1

Date: November 22, 2010

Subject: Summary of Cost Data Received from Section 114 ICR

Nitric Acid NSPS Review

EPA Contract No. EP-D-06-118; Work Assignment No. 4-3 

RTI Project No. 0210426.004.003

From: Melissa Icenhour

To: Bill Neuffer

OAQPS/SPPD/MMG (D243-02)

U. S. Environmental Protection Agency

Research Triangle Park, NC 27711

I. Introduction

The EPA is required by section 111(b)(1)(B) of the Clean Air Act (CAA) to review and, if 

appropriate, revise existing New Source Performance Standards (NSPS) at least every 8 years.

The nitric acid NSPS (part 60, subpart G) has been reviewed in the past but the last review was 

more than 8 years ago. As a result of this, EPA has received a citizen suit from Sierra Club and 

Environmental Integrity Project prompting a review of the standards.

The purpose of an NSPS review is to determine if the standards reflect the “degree of emissions 

limitation achievable through application of the best system of emission reduction which (taking 

into account the cost of achieving such reduction and any nonair quality health and 

environmental impact and energy requirements) the Administrator determines has been 

adequately demonstrated.”

EPA issued an Information Collection Request (ICR) under Section 114 authority to obtain NOX

emissions data using EPA Methods 7, 7A, 7B, 7C, 7D, 7E (modified version), or 320. The ICR 

also collected cost data for NOX CEMS and NOX abatement technologies, including nonselective 

catalytic reduction (NSCR), selective catalytic reduction (SCR), and H2O2 injection. Cost data 

were received from 9 facilities with a total of 12 nitric acid production trains.

The facilities reported information on capital costs and annual operation and maintenance 

(O&M) costs. The annualized costs were estimated by multiplying the capital recovery factor 

(CRF) by the capital costs and summing with the annual O&M costs. The capital recovery factor 

for NOX CEMS (0.1424) was calculated based on an interest rate of 7% and an equipment life of 

10 years. The capital recovery factor for NSCR, SCR, and hydrogen peroxide injection (0.1098), 
2

the capital recovery factor was calculated based on an interest rate of 7% and an equipment life 

of 15 years.

The supplied cost data were not based on the same year. As the value of money varies with 

inflation, all annualized data were scaled to the second quarter of 2010 using the Marshall and 

Swift Index as shown in Table 1.

The year on which the costs were based varied from 1973 to 2010 but was not supplied in most 

cases. For capital costs, the year was not given for 38 of the 53 data points; for operation and 

maintenance costs, the year was not given for 37 of the 53 data points. For the data points 

without specific years, we assumed that the capital costs were based on the year the equipment 

was installed and that operation and maintenance costs were based on first quarter 2010 (when 

the questionnaires were delivered). Using these assumptions, annualized costs were scaled to the 

second quarter of 2010.

The annualized cost data for monitoring and control devices are presented for the following: 

costs as reported in ICR responses (Section II); total facility costs (Section III); and costs 

normalized to production (Section IV) by plant size. The data are summarized in Section V.

II. Cost Data as Reported in the ICR

The respondents provided costs in various ways. Some data were divided into categories such as 

testing, maintenance, or calibration; other data were provided as a total number, with no 

explanation of the categories included. The following sections summarize the cost data as 

reported by the respondents. The data are broken out by NOX CEMS, NSCR, SCR, and 

hydrogen peroxide (H2O2) injection. 

a. NOX CEMS

As shown in Table 2, cost for CEMS testing ranges from $7,700 to $31,000 per 

facility. As shown in Table 3, cost for CEMS calibration ranges from $3,000 to 

$24,000 per facility. As shown in Table 4, cost for CEMS maintenance and parts 

varies from $1,600 to $61,000 per year. As shown in Table 5, CEMS equipment 

costs range from $5,400 to $72,000 per year.

All respondents were contacted for additional information on how the estimates 

were determined and the type of information included in their estimates. No 

additional information was received related to NOX CEMS.

The data are analyzed on a facility basis in Section III to determine whether the 

total cost of testing, calibration, maintenance, parts, and equipment have less 

variation.
3

b. NSCR

As shown in Table 6, NSCR equipment costs range from $50,000 to $1.4 million

per year. As shown in Table 7, gas costs for operating the NSCR range from 

$246,000 to $1.3 million per year. As shown in Table 8, NSCR catalyst costs 

range from $68,000 to $207,000 per year. As shown in Table 9, NSCR 

maintenance costs range from $23,000 to $115,000 per year. 

Variations in costs are likely due to several differences among reporting facilities. 

For example, annualized fuel costs are affected by the type of fuel reported, 

market conditions, and differences in plant sizes. In the case of equipment costs, 

not all plants reported annual O&M costs and not all plants reported capital costs. 

Due to the CRF, a plant reporting capital costs greater than other plants would 

have less of an impact on the annualized costs than a plant reporting O&M costs 

greater than other plants.

The data are analyzed on a facility basis in Section III to determine whether the 

total cost of testing, calibration, maintenance, parts, and equipment have less 

variation.

c. SCR

As shown in Table 10, SCR equipment costs range from $148,000 to $586,000 

per year. As shown in Table 11, SCR catalyst costs range from $55,000 to 

$120,000 per year. As shown in Table 12, SCR maintenance costs range from 

$19,000 to $28,000 per year. As shown in Table 13, ammonia costs range from 

$25,000 to $413,000 per year. 

