192,077

Georgia Gulf

– Plaquemine 188,913 26,897 73,199 65,862 262,112 92,759

OxyVinyls - Pasadena 965,953 382,085 75,161 59,224 1,041,114 441,309 OxyVinyls

– Pedricktown 188,913 26,897 22,001 39,490 210,914 66,387

PolyOne – Henry 248,142 132,556 78,276 68,858 326,418 201,413
PolyOne - Pedricktown 236,411 130,818 73,199 57,262 309,610 188,080
Shintech – Addis 188,913 26,897 73,199 52,962 262,112 79,859
Shintech – Freeport 188,913 26,897 72,218 51,981 261,131 78,878
Shintech - Plaquemine 188,913 26,897 72,708 52,472 261,621 79,369
Westlake - Calvert City 773,063 291,082 72,218 51,981 845,281 343,063
Westlake – Geismar 10,188,913 970,826 72,708 52,472 10,261,621 1,023,298
TOTAL* 15,424,258 2,848,906 1,050,724 835,527 16,474,982 3,684,433

TAC – Total annual cost $ - Dollars $/yr – Dollars per year *Totals may not add exactly due to rounding

21

# Table 20. Summary of Emission Limits Control Equipment and T esting and Monitoring Costs by Emission Point

Emission Point Costs

Control Costs Testing, Monitoring, and Recordkeeping Costs Total Emission Limits Costs

Total Initial Costs ($) TAC

($/yr) Total

Initial Costs ($) TAC

($/yr) Total

Initial Costs ($) TAC

($/yr)

Process Vents 2,590,563 1,501,522 787,359 221,666 3,377,922 1,723,188
Resin 10,000,000 943,929 74,437 184,778 10,074,437 1,128,707
Wastewater - - 74,837 164,505 74,837 164,505
Equipment Leaks 2,833,695 403,455 34,478 65,730 2,868,173 469,185
Storage - 16,530 - 23,309 16,530 23,309 Heat Exchange Systems - - 46,552 152,230 a 

## 46,552 152,230

Other Emission Sources - - 16,530 23,309 16,530 23,309

TOTAL* 15,424,258 2,848,906 1,050,724 835,527 16,474,982 3,684,433

a 

## – Includes cost of leak repair TCI – Total capital investment TAC – Total annual cost $ - Dollars $/yr – Dollars per year *Totals may not add exactly due to rounding

22Table 21. Summary of Control Equipment and Testing and Monitoring Costs by Facility and Emission PointCompanyProcess Vents Resins Storage VesselsHeat ExchangeSystemsEquipment LeaksOther EmissionSourcesWastewaterTotalInitialCosts ($)TAC($/yr)TotalInitialCosts ($)TAC($/yr)TotalInitialCosts ($)TAC($/yr)TotalInitialCosts($)TAC($/yr)TotalInitialCosts($)TAC($/yr)TotalInitialCosts ($)TAC($/yr)TotalInitialCosts($)TAC($/yr)TotalInitialCosts($)TAC($/yr)Dow – Midland 55,904 15,677 4,602 10,876 1,102 1,554 3,103 7,855 191,212 31,279 1,102 1,554 5,087 11,066262,112 79,859Formosa - BatonRouge640,054 279,862 4,602 10,876 1,102 1,554 3,103 7,855 191,212 31,279 1,102 1,554 4,106 10,085845,281 343,063Formosa - PointComfort491,355 212,808 4,602 10,876 1,102 1,554 3,103 7,855 191,212 31,279 1,102 1,554 5,087 11,066697,563 276,990Formosa -Delaware City110,499 122,332 6,405 18,088 1,102 1,554 3,103 12,155 191,212 31,279 1,102 1,554 5,087 11,066318,510 198,026Georgia Gulf –Aberdeen104,354 120,276 4,602 10,876 1,102 1,554 3,103 16,455 191,212 31,279 1,102 1,554 4,106 10,085309,581 192,077Georgia Gulf –Plaquemine55,904 15,677 4,602 10,876 1,102 1,554 3,103 20,755191,212 31,279 1,102 1,554 5,087 11,066262,112 92,759OxyVinyls -Pasadena832,944 370,865 4,602 10,876 1,102 1,554 3,103 12,155 191,212 31,279 1,102 1,554 7,049 13,0281,041,114 441,309OxyVinyls –Pedricktown4,706 2,204 4,602 10,876 1,102 1,554 3,103 7,855 191,212 31,279 1,102 1,554 5,087 11,066210,914 66,387PolyOne –Henry115,133 121,336 8,208 25,300 1,102 1,554 3,103 7,855 191,212 31,279 1,102 1,554 6,559 12,537326,418 201,413PolyOne -Pedricktown103,402 119,598 4,602 10,876 1,102 1,554 3,103 12,155 191,212 31,279 1,102 1,554 5,087 11,066309,610 188,080Shintech –Freeport55,904 15,677 4,602 10,876 1,102 1,554 3,103 7,855191,212 31,279 1,102 1,554 4,106 10,085261,131 78,878Shintech -Plaquemine55,904 15,677 4,602 10,876 1,102 1,554 3,103 7,855191,212 31,279 1,102 1,554 4,597 10,575261,621 79,369Shintech – Addis 55,904 15,677 4,602 10,876 1,102 1,554 3,103 7,855 191,212 31,279 1,102 1,554 5,087 11,066262,112 79,859Westlake -Calvert City640,054 279,862 4,602 10,876 1,102 1,554 3,103 7,855 191,212 31,279 1,102 1,554 4,106 10,085845,281 343,063Westlake –Geismar55,904 15,677 10,004,602 954,805 1,102 1,554 3,1037,855 191,212 31,279 1,102 1,554 4,597 10,57510,261,621 1,023,298TOTAL* 3,377,922 1,723,188 10,074,437 1,128,707 16,530 23,309 46,552 152,230 2,868,173 469,185 16,53023,309 74,837 164,505 16,474,982 3,684,433TAC – Total annual cost$ - Dollars$/yr – Dollars per year*Totals may not add exactly due to rounding



### 23

# 9.2 Costs

Industry wide VC reductions were estimated at 108 tons per y ear, HCl at 21.4 tons per year, CDD/CDF at 1.87E-08 tons per year, and total HAP at 110 tons per year. Tables 22 and 23 summarize the reductions by facility and by emission poin t, respectively.

Table 22. Summary of Industry Emission Reductions by Facility

Company/Facility Emission Reduction (Tons per Year)

VC HCl Cl 2 

## CDD/CDF Total Organic HAP [1]



## Dow – Midland 41.1 -

- - 41.1 Formosa – Baton Rouge 1.39E-02 5.84 2.74E

- 01 2.91E-09 1.31E-01
Formosa – Delaware 2.20 5.04E-01 1.04E

- 03 7.32E-12 2.22
Formosa – Point Comfort 38.9 5.87 2.76E

- 01 1.29E-08 39.0 Georgia Gulf – Aberdeen 1.14E-02 5.22E-01 2.51E

- 01 1.03E-11 3.82E-02 Georgia Gulf – Plaquemine - - - - - OxyVinyls – Pasadena 1.29E-02 2.78 9.06E

- 02 3.92E-11 2.21E-01 OxyVinyls – Pedricktown 2.01 -

- - 2.01 Poly One – Henry 9.54 1.58E-05 1.96E

- 05 - 10.5 Poly One – Pedricktown 9.18E-01 5.93E-06 3.39E

- 04 - 1.27
Shintech – Addis 1.10E-01 -

- - 1.10E-01 Shintech – Freeport 8.81E-02 -

- - 8.81E-02 Shintech – Plaquemine 1.06E-01 -

- - 1.06E-01 Westlake – Calvert City 5.64 5.84 2.74E

- 01 2.91E-09 5.76
Westlake – Geismar 7.58 -

- - 7.58

TOTAL* 108 21.4 1.17 1.87E-08 110 [1] – Total Organic HAP includes VC and CDD/CDF but does n ot include HCl. VC – Vinyl Chloride HCl – Hydrogen chloride Cl 2 

## - Chlorine CDD/CDF – Chlorinated dibenzodioxin and chlorinated dibenzofuran s HAP - Hazardous air pollutant *Totals may not add exactly due to rounding

24

# Table 23. Summary of Industry Emission Reductions by Emission Point

Emission Point Emission Reduction (tons per year)

VC HCl Cl 2 

## CDD/CDF Total Organic HAP [1]



## Process Vents 1.02E-01 21.4 1.17 1.87E-08 1.93
Resin 7.58 -

- - 7.58

Wastewater - -

- - - Equipment Leaks - -

- - - Storage - -

- - - Heat Exchange Systems 101 -

- - 101
Other Emission Sources - -

- - - TOTAL* 108 21.4 1.17 1.87E-08 110 [1] – Total Organic HAP includes VC and CDD/CDF but does n ot include HCl VC – Vinyl Chloride HCl – Hydrogen chloride Cl 2 

## - Chlorine CDD/CDF – Chlorinated dibenzodioxin and chlorinated dibenzofuran s HAP - Hazardous air pollutant *Totals may not add exactly due to rounding

25

# 10.0 References

1. “Revised Maximum Achievable Control Technology (MACT) Flo or Analysis for the Polyvinyl Chloride and Copolymers (PVC) Production Source Category.” Memorandum from Eastern Research Group, Inc. to Jodi Howard, U.S. Environmental Protection Agency. February 2012.

2. “Revised Baseline Emission Estimates for Major Sources in the Polyvinyl Chloride and Copolymers (PVC) Production Source Category.” Memorandum from Eastern Research Group, Inc. to Jodi Howard, U.S. Environmental Protection Agency. February 2012.

3. U.S. Environmental Protection Agency. December 1995. OAQPS Control Cost Manual. Section 3.1: VOC Recapture Controls Chapter 2: Refrigerate d Condensers. Publication Number EPA/452/B-02-001.

4. U.S. Environmental Protection Agency. November 1992. Hazardous Air Pollutant Emissions from Process Units in the Synthetic Organic Chemical Manuf acturing Industry—Background Information for Proposed Standards. Publication Number EPA453/D-92-016c.

5. “Proposed Amended Rule 1173 – Control of Volatile Organic Compo und Leaks and Releases from Components at Petroleum Facilities and Chemical Plants.” South Coast Air Quality Management District. May 15 th 

# , 2007.

26

# Attachments

Attachment A. Refrigerated Condenser Cost Algorithm

Attachment B. Refrigerated Condenser Input Calculations

Attachment C. Process Vent Emissions Testing and Monitorin g Cost Algorithm

Attachment D. Recordkeeping and Reporting Cost Algorithm

Attachment E. Cost Algorithm for Additional Resin Stripp ing

Attachment F. Resin Testing and Monitoring Cost Algorithm

Attachment G. Heat Exchange System Cost Analysis

Attachment H. Equipment Leak Testing and Monitoring Cost Al gorithm

Attachment I. Wastewater Testing and Monitoring Cost Algo rithm

27

# Attachment A

Refrigerated Condenser Cost Algorithm

28ATTACHMENT A: REFRIGERATED CONDENSER COST ALGORITHM02/09/2012Condenser Costing AlgorithmOVPA CTLC SHTFP FPC DE GGA POH POP SHTA FPC BR FPC TX OVLADP GGP SHTP WLG WLCC DOWMI TotalsPVC - Only Area Source PVC - Only PVC - Only PVC - OnlyPVC - Only PVC - Only PVC - OnlyPVC - CombinedPVC - CombinedArea SourcePVC - CombinedPVC - CombinedPVC - CombinedPVC - CombinedPVC - Combined-- Inlet stream flowrate (DSCMM):1.51E+01 5.65E+00 5.47E-01 5.26E-01 1.12E-01 1.13E-01 4.36E-02 9.97E+00 9.08E+00 3.00E+00 2.33E+01 1.42E+00 5.54E+00 2.61E+01 9.08E+00 7.62E-01-- Inlet stream flowrate (scfm): (Qin)=DSCMM/35.31535 200 19 19 4 4 2 352 321 106 823 50 196 921 321 27-- Inlet stream temperature (oC):1.89E+01 6.47E+01 1.56E+01 7.40E-01 1.63E+01 -6.37E+00 -3.63E-01 1.89E+01 1.89E+01 1.89E+01 1.89E+01 1.89E+01 1.89E+01 1.89E+01 1.89E+01 1.89E+01-- Inlet stream temperature (oF): (Tin)=oC*1.8+3266 148 60 33 61 21 31 66 66 66 66 66 66 66 66 66-- VOC to be condensed:Vinyl chloride Vinyl chloride Vinyl chloride Vinyl chloride Vinyl chloride IsoOctance IsoOctance Vinyl chloride Vinyl chloride Vinyl chloride Vinyl chloride Vinyl chloride Vinyl chloride Vinyl chloride Vinyl chloride Vinyl chloride-- VOC inlet volume fraction:(Yvoc,in)=ppm/1E60.18791389 0.095862393 0.000283667 0.633376328 0.484980983 9.72E-03 2.52E-02 1.56667E-07 0.012787174 0.043914959 0.0192627 0.518207166 0.012787174 0.125832627 0.012787174 0.00045057-- Required VOC removal (fraction): (n)0.78 0.00 0.00 0.36 0.50 0.995 0.998 0.00 0.28 0.84 0.00 0.00 0.00 0.00 0.28 0.00-- Antoine equation constants for VOC: [4]A:6.497 6.497 6.497 6.497 6.497 6.812 6.812 6.497 6.497 6.497 6.497 6.497 6.497 6.497 6.497 6.497B:783.400 783.400 783.400 783.400 783.400 1257.840 1257.840783.400 783.400 783.400 783.400 783.400 783.400 783.400 783.400 783.400C:230.010 230.010 230.010 230.010 230.010 220.735 220.735 230.010 230.010 230.010 230.010 230.010 230.010 230.010 230.010 230.010-- VOC heat of condensation (BTU/lb-mole): (****Hvoc,r)10080 10080 10080 10080 13260 13260 10080 10080 10080 10080 10080 10080 10080 10080 10080 10080-- VOC heat capacity (BTU/lb-mole-oF): (Cp,voc)11.655 11.655 11.655 11.655 11.655 45.080 45.080 11.655 11.655 11.655 11.655 11.655 11.655 11.655 11.655 11.655-- Coolant specific heat (BTU/lb-oF): Cp,cool0.650 0.650 0.650 0.650 0.650 0.650 0.650 0.650 0.650 0.650 0.650 0.650 0.650 0.650 0.650 0.650-- VOC boiling point (oF): (Tboil)7 7 7 7 7 211 211 7 7 7 7 7 7 7 7 7-- VOC critical temperature (oR): (Tc)773 773 773 773 773 979 979 773 773 773 773 773 773 773 773 773-- VOC molecular weight (lb/lb-mole): (MWvoc)63 63 63 63 63 114 114 63 63 63 63 63 63 63 63 63-- VOC condensate density (lb/gal):8.15 8.15 8.15 8.15 8.15 5.77 5.77 8.15 8.15 8.15 8.15 8.15 8.15 8.15 8.15 8.15-- Air heat capacity (BTU/lb-mole-oF): (Cp,air)6.95 6.95 6.95 6.95 6.95 6.95 6.95 6.95 6.95 6.95 6.95 6.95 6.95 6.95 6.95 6.95DESIGN PARAMETERS:-- Outlet VOC partial pressure (mm Hg): (Pvoc)=760*(Yvoc,in*(1-n)/(1-Yvoc,in*n))36.3 72.9 0.2 399.9 242.5 0.0 0.0 0.0 7.1 5.7 14.6 393.8 9.7 95.6 7.1 0.3-- Condensation temperature, Tc (oF): (Tcon)=(B/(A-log10(Pvoc))-C)*1.8+32-96.4 -77.8 -185.2 -20.0 -39.1 -89.6 -90.1 -246.7 -132.4 -136.4 -117.5 -20.6 -126.1 -69.8 -132.4 -179.5(oR): =Tcon+460363.6 382.2 274.8 440.0 420.9 370.4 369.9 213.3 327.6 323.6 342.5 439.4 333.9 390.2 327.6 280.5-- VOC flowrate in (lb-moles/hr): (Mvoc,in)=Qin*Yvoc,in*60/39215.39 2.93 0.00 1.80 0.29 0.01 0.01 0.00 0.63 0.71 2.43 3.97 0.38 17.73 0.63 0.00-- VOC flowrate out (lb-moles/hr): (Mvoc,out)=Mvoc,in*(1-n)3.336 2.930 0.001 1.157 0.146 0.000 0.000 0.000 0.454 0.117 2.426 3.973 0.383 17.733 0.454 0.002-- VOC condensed (lb-moles/hr): (Mvoc,con)=Mvoc,in-Mvoc,out12.051 0.000 0.000 0.643 0.148 0.006 0.006 0.000 0.173 0.5960.000 0.000 0.000 0.000 0.173 0.000(lb/hr): (Lb/hrvoc,con)=Mwvoc*Mvoc,con753.2 0.0 0.0 40.2 9.2 0.7 0.7 0.0 10.8 37.2 0.0 0.0 0.0 0.0 10.80.0-- VOC heat of condensation @ Tc (BTU/lb-mole): (****Hvoc)=(****Hvoc,r)*[(1-Tcon/Tc)/(1-Tboil/Tc)]^0.3811251 11054 12122 10403 13978 17175 13060 12670 11617 11657 11468 10410 11554 10968 11617 12069-- Enthalpy change, condensed VOC (BTU/hr): (****Hcon)=Mvoc,con[****Hvoc+Cp,voc(Tin-Tcon)158405 0 0 7088 2235 130 110 0 2414 8352 0 0 0 0 2414 0-- Enthalpy change, uncondensed VOC (BTU/hr):(****Huncon)=Mvoc,out*Cp,voc*(Tin-Tcon)6316 7722 2 719 171 0 0 0 1050 277 5191 4011 858 28071 1050 5-- Enthalpy change, air (BTU/hr): (****Hnoncon)=Cp,air*(Tin-Tcon)*(Qin*60/392-Mvoc,in)75064 43432 5035 386 218 462 194 117088 66789 21843 157588 2224 39500 116285 66789 7021-- Condenser heat load (BTU/hr): (Hload)=****Hcon+****huncon+****Hnoncon239785 51154 5038 8193 2623 592 304 117088 70253 30471 1627786235 40358 144356 70253 7027-- Heat transfer coefficient, U (BTU/hr-ft2-oF):Estimate from OAQPS Manual20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20-- Log-mean temperature difference (oF): Tlm=(Tin-Tcon-25)/ln((Tin-Tcon-10)/15)59.3 75.4 80.0 26.7 42.0 44.9 48.1 95.8 68.5 69.5 64.8 37.8 66.9 52.1 68.5 80.1-- Condenser surface area (ft2): (Acon)=Hload/U*Tlm202.3 33.9 3.1 15.3 3.1 0.7 0.3 61.1 51.3 21.9 125.7 8.3 30.1 138.5 51.3 4.4-- Coolant flowrate (lb/hr):=Hload/(Cp,cool*(Tcon-15+25)-(Tcon-15))14756 3148 310 504 161 36 19 7205 4323 1875 10017 384 2484 8883 4323 432-- Refrigeration capacity (tons): (R)=Hload/120019.98 4.26 0.42 0.68 0.22 0.05 0.03 9.76 5.85 2.54 13.56 0.52 3.36 12.03 5.85 0.59-- Electricity requirement (kW/ton) [6]: (kW)=-9E-06(Tcon)^3 - 0.0004(Tcon)2 - 0.0331(Tcon) + 3.560 11.10 0.00 0.00 4.13 4.78 9.79 9.87 0.00 21.81 23.48 0.00 0.00 0.00 0.00 21.81 0.00CAPITAL COSTSEquipment Costs ($):-- Refrigeration unit/single-stage (< 10 tons): (Rss<10)=exp(9.83-0.014Tcon+0.340lnR)0 90,367 184,842 21,595 19,165 23,428 18,788 1,274,956 216,206 172,245 0 19,851 163,969 0 216,206 191,161-- Refrigeration unit/single-stage (> 10 tons): (Rss>10)=exp(9.26-0.007Tcon+0.627lnR)134,937 0 0 0 0 0 0 0 0 0 122,715 0 0 81,487 0 0-- Multistage refrigeration unit: (Mru)exp(9.73-0.012Tcon+0.584lnR)307,36399,69793,445-11,0658,5035,7901,227,936231,064148,928315,89514,691155,007166,085231,064106,012Total equipment cost ($)--base: (ECp)=1.25*MAX(Rss<10,Rss>10,Mru)384,204 124,622 231,052 26,994 23,956 29,285 23,485 1,593,694 288,830 215,307 394,869 24,813 204,961 207,606 288,830238,951Cost Indexa. 2010 CE Equip (Feb Final)CE Equipment index (Feb 2010 Final)641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1 641.1b. 1990 CE Equip (Oct Final)CE Equipment index (Oct 1990 Final)394 394 394 394 394 394 394 394 394 394 394 394 394 394 394 394' ' ' ' --escalated: (ECpe)=(ECp)*(FebFinal/OctFinal)625,636 202,934 376,245 43,957 39,010 47,688 38,243 2,595,168 470,330 350,605 643,004 40,406 333,758 338,066 470,330389,107Purchased Equipment Cost ($): (PECp)=ECpe*1.08675,687 219,169 406,344 47,474 42,130 51,503 41,303 2,802,781 507,957 378,653 694,444 43,639 360,459 365,111 507,957420,235Total Capital Investment ($): (TCI)=PECp*1.15777,040 0 0 54,595 48,450 59,229 47,498 0 584,150 435,451 0 0 00 584,150 02,590,563ANNUAL COST INPUTS:Operating factor (hr/yr): (OF)8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400 8400Operating labor rate ($/hr): (LR)34.60 34.60 34.60 34.60 34.60 34.60 34.60 34.60 34.60 34.60 34.60 34.60 34.60 34.60 34.60 34.60Maintenance labor rate ($/hr): (MR)38.06 38.06 38.06 38.06 38.06 38.06 38.06 38.06 38.06 38.06 38.06 38.06 38.06 38.06 38.06 38.06Operating labor factor (hr/sh): (OLF)1/2 hour per 8 hour shift0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50Maintenance labor factor (hr/sh): (MLF)1/2 hour per 8 hour shift0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50Electricity price ($/kWhr): (EP)0.0700 0.0700 0.0700 0.0700 0.0700 0.0700 0.0700 0.0700 0.0700 0.0700 0.0700 0.0700 0.0700 0.0700 0.0700 0.0700Recovered VOC value ($/lb)[5]: (Rvoc)0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00Annual interest rate (fraction): (Int)0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07Control system life (years): (EL)20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20Capital recovery factor: (CRF)=Int*(1+Int)^EL/((1+Int)^EL-1)0.0944 0.0944 0.0944 0.0944 0.0944 0.0944 0.0944 0.0944 0.0944 0.0944 0.0944 0.0944 0.0944 0.0944 0.0944 0.0944Taxes, insurance, admin. factor: (TaxF)0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04ANNUAL COSTS:ItemCost ($/yr) Cost ($/yr) Cost ($/yr) Cost ($/yr) Cost ($/yr) Cost ($/yr) Cost ($/yr) Cost ($/yr) Cost($/yr) Cost ($/yr) Cost ($/yr) Cost ($/yr) Cost ($/yr) Cost ($/yr) Cost ($/yr) Cost ($/yr)Operating labor=OF/8*OLF*LR18,165 18,165 18,165 18,165 18,165 18,165 18,165 18,165 18,165 18,165 18,165 18,165 18,165 18,165 18,165 18,165Supervisory labor=.15*Operating Labor2,725 2,725 2,725 2,725 2,725 2,725 2,725 2,725 2,725 2,725 2,725 2,725 2,725 2,725 2,725 2,725Maintenance labor=OF/8*MLF*MR19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982Maintenance materials100% of maintenance labor19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982 19,982Electricity=EP*OF*kW*R/0.85153,395 0 0 1,953 723 334 173 0 88,315 41,245 0 0 0 0 88,315 0Overhead=.60*(Operating Labor+Supervisory Labor+Maint Labor+Maint Materials) 36,512 36,512 36,512 36,512 36,512 36,512 36,512 36,512 36,512 36,512 36,512 36,512 36,512 36,512 36,512 36,512Taxes, insurance, administrative=TaxF*TCI31,082 0 0 2,184 1,938 2,369 1,900 0 23,366 17,418 0 0 0 0 23,3660Capital recovery=CRF*TCI73,347 0 0 5,153 4,573 5,591 4,483 0 55,140 41,104 0 0 0 0 55,1400Total Annual Cost (without credits) (TACwoc)=sum of all annual costs355,188 0 0 106,655 104,599 105,659 103,921 0 264,185 197,131 0 0 0 0 264,185 01,501,522Recovery credits (RC)=-Rvoc*OF*Lb/hrvoc,con0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0Total Annual Cost (with credits)=TACwoc+RC355,188 0 0 106,655 104,599 105,659 103,921 0 264,185 197,131 0 0 0 0 264,185 01,501,522NOTES:----------1. Base equipment costs reflect Third Quart 19902. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2008 National Industry-Specific Occupational Employment andWage Estimates3. Electricity cost: Energy Information Administration. Average Industrial Retail Price of Electricity: October 2009.4. Antoine constants listed in OAQPS Manual5. ICIS, http://www.icis.com/v2/chemicals/9076567/vinyl-chloride/pricing.html, October 20, 2010. (Avg. $690/tonne = $0.313/lb)6. Polynomial of best fit based on Table 2.5 OAQPSControl Cost Manual Section 3.1 Chapter 2.INPUT PARAMETERS:Equation



### 29

# Attachment B

Refrigerated Condenser Input Calculations

30ATTACHMENT B: REFRIGERATED CONDENSER COST ALGORITHM02/09/2012PolyOne Isooctane Reduction Requirements for Condenser Cost AlgorithmHAPHAPHAP_Cat_Name(All)Inlet_OutletOutletControl Device(All)Colocated with with EDC/VCM (0=No,1=Yes) (All)Compounds via Multiple Test Methods (0= Multiple ResultsExcluded) 0Test Representative of Normal Op. Conditions (Yes=1, 0=No) (All)Test Included Streams Other Than PVC (0=No, 1=Yes) (All)Test Included Streams Other Than PVC/VCM/EDC (0=No, 1=Yes) (All)Exclude Previous Test Data (1=data excluded) 1DataStd FacilityCompound_StdAverage of MW Sum of Avg_Conc_ERG_UnitsTotal of Non-Iso Octane Compounds TOH Limit Maximum ISO Conc (ppmvd @ 3%O2) % Redux of ISO Req.POHEthyl Chloride 6.45E+01 8.09E-014.19E+00 56 5.18E+01 99.47Isooctane 1.14E+02 9.72E+03Methyl Chloride 5.05E+01 1.21E+00Vinyl Chloride 6.25E+01 2.18E+00POPEthyl Chloride 6.45E+01 1.19E+00 6.49E+00564.95E+0199.80Isooctane 1.14E+02 2.52E+04Methyl Chloride 5.05E+01 2.64E+00Vinyl Chloride 6.25E+01 2.66E+00



### 31

# Attachment C

Process Vent Emissions Testing and Monitoring Cost Algorithm

32ATTACHMENT C: PROCESS VENT EMISSIONS TESTING AND MONITORING COST ALGORITHM02/09/2012Process Vent Emissions Testing Cost AlgorithmProcess Vents Emission Testing CostsParameters/CostsEquation Values Testing Freq.* Annual Cost of TestAnnualized Cost of Initial TestTAC of TestingA. Parameters1. CE Plant Cost indexa. 2010 (Feb 10 Final CE Index)539.1b. 2009 (Annual CE Index)521.9c. 1992 (Annual CE Index)358.2B. Testing Costs, $1. Method 1 or 1A Included as part of M 23 -$5 -$ -$ -$2. Method 26 (HCl) = $5,000 x (539.1/358.2) $8,000755$ 755$3. Method 23 (CDD/CDF) = $21,000 x (539.1/358.2) - $5,000 $27,0005 5,400$ 2,549$ 7,949$4. Method 25A (THC) =$6,000x(539.1/521.9) $6,1985 1,240$ 585$ 1,825$5. Method 18 (Assumed cost equal to 0031)$10,0005 2,000$ 944$ 2,944$C. CRF (20 yr, 7%): (0.07*(1+0.07)^20)/((1+0.07)^20-1)0.09439D. Facility Totals1. HCl, TOH, &VC2. CDD/CDF3. Facility Total$ 51,197.748,640$* Number of Years Between Tests. Note testing frequency is reduced to once every five years after three consecutive years of compliance demonstration.Note:4. Conversation with Ray Merrill, ERG - 11/5/2010.5. Email from Peter Westlin, EPA 4/8/2011 to ERG: Method 18 Costs1. Initial testing costs to be annualized over 20 years at 7% interest.2. Testing costs have been rounded to the nearest$1,000 to be consistent with level of rounding inoriginal costs; costs alsoadjusted based on additional information from EPA.Sources:1. Memorandum from R. Segall, EPA/EMB, to R. Copland, EPA/SDB. October 14, 1992. Medical Waste Incinerator Study:Emission Measurement and Continuous Monitoring. (II-B-89)2. E-mail from Jason Dewees, EPA, to Peter Westlin, EPA. August 20, 2008. Monitoring Options for SNCR & Test Cost Questions.3. E-mail from Jason Dewees, EPA, to Mary Johnson,EPA. August 20, 2008. Re: Monitoring Options forSNCR & Test CostQuestions.



### 33

# Attachment D

Recordkeeping and Reporting Cost Algorithm

34ATTACHMENT D: RECORDKEEPING AND REPORTING COST ALGO RITHM

02/09/12

(A) (B) (C) (D) (E) (F) (G) (H) Respondent Non-Labor Number of Hours Number of Technical Management Clerical Total Total Total Hours per Costs Occurrences Per Respondents Hours Hours Ho urs Labor Costs Non-Labor Responses Occurrence Per Per Respondent Per Year Per Year Per Year P er Year Per Year Costs Per Year (Technical Occurrence Respondent Per Year Per Year
Burden Item hours) Per Year (C=A x C (D x E) (F x 0.05) (F x 0.1)

1. Applications N/A
2. Surveys and Studies N/A

3. Reporting Requirements

A. Read and Understand Rule Requirements 25 $100 1 25 15 375 19 38 $40,790 $1,500 0 a,b,c

B. Required Activities

1) Initial performance test, sampling, and report

a) Process Vents 32 $51,198 1 32 14 448 22 45 $48,731 $716,768 0 a,d

b) Resins 2 $1,803 1 2 18 36 2 4 $3,916 $32,454 0 a,e

c) wastewater 2 $491 1 2 57 114 6 11 $12,400 $27,987 0 a,f

d) heat exchangers

- $0 0 0 23 0 0 0 $0 $0 0 g

e) equipment leaks 2 $77,798 1 2 13 26 1 3 $2,828 $1,011,368 0 h

2) Periodic performance test, sampling, and report

a) Process Vents 32 $48,030 1 32 0 0 0 0 $0 $0 0 i

b) Resins 1 $601 11 11 18 198 10 20 $21,537 $118,998 0 e

c) wastewater 1 $491 11 11 15 165 8 17 $17,948 $80,933 0 f

d) uncontrolled wastewater 1 $491 1 1 0 0 0 0 $0 $0 0 f

e) heat exchangers 1 $0 12 12 23 276 14 28 $30,022 $0 0 g

f) equipment leaks 1 $18,205 1 1 13 13 1 1 $1,414 $236,666 0 h

3) Establish operating parameters and monitoring pl an

a) Process Vents 3.5 $0 1 3.5 14 49 2 5 $5,330 $0 0 a,b,c

4) Continuous parameter monitoring

a) Initial capital costs (PRD Electronic Monitor) 0 $188,913 1 0 15 0 0 0 $0 $2,833,695 0 a,b

b) Annualized capital and O&M costs (PRD Electronic Monitor) 11 $26,897 1 11 15 165 8 17 $17,948 $403,455 0 b

C. Create Information Incl. in 3.B

D. Gather Information Incl. in 3.E

E. Report Preparation

1) Initial Notification 5 $0 1 5 15 75 4 8 $8,158 $0 15 a,b

2) Batch precompliance report 5 $0 1 5 15 75 4 8 $8,158 $0 15 a,b

3) Notification of performance test with test plan 10 $0 1 10 15 150 8 15 $16,316 $0 15 a,b

4) Notification of compliance status 20 $0 1 20 15 300 15 30 $32,632 $0 15 a,b

5) Compliance report 25 $0 1 25 0 0 0 0 $0 $0 0 b,k

6) Notice of inspection 5 $0 1 5 15 75 4 8 $8,158 $0 15 b,k

7) Affirmative defense 18 $0 1 18 0 18 12 0 $0 $0 0 j

ReportingSubtotal 2,540 127 254 $276,285 $2,630,128 75 l

4. Recordkeeping Requirements

A. Read Instructions Incl. in 3.A

B. Implement Activities N/A
C. Develop Record System N/A

D. Record Information

1) Records of process vent requirements 10 $0 1 10 0 0 0 0 $0 $0 0 b,k

2) Records of resin stripper requirements 15 $0 1 15 0 0 0 0 $0 $0 0 b,k

3) Records wastewater requirements 15 $0 1 15 0 0 0 0 $0 $0 0 b,k

4) Records of storage vessel requirements 10 $0 1 10 0 0 0 0 $0 $0 0 b,k

5) Records of equipment leak requirements 25 $0 1 25 0 0 0 0 $0 $0 0 b,k

6) Records of heat exchanger requirements 10 $0 1 10 0 0 0 0 $0 $0 0 b,k

7) Records of other emission sources requirements 10 $0 1 10 0 0 0 0 $0 $0 0 b,k

E. Personnel Training Incl. in 3.B

F. Time for Audits N/A

Recordkeeping Subtotal 0 0 0 $0 $0 0

TOTAL: 2,540 127 254 $276,285 $2,630,128 75

Total Hours Labor Non-Labor Total

Summary of Respondent Burden 2,921 $276,285 $2,630,128 $2,906,413

Initial Capital and Startup $2,835,195

$2,630,128

FOOTNOTES

a One-time only costs.

b Cost incurred by a facility regardless of the numb er of affected units at the plant.

c 15 major sources in affected source category

d 14 major sources are expected to perform testing f or process vents. OxyVinyls Pasadena does not oper ate a process vent control, but rather sends proces s vent gas streams to PolyOne Pedricktown for contr ol.

e 18 respondents equivalent to 19 unique combination s of facilities and resin types.

f An estimated 42 uncontrolled streams and 15 wastew ater stripper outlets (across 15 facilities) are ex pected to require initial wastewater testing. 15 wa stewater stripper outlets are expected to require m onthly testing. 42 uncontrolled streams will requi re annual testing

g All heat exchnager testing and monitoring costs as sumed to be incurred annually. 23 cooling towers a t 15 facilities.

h

i process vent testing is required initially and onc e every five years, therefore no additional costs a re expected in additional to the initial testing re quirement.

j Hours for affirmative defense are shown only for i llustration and are not included in the total burde n estimate

k Annual cost. Annual costs are not incurred until the second year of operation. l Reporting subtotal does not include capital costs for PRD monitoring system. Annualized Capital/Start-up and O & M for Existing Major Sources: Polyvinyl Chloride and Copolymer Manufacturing Units - Year 1 Table 1 - Annual Respondent Burden and Cost of Reco rdkeeping and Reporting Requirements of the MACT Fl oorFootnotes

13 facilities are expected to be required to increa se stringency of their LDAR programs to 40 CFR Part 63, Subpart UU. Non-Labor costs technically inclu de labor to perform LDAR testing in addition to mon itoring equipment and maintenance materials. Respo ndent hours are an estimation of the additional reporting required by the final rule.



### 35ATTACHMENT D: RECORDKEEPING AND REPORTING COST ALGO RITHM

02/09/12

(A) (B) (C) (D) (E) (F) (G) (H) Respondent Non-Labor Number of Hours Number of Technical Management Clerical Total Total Total Hours per Costs Occurrences Per Respondents Hours Hours Ho urs Labor Costs Non-Labor Responses Occurrence Per Per Respondent Per Year Per Year Per Year P er Year Per Year Costs Per Year (Technical Occurrence Respondent Per Year Per Year
Burden Item hours) Per Year (C=A x C (D x E) (F x 0.05) (F x 0.1)

1. Applications N/A
2. Surveys and Studies N/A

3. Reporting Requirements

A. Read and Understand Rule Requirements 25 $100 1 25 0 0 0 0 $0 $0 0 a,b,c

B. Required Activities

1) Initial performance test, sampling, and report

a) Process Vents 32 $51,198 1 32 0 0 0 0 $0 $0 0 a,d

b) Resins 2 $1,803 1 2 0 0 0 0 $0 $0 0 a,e

c) wastewater 2 $491 1 2 0 0 0 0 $0 $0 0 a,f

d) heat exchangers

- $0 0 0 0 0 0 0 $0 $0 0 g

e) equipment leaks 2 $77,798 1 2 0 0 0 0 $0 $0 0 h

2) Periodic performance test, sampling, and report

a) Process Vents 32 $48,030 1 32 3 90 4 9 $9,746 $134,484 0 i

b) Resins 1 $601 12 12 18 216 11 22 $23,495 $129,816 0 e

c) wastewater 1 $491 12 12 15 180 9 18 $19,579 $88,290 0 f

d) uncontrolled wastewater 1 $491 1 1 42 42 2 4 $4,568 $20,601 0 f

e) heat exchangers 1 $0 12 12 23 276 14 28 $30,022 $0 0 g

f) equipment leaks 1 $18,205 1 1 13 13 1 1 $1,414 $236,666 0 h

3) Establish operating parameters and monitoring pl an

a) Process Vents 3.5 $0 1 3.5 0 0 0 0 $0 $0 0 a,b,c

4) Continuous parameter monitoring

a) Initial capital costs (PRD Electronic Monitor) 0 $188,913 1 0 0 0 0 0 $0 $0 0 a,b

b) Annualized capital and O&M costs (PRD Electronic Monitor) 11 $26,897 1 11 15 165 8 17 $17,948 $403,455 0 b

C. Create Information Incl. in 3.B

D. Gather Information Incl. in 3.E

E. Report Preparation

1) Initial Notification 5 $0 1 5 0 0 0 0 $0 $0 0 a,b

2) Batch precompliance report 5 $0 1 5 0 0 0 0 $0 $0 0 a,b

3) Notification of performance test with test plan 10 $0 1 10 0 0 0 0 $0 $0 0 a,b

4) Notification of compliance status 20 $0 1 20 0 0 0 0 $0 $0 0 a,b

5) Compliance report 25 $0 1 25 15 375 19 38 $40,790 $0 15 b,k

6) Notice of inspection 5 $0 1 5 15 75 4 8 $8,158 $0 15 b,k

7) Affirmative defense 18 $0 1 18 0 18 12 0 $0 $0 0 j

ReportingSubtotal 1,432 72 143 $155,720 $1,013,312 30 l

4. Recordkeeping Requirements

A. Read Instructions Incl. in 3.A

B. Implement Activities N/A
C. Develop Record System N/A

D. Record Information

1) Records of process vent requirements 10 $0 1 10 15 150 8 15 $16,316 $0 0 b,k

2) Records of resin stripper requirements 15 $0 1 15 15 225 11 23 $24,474 $0 0 b,k

3) Records wastewater requirements 15 $0 1 15 15 225 11 23 $24,474 $0 0 b,k

4) Records of storage vessel requirements 10 $0 1 10 15 150 8 15 $16,316 $0 0 b,k

5) Records of equipment leak requirements 25 $0 1 25 15 375 19 38 $40,790 $0 0 b,k

6) Records of heat exchanger requirements 10 $0 1 10 15 150 8 15 $16,316 $0 0 b,k

7) Records of other emission sources requirements 10 $0 1 10 15 150 8 15 $16,316 $0 0 b,k

E. Personnel Training Incl. in 3.B

F. Time for Audits N/A

Recordkeeping Subtotal 1425 71.25 142.5 $155,003 $0 0

TOTAL: 2,857 143 286 $310,723 $1,013,312 30

Total Hours Labor Non-Labor Total

Summary of Respondent Burden 3,285 $310,723 $1,013,312 $1,324,035

Initial Capital and Startup $0

$1,013,312

FOOTNOTES

a One-time only costs.

b Cost incurred by a facility regardless of the numb er of affected units at the plant.

c 15 major sources in affected source category

d 14 major sources are expected to perform testing f or process vents. OxyVinyls Pasadena does not oper ate a process vent control, but rather sends proces s vent gas streams to PolyOne Pedricktown for contr ol.

e 18 respondents equivalent to 19 unique combination s of facilities and resin types.

f An estimated 42 uncontrolled streams and 15 wastew ater stripper outlets (across 15 facilities) are ex pected to require initial wastewater testing. 15 wa stewater stripper outlets are expected to require m onthly testing. 42 uncontrolled streams will requi re annual testing

g All heat exchnager testing and monitoring costs as sumed to be incurred annually. 23 cooling towers a t 15 facilities.

h

i process vent testing is required initially and onc e every five years, therefore no additional costs a re expected in additional to the initial testing re quirement.

j Hours for affirmative defense are shown only for i llustration and are not included in the total burde n estimate

k Annual cost. Annual costs are not incurred until the second year of operation. l Reporting subtotal does not include capital costs for PRD monitoring system. Table 2 - Annual Respondent Burden and Cost of Reco rdkeeping and Reporting Requirements of the MACT Fl oor

for Existing Major Sources: Polyvinyl Chloride and Copolymer Manufacturing Units - Year 2Footnotes

Annualized Capital/Start-up and O & M

13 facilities are expected to be required to increa se stringency of their LDAR programs to 40 CFR Part 63, Subpart UU. Non-Labor costs technically inclu de labor to perform LDAR testing in addition to mon itoring equipment and maintenance materials. Respo ndent hours are an estimation of the additional reporting required by the final rule.



### 36ATTACHMENT D: RECORDKEEPING AND REPORTING COST ALGO RITHM

02/09/12

(A) (B) (C) (D) (E) (F) (G) (H) Respondent Non-Labor Number of Hours Number of Technical Management Clerical Total Total Total Hours per Costs Occurrences Per Respondents Hours Hours Ho urs Labor Costs Non-Labor Responses Occurrence Per Per Respondent Per Year Per Year Per Year P er Year Per Year Costs Per Year (Technical Occurrence Respondent Per Year Per Year
Burden Item hours) Per Year (C=A x C (D x E) (F x 0.05) (F x 0.1)

1. Applications N/A
2. Surveys and Studies N/A

3. Reporting Requirements

A. Read and Understand Rule Requirements 25 $100 1 25 0 0 0 0 $0 $0 0 a,b,c

B. Required Activities

1) Initial performance test, sampling, and report

a) Process Vents 32 $51,198 1 32 0 0 0 0 $0 $0 0 a,d

b) Resins 2 $1,803 1 2 0 0 0 0 $0 $0 0 a,e

c) wastewater 2 $491 1 2 0 0 0 0 $0 $0 0 a,f

d) heat exchangers

- $0 0 0 0 0 0 0 $0 $0 0 g

e) equipment leaks 2 $77,798 1 2 0 0 0 0 $0 $0 0 h

2) Periodic performance test, sampling, and report

a) Process Vents 32 $48,030 1 32 3 90 4 9 $9,746 $134,484 0 i

b) Resins 1 $601 12 12 18 216 11 22 $23,495 $129,816 0 e

c) wastewater 1 $491 12 12 15 180 9 18 $19,579 $88,290 0 f

d) uncontrolled wastewater 1 $491 1 1 42 42 2 4 $4,568 $20,601 0 f

e) heat exchangers 1 $0 12 12 23 276 14 28 $30,022 $0 0 g

f) equipment leaks 1 $18,205 1 1 13 13 1 1 $1,414 $236,666 0 h

3) Establish operating parameters and monitoring pl an

a) Process Vents 3.5 $0 1 3.5 0 0 0 0 $0 $0 0 a,b,c

4) Continuous parameter monitoring

a) Initial capital costs (PRD Electronic Monitor) 0 $188,913 1 0 0 0 0 0 $0 $0 0 a,b

b) Annualized capital and O&M costs (PRD Electronic Monitor) 11 $26,897 1 11 15 165 8 17 $17,948 $403,455 0 b

C. Create Information Incl. in 3.B

D. Gather Information Incl. in 3.E

E. Report Preparation

1) Initial Notification 5 $0 1 5 0 0 0 0 $0 $0 0 a,b

2) Batch precompliance report 5 $0 1 5 0 0 0 0 $0 $0 0 a,b

3) Notification of performance test with test plan 10 $0 1 10 0 0 0 0 $0 $0 0 a,b

4) Notification of compliance status 20 $0 1 20 0 0 0 0 $0 $0 0 a,b

5) Compliance report 25 $0 1 25 15 375 19 38 $40,790 $0 15 b,k

6) Notice of inspection 5 $0 1 5 15 75 4 8 $8,158 $0 15 b,k

7) Affirmative defense 18 $0 1 18 0 18 12 0 $0 $0 0 j

ReportingSubtotal 1,432 72 143 $155,720 $1,013,312 30 l

4. Recordkeeping Requirements

A. Read Instructions Incl. in 3.A

B. Implement Activities N/A
C. Develop Record System N/A

D. Record Information

1) Records of process vent requirements 10 $0 1 10 15 150 8 15 $16,316 $0 0 b,k

2) Records of resin stripper requirements 15 $0 1 15 15 225 11 23 $24,474 $0 0 b,k

3) Records wastewater requirements 15 $0 1 15 15 225 11 23 $24,474 $0 0 b,k

4) Records of storage vessel requirements 10 $0 1 10 15 150 8 15 $16,316 $0 0 b,k

5) Records of equipment leak requirements 25 $0 1 25 15 375 19 38 $40,790 $0 0 b,k

6) Records of heat exchanger requirements 10 $0 1 10 15 150 8 15 $16,316 $0 0 b,k

7) Records of other emission sources requirements 10 $0 1 10 15 150 8 15 $16,316 $0 0 b,k

E. Personnel Training Incl. in 3.B

F. Time for Audits N/A

Recordkeeping Subtotal 1425 71.25 142.5 $155,003 $0 0

TOTAL: 2,857 143 286 $310,723 $1,013,312 30

Total Hours Labor Non-Labor Total

Summary of Respondent Burden 3,285 $310,723 $1,013,312 $1,324,035

Initial Capital and Startup $0

$1,013,312

FOOTNOTES

a One-time only costs.

b Cost incurred by a facility regardless of the numb er of affected units at the plant.

c 15 major sources in affected source category

d 14 major sources are expected to perform testing f or process vents. OxyVinyls Pasadena does not oper ate a process vent control, but rather sends proces s vent gas streams to PolyOne Pedricktown for contr ol.

e 18 respondents equivalent to 19 unique combination s of facilities and resin types.

f An estimated 42 uncontrolled streams and 15 wastew ater stripper outlets (across 15 facilities) are ex pected to require initial wastewater testing. 15 wa stewater stripper outlets are expected to require m onthly testing. 42 uncontrolled streams will requi re annual testing

g All heat exchnager testing and monitoring costs as sumed to be incurred annually. 23 cooling towers a t 15 facilities.

h

i process vent testing is required initially and onc e every five years, therefore no additional costs a re expected in additional to the initial testing re quirement.

j Hours for affirmative defense are shown only for i llustration and are not included in the total burde n estimate

k Annual cost. Annual costs are not incurred until the second year of operation. l Reporting subtotal does not include capital costs for PRD monitoring system. Table 3 - Annual Respondent Burden and Cost of Reco rdkeeping and Reporting Requirements of the MACT Fl oor

for Existing Major Sources: Polyvinyl Chloride and Copolymer Manufacturing Units - Year 3Footnotes

Annualized Capital/Start-up and O & M

13 facilities are expected to be required to increa se stringency of their LDAR programs to 40 CFR Part 63, Subpart UU. Non-Labor costs technically inclu de labor to perform LDAR testing in addition to mon itoring equipment and maintenance materials. Respo ndent hours are an estimation of the additional reporting required by the final rule.



### 37ATTACHMENT D: RECORDKEEPING AND REPORTING COST ALGORITHM02/09/12YearTechnical HoursManagementHours Clerical Hours Total Hours Labor CostsNon-Labor(AnnualizedCapital/Startup andO&M) Costs Total Costs1 2,540 127 254 2,921 $276,285 $2,630,128 $2,906,4132 2,857 143 286 3,285 $310,723 $1,013,312 $1,324,0353 2,857 143 286 3,285 $310,723 $1,013,312 $1,324,035Total 8,253 413 825 9,491 $897,731 $4,656,752 $5,554,483Average 2,751 138 275 3,164 $299,244 $1,552,251 $1,851,494Table 4 - Summary of Annual Respondent Burden and Cost of Recordkeeping and Reporting Requirements ofthe MACT Floor for Existing Sources: Polyvinyl Chloride and Copolymer Manufacturing Units



### 38

# Attachment E

Cost Algorithm for Additional Resin Stripping

39ATTACHMENT E. COST ALGORITHM FOR ADDITIONAL RESIN STRIPPING02/09/2012Steam Stripper - PVC Resin - Cost Analysis - VC andTOHCompanyWestlakeChemicalCorporationFacilityWestlakeGeismarProcess TypeSuspensionProcess Type StdSuspensionProcess Unit IDP-1Stripped Resin Stream IDS-1Stripping TypeContinuousInlet Stream Flow, liters/min1930A. Parameters(Inputs and ExampleCalculation)1. Stripper inlet flow rate,pm (Q)50019302. Annual operating hours, hr/yr (H)840084003. Steam to Feed Ratio, kg /(S)0.0960.060assume same from WW stripper4. Electricity use, kWhr/day (EU)2602605. Operating labor rate, $/hr (LR) [2]$34.60$34.606. Electricity cost, $/kWh (EC) [3]$0.07$0.077. Water cost, $/1,000 gal (WC) [4]$0.20$0.208. Steam cost, $/1,000 lb (SC) [4]$4.65$4.659. Capital recovery factor= [i x (1 + i)a] / [(1 + i)a- 1], where i = interest rate, a = equipment lifea. Equipment CRF, 20-yr life, 7%interest0.094390.0943910. Cost indexa. 2010641.1641.1b. 1989356.0356.011. VCM Concentration, ppm [C]68.6512. VCM limit, ppm [L]20.036.8413. VCM recovery percentage, % [RP]99.046.314. VOC recovery value, $/lb [RV] [5]$0.313$0.000B. Total Capital Investment1. $= 0.3731 x Q^0.267 x 10^6$0$10,000,000estimated total capital provided by facility2. $ /pm= $ / Q$0$5,182C. Direct Annual Operating Costs, $/yr1. Electricity = EU / (24 hr/day) x H x EC$6,079$02. Steam = Q x S x (2.2 lb/kg) x (60 min/hr) x H x SC / 1000$247,484$03. Water = Q x (5220 liters water-min / liters feed-day) x (1 day / 24 hr) x H x (0.264 gal/liter) xWC / 1000$0$04. Operating labor = (1 hr/shift) x (1 shift/8 hr) x Hx LR$36,330$05. Supervisory labor = 0.15 x (operating labor)$5,450$06. Maintenance labor = (0.5 hr/shift) x (1 shift/8 hr)x H x (LR x 1.1)$19,982$07. Maintenance materials = 0.02 x TCI$0$0D. Indirect Annual Costs, $/yr1. Overhead = 0.6 x (labor + maintenance materials)$37,057$02. Property taxes, insurance, andadministration= 0.04 x TCI$0$03. Capital recovery = Equipment CRF x TCI$0$943,929E. Recovery Credit, $/yra. Recovered vinyl chloride, kg/yr [VCR] = C x 10^-6 x Qx (1 kg/) x (60 min/hr) x H x RP0.0030944.10b. Value of recovered vinyl chloride, $/yr = VCR x (2.2 lb/kg) x RV$0$0F. Include in Annual Cost?YesF. Total Annual Cost1. $/yr= Direct Annual Costs + Indirect Annual Costs - Recovery Credit$352,381$943,9292. ($/yr) /pm= ($/yr) / Q$705$489Sources:1. Cost equations: HON BID, Vol 1-b and 1-c, Nov 1992(EPA-453/D-92-016c)2. Operating labor rate: Bureau of Labor Statistics,Occupational Employment Statistics, May 2008 National Industry-Specific Occupational Employment and Wage Estimates3. Electricity cost: Energy Information Administration.Average Industrial Retail Price of Electricity: October 2009.4. Water cost and steam cost: Air Compliance Advisor,version 7.5.5. ICIS, http://www.icis.com/v2/chemicals/9076567/vinyl-chloride/pricing.html, October 20, 2010. (Avg. $690/tonne = $0.313/lb)Parameters/CostsEquation



### 40

# Attachment F

Resin Testing and Monitoring Cost Algorithm

41

## ATTACHMENT F: RESIN TESTING AND MONITORING COST ALG ORITHM

02/09/2012

Resin Sampling and Monitoring

Low High Average Cost of US EPA Method 8260B [1] $201 $400 $301

Initial Compliance

3 outlet tests x 2 strippers 2 $1,803.00

Total Compliance Cost $1,803.00

Monitoring

1 tests per month for each type of resin x 2 strippers 2 $601.00

Company Location Initial Compliance
Costs Annualized Initial

Compliance
Costs TAC of Resin

Testing TAC of Resin Testing

Certain Teed - Lake Charles Bulk $1,803.00 $0.00 $7,212.00 $7,212.00 PolyOne - Pedricktown Dispersion $1,803.00 $0.00 $7,212.00 $7,212.00 PolyOne - Henry Dispersion $1,803.00 $0.00 $7,212.00 $7,212.00 Formosa - Delaware City Dispersion $1,803.00 $0.00 $7,212.00 $7,212.00 Formosa - Baton Rouge Suspension $1,803.00 $0.00 $7,212.00 $7,212.00 OxyVinyls - Deer Park Suspension $1,803.00 $0.00 $7,212.00 $7,212.00 PolyOne - Henry Suspension $1,803.00 $0.00 $7,212.00 $7,212.00 Formosa - Point Comfort Suspension $1,803.00 $0.00 $7,212.00 $7,212.00 Shintech - Plaquemine Suspension $1,803.00 $0.00 $7,212.00 $7,212.00 Shintech - Freeport Suspension $1,803.00 $0.00 $7,212.00 $7,212.00 Georgia Gulf - Plaquemine Suspension $1,803.00 $0.00 $7,212.00 $7,212.00 OxyVinyls - Pasadena Suspension $1,803.00 $0.00 $7,212.00 $7,212.00 Shintech - Addis Suspension $1,803.00 $0.00 $7,212.00 $7,212.00 OxyVinyls - Pedricktown Suspension $1,803.00 $0.00 $7,212.00 $7,212.00 Westlake - Calvert City Suspension $1,803.00 $0.00 $7,212.00 $7,212.00 Georgia Gulf - Aberdeen Suspension $1,803.00 $0.00 $7,212.00 $7,212.00 Westlake - Geismar Suspension $1,803.00 $0.00 $7,212.00 $7,212.00 Dow - Midland Copolymer (VDCO-S) $1,803.00 $0.00 $7,212 .00 $7,212.00 Formosa - Delaware City Copolymer (VACO-D) $1,803.00 $0 .00 $7,212.00 $7,212.00 PolyOne - Henry Suspension Blending $1,803.00 $0.00 $7,21 2.00 $7,212.00

2. Average number of strippers calculated from facility su bmitted survey data 1. National Environmental Methods Index Website



### 42

# Attachment G

Heat Exchange System Cost Analysis

43	
	

Heat Exchange Systems - Summary of Clarification Data Submitted to EPACalculated Emissions, Reductions, and CostsOVP Conc (ppbw) 5.93% of LAL 12%Avg LAL (ppbw) 1363 Based on M107 onlyAvg Conc (ppbw) 162LAL (ppbw) 50Cost per Repair ($/tower/yr)4300DOR LAL (ppbw) 800DOR Period (days) 120Repairs per yr 1REPORTEDEMISSIONSFROMVC Conc LALBASELINEEMISSIONSEMISSIONREDUCTIONSREPAIR COSTSCompany Facility CT # Flow Rate (gpm) Pollutant Measured Leak Action Level Units Monitoring Frequency Monitoring Method Note(s) VC (tpy) (ppbw) (ppbw) VC (tpy) VC (tpy) ($/yr)1 10,000 Vinyl chlorideWeekly Water sampling - GC headspace162 1363 3.54E+00 2.45E+00 4,3002 5,000 Vinyl chlorideWeekly Water sampling - GC headspace162 1363 1.77E+00 1.22E+00 4,300Vinyl chloride 10000 ppbw Quarterly Method 415.11186 10000 4.29E+01 4.11E+01 4,300Formosa Baton Rouge 1 48,000 Vinyl chloride 10 ppbw Daily Method 6011 10 1.25E-01 0.00E+00 4,3001 6,000[no data]162 1363 2.13E+00 1.47E+00 4,3002 3,000[no data]162 1363 1.06E+00 7.34E-01 4,300Formosa Point Comfort158700162 1363 5.62E+01 3.88E+01 4,3001 13,500 Vinyl chloride 250 ppbw Quarterly Method 10730 250 8.78E-01 0.00E+00 4,3002 18,000 Vinyl chloride 250 ppbw Quarterly Method 10730 250 1.17E+00 0.00E+00 4,3003 18,000 Vinyl chloride 250 ppbw Quarterly Method 10730 250 1.17E+00 0.00E+00 4,3001 40,000[cw pressure > process pressure]4,3002 22,300[cw pressure > process pressure]4,3003 1,181[no heat exchangers]4,3004 11,000[utility system]4,300Vinyl chloride 5000 ppbw Monthly Method 107593 5000 1.09E+01 1.00E+01 4,300Vinyl chloride 5000 ppbw Monthly Method 107593 5000 1.56E+00 1.43E+00 4,300Vinyl chloride 50 ppbw Monthly Method 1079.40E-026 50 9.40E-02 0.00E+00 4,300Vinyl chloride 50 ppbw Monthly Method 1071.81E-016 50 1.81E-01 0.00E+00 4,300OxyVinyls Pasadena1 9,000211,600OxyVinyls Deer Park1 8,4002 1,200Formosa Delaware CityGeorgia Gulf AberdeenGeorgia Gulf PlaquemineCertainTeed Lake CharlesDow Midland 1 16,500OxyVinyls Pedricktown 1 13,333 Vinyl chloride 1000 ppbv Continuous Similar to M106 and M21 [continuous monitoring of air above cooling tower]119 1000 3.47E+00 2.01E+00 4,300PolyOne Henry39000162 1363 1.38E+01 9.54E+00 4,3001 1,900162 1363 6.73E-01 4.65E-01 4,3002 1,850162 1363 6.55E-01 4.53E-01 4,300Shintech Addis449162 1363 1.59E-01 1.10E-01 4,300Shintech Freeport360162 1363 1.28E-01 8.81E-02 4,300Shintech Plaquemine433162 1363 1.53E-01 1.06E-01 4,300Westlake Calvert City 1 23,000[no data]162 1363 8.15E+00 5.63E+00 4,300Westlake Geismar 1 10,653 Vinyl chloride 50 ppbw Yearly Method 1076 50 1.39E-01 0.00E+00 4,300151.1 115.6 116,100PolyOne Pedricktown211,600



### 44	
	

Calculated Emissions, Reductions, and CostsTotal Capital CostTtal Annual CostControl EquipT&M$ $/yr VCM HCl D/F TOH VCM HCl D/F TOHControl Testing and Control Control Testing and Testing andTotal CapitalTotal Baseline - Baseline - Baseline - Baseline - Reduction - Reduction - Reduction - Reduction -Certain Teed - Lake Charles Area Source Bulk8,600 5.31E+005.31E+00 3.67E+003.67E+00PolyOne - Henry PVC - Only Suspension, Dispersion, Suspension Blending4,300 1.38E+011.38E+01 9.54E+009.54E+00PolyOne - Pedricktown PVC - Only Dispersion8,600 1.33E+001.33E+00 9.18E-019.18E-01Formosa - Delaware City PVC - Only Dispersion, Copolymer (VACO-D)8,600 3.19E+003.19E+00 2.20E+002.20E+00Dow - Midland PVC - Combined Copolymer (VDCO-S)4,300 4.29E+014.29E+01 4.11E+014.11E+01Formosa - Baton Rouge PVC - Combined Suspension4,300 1.25E-011.25E-01 0.00E+000.00E+00Formosa - Point Comfort PVC - Combined Suspension4,300 5.62E+015.62E+01 3.88E+013.88E+01Georgia Gulf - Aberdeen PVC - Only Suspension12,900 3.22E+003.22E+00 0.00E+000.00E+00Georgia Gulf - Plaquemine PVC - Combined Suspension17,200 0.00E+000.00E+00 0.00E+000.00E+00OxyVinyls - Deer Park PVC - Combined Suspension8,600 1.25E+011.25E+01 1.14E+011.14E+01OxyVinyls - Pasadena PVC - Only Suspension8,600 2.75E-012.75E-01 0.00E+000.00E+00OxyVinyls - Pedricktown PVC - Only Suspension4,300 3.47E+003.47E+00 2.01E+002.01E+00Shintech - Addis PVC - Only Suspension4,300 1.59E-011.59E-01 1.10E-011.10E-01Shintech - Freeport PVC - Only Suspension4,300 1.28E-011.28E-01 8.81E-028.81E-02Shintech - Plaquemine PVC - Combined Suspension4,300 1.53E-011.53E-01 1.06E-011.06E-01Westlake - Calvert City PVC - Combined Suspension4,300 8.15E+008.15E+00 5.63E+005.63E+00Westlake - Geismar PVC - Combined Suspension4,300 1.39E-011.39E-01 0.00E+000.00E+00Control Equip T&MMACT Floor CostsBaseline Emissions and MACT Floor Emissions ReductionsMACT Floor Capital Cost ($)MACT Floor - Annual Costs ($/yr)Baseline Emissions (TPY)MACT Floor Emissions Reductions (TPY)



### 45

# Attachment H

Equipment Leak Testing and Monitoring Cost Algorithm

46ATTTACHMENT H: EQUIPMENT LEAK TESTING AND MONITORING COST ALGORITHM02/09/2012Equipment Leaks - MACT Floor Cost AnalysisCost Summary for PRD Monitoring SystemsCapital CostsAnnual CostsMajor Sources188,91326,897Cost Summary for Equipment LeaksCompanyLDAR Program[1](A) PRV MonitoringSystem Capital Cost ($)(B) AnnualizeCapital Cost of PRVMonitoring System($)BaselineEmission[2](Tons/yr)Part 61AllowableEmissions(Tons/yr)EstimatedEmissionReductions(Tons/yr)Formosa - Baton Rouge40CFR61 V 188,913.0026,897.0014.6414.64Formosa - Delaware City40CFR63 UU 188,913.0026,897.008.1014.64Formosa - Point Comfort40CFR61 V 188,913.0026,897.0014.6414.64Georgia Gulf - Aberdeen40CFR61 V 188,913.0026,897.0014.6414.64Georgia Gulf - Plaquemine40CFR63 UU 188,913.0026,897.008.1014.64OxyVinyls - Pasadena40CFR61 V 188,913.0026,897.0014.6414.64OxyVinyls - Pedricktown40CFR61 V 188,913.0026,897.0014.6414.64PolyOne - Henry40CFR61 V 188,913.0026,897.0014.6414.64PolyOne - Pedricktown40CFR61 V 188,913.0026,897.0014.6414.64Shintech - Addis40CFR61 V 188,913.0026,897.0014.6414.64Shintech - Freeport40CFR61 V 188,913.0026,897.0014.6414.64Shintech - Plaquemine40CFR61 V 188,913.0026,897.0014.6414.64Dow - Midland40CFR61 V 188,913.0026,897.0014.6414.64Westlake - Calvert City40CFR61 V 188,913.0026,897.0014.6414.64Westlake - Geismar40CFR61 V 188,913.0026,897.0014.6414.64Totals2,833,695.00403,455.00207220-[1] - LDAR program type reported by facility in August 12, 2009 information collection request.[2] - VOC assumed to equal total HAP.Source TypePRD Monitoring Costs[1][1] - From South Coast Air Quality Management District "Proposed AmendedRule 1173 - Control of Volatile Organic Compound Leaks and Releases fromComponents at Petroleum Facilities and Chemical Plants". May 15, 2007Includes device parts, installation, maintenance, and data retrieval system.



### 47

# Attachment I

Wastewater Testing and Monitoring Cost Algorithm

48ATTACHMENT I: WASTEWATER TESTING AND MONITORING COST ALGORITHM02/09/2012Wastewater Sampling and MonitoringCost of US EPA Method 8260B$201 $400 $301 *National Environmental Methods Index Website https://www.nemi.gov/apex/f?p=237:38:951365369293524::::P38_METHOD_ID:7041Cost of US EPA Method 305$190 http://analyticallaboratories.com/page.cfm?pageid=90 (Cost of Volatile Organics)Cost of US EPA Method 107$0 Assume no cost since facilities are presumably already testing VC (Based on VI submitted data).Number of Initial Test Runs1.00Number of Strippers1.00Number of Continuous Test Runs1.00Number of Continuous Tests per Year Monthly Testing12.00Number of Uncontrolled Streams (Asreported in survey data)Number of Uncontrolled Streamswith average for missing dataNon-VC HAP MeOH VC VCTotal Non-VC HAPMeOH VCTotal Non-VC HAPMeOHCertain Teed - Lake Charles1 1 $300.50 $190.00 $0.00 $0.00 $300.50 $190.00 $0.00 $3,606.00 $2,280.00 $981.00 $6,376.50PolyOne - Henry6 6 $1,803.00 $1,140.00 $0.00 $0.00 $300.50 $190.00 $0.00 $3,606.00 $2,280.00 $3,433.50 $8,829.00PolyOne - Pedricktown3 $901.50 $570.00 $0.00 $0.00 $300.50 $190.00 $0.00 $3,606.00 $2,280.00 $1,962.00 $7,357.50Formosa - Delaware City3 $901.50 $570.00 $0.00 $0.00 $300.50 $190.00 $0.00 $3,606.00 $2,280.00 $1,962.00 $7,357.50Dow - Midland3 $901.50 $570.00 $0.00 $0.00 $300.50 $190.00 $0.00 $3,606.00 $2,280.00 $1,962.00 $7,357.50Formosa - Baton Rouge1 1 $300.50 $190.00 $0.00 $0.00 $300.50 $190.00 $0.00 $3,606.00 $2,280.00 $981.00 $6,376.50Formosa - Point Comfort3 $901.50 $570.00 $0.00 $0.00 $300.50 $190.00 $0.00 $3,606.00 $2,280.00 $1,962.00 $7,357.50Georgia Gulf - Aberdeen1 1 $300.50 $190.00 $0.00 $0.00 $300.50 $190.00 $0.00 $3,606.00 $2,280.00 $981.00 $6,376.50Georgia Gulf - Plaquemine3 $901.50 $570.00 $0.00 $0.00 $300.50 $190.00 $0.00 $3,606.00 $2,280.00 $1,962.00 $7,357.50OxyVinyls - Deer Park1 1 $300.50 $190.00 $0.00 $0.00 $300.50 $190.00 $0.00 $3,606.00 $2,280.00 $981.00 $6,376.50OxyVinyls - Pasadena7 7 $2,103.50 $1,330.00 $0.00 $0.00 $300.50 $190.00 $0.00 $3,606.00 $2,280.00 $3,924.00 $9,319.50OxyVinyls - Pedricktown3 $901.50 $570.00 $0.00 $0.00 $300.50 $190.00 $0.00 $3,606.00 $2,280.00 $1,962.00 $7,357.50Shintech - Addis3 3 $901.50 $570.00 $0.00 $0.00 $300.50 $190.00 $0.00 $3,606.00 $2,280.00 $1,962.00 $7,357.50Shintech - Freeport1 1 $300.50 $190.00 $0.00 $0.00 $300.50 $190.00 $0.00 $3,606.00 $2,280.00 $981.00 $6,376.50Shintech - Plaquemine2 2 $601.00 $380.00 $0.00 $0.00 $300.50 $190.00 $0.00 $3,606.00 $2,280.00 $1,471.50 $6,867.00Westlake - Calvert City1 1 $300.50 $190.00 $0.00 $0.00 $300.50 $190.00 $0.00 $3,606.00 $2,280.00 $981.00 $6,376.50Westlake - Geismar2 2 $601.00 $380.00 $0.00 $0.00 $300.50 $190.00 $0.00 $3,606.00 $2,280.00 $1,471.50 $6,867.00Average3Totals $27,958.50 $108,891.00Count of Wastewater StreamID_STDFacilityName TotalFormosa Plastics Corporation Baton Rouge1Georgia Gulf Chemicals Aberdeen Facility1Lake Charles Polymer Plant1OxyVinyls Deer Park1OxyVinyls Pasadena7PolyOne Henry6Shintech Addis3Shintech Freeport1Shintech Plaquemine2Union Carbide Texas City6Westlake Calvert City1Westlake Geismar2Grand Total32Total Initial Cost($)AnnualTesting CostInitial ContinuousInitial Uncontrolled Stream TestingStripper Outlet Testing



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