The differences are explained by the fact that not all facilities with an SCR 

reported each of the costs shown above as a separate entry. Also, variations can 

be explained by plant size, the amount of ammonia required, and possibly the age 

of the equipment.

The data are analyzed on a facility basis in Section III to determine whether the 

total cost of equipment, ammonia costs, catalysts, and maintenance have less 

variation.

d. Hydrogen Peroxide Injection

As shown in Table 14, hydrogen peroxide injection costs between $216,000 and 

$323,000 per year.
4

III. Total Facility Costs by Production Train

As shown in the previous section, information was not reported consistently by facilities 

responding to the ICR. For example, the ICR asked for the capital cost of equipment and 

annual O&M costs. Some of the facilities divided their costs into subcategories such as 

calibration, testing, gas costs, and maintenance. To possibly correct the variation in costs 

among facilities, costs for each train and technology combination were combined into a 

total facility capital cost and a total O&M cost and then annualized. The results are 

shown in Table 15.

a. NOX CEMS

The annualized costs for NOX CEMS from 8 trains vary from $5,400 to $182,000 

per year and average $58,000 per year. All respondents were contacted for 

additional information on how the estimates were determined and the type of 

information included in their estimates. No additional information was received 

related to NOX CEMS.

b. NSCR

The annualized costs for NSCR from 6 trains vary from $266,000 to $1.6 million 

per year and average $1.2 million per year. All respondents were contacted for 

additional information on how the estimates were determined and the type of 

information included in their estimates. However, the lowest cost is from the 

smallest plant surveyed. The other annualized costs have less variation, ranging 

from $1.1 million to $1.6 million.

c. SCR

The annualized costs for SCR from 5 trains are relatively consistent and vary 

from $304,000 to $601,000 per year and average $434,000 per year.

d. Hydrogen Peroxide Injection

The hydrogen peroxide injection costs from 2 trains vary from $216,000 to 

$323,000 per year and average $270,000 per year.
5

IV. Cost Data Normalized by Production

As shown in the previous two sections, there can be considerable variation in costs. To account 

for the effect of plant size on costs, costs were normalized using annual nitric acid production. 

The plants were grouped by those that produce less than 500 tons per day of nitric acid (tpd) and 

those that produce greater than 501 tons per day of nitric acid.

a. Plants producing less than 500 tpd

Five facilities (6 production trains) producing less than 500 tons per day (tpd) of 

nitric acid reported cost information.

The data are shown in Table 16. 

i. NOX CEMS

The normalized costs per ton of nitric acid for NOX CEMS from 4

facilities vary from $0.37 to $1.73 and average $1.03.

ii. NSCR

The normalized costs per ton of nitric acid for NSCR from 4 facilities vary 

from $12.84 to $29.75 and average $20.02.

iii. SCR

The normalized costs per ton of nitric acid for SCR per ton of nitric acid 

from one facility are $3.93.

iv. Hydrogen Peroxide Injection

Normalized costs of hydrogen peroxide injection per ton of nitric acid 

from one facility are $2.06.
6

b. Plants producing greater than 501 tpd

Four facilities (6 production trains) with nitric acid production greater than 501

tpd reported cost information.

The data are shown in Table 17.

i. NOX CEMS

The normalized costs per ton of nitric acid for NOX CEMS from 4

facilities vary from $0.07 to $0.26 and average $0.13. 

ii. NSCR

The normalized costs per ton of nitric acid for NSCR per ton of nitric acid 

from one facility are $7.80.

iii. SCR

The normalized costs per ton of nitric acid for SCR from 3 facilities vary 

from $1.03 to $1.39 and average $1.10. 

iv. Hydrogen Peroxide Injection

Normalized costs of hydrogen peroxide injection from one facility are

$1.39.

c. Data from Alternative Control Techniques Document—Nitric Acid and 

Adipic Acid Manufacturing Plants (ACT) published in 1991

Table 18 shows the costs for SCR and NSCR as they were published in the ACT 

in 1991. The annualized and normalized costs were scaled to 2010 dollars. No 

data were available for NOX CEMS or hydrogen peroxide injection.
7

V. Summary

a. Total Facility Annualized Costs

Annualized costs are summarized in Table 19. 

i. NOX CEMS

The overall average total facility annualized cost of NOX CEMS is 

$58,000 per year. 

ii. NSCR

The average total facility annualized cost of NSCR is $1.11 million per 

year for plants producing less than 500 tpd and $1.6 million for plants 

producing greater than 501 tpd. The overall average is $1.18 million.

The average NSCR costs for plants producing less than 500 tpd are 

consistent with the ACT costs for 200 and 500 tpd plants, which fall 

between $800,000 and $1.6 million.

The average NSCR costs for plants producing greater than 500 tpd are 

lower than the ACT costs for 1,000 tpd plants, which are $2.9 million.

iii. SCR

The average total facility annualized cost of SCR is $413,000 per year for 

plants producing less than 500 tpd and $385,000 for plants producing 

greater than 501 tpd. The overall average is $434,000.

The SCR costs for plants producing less than 500 tpd are consistent with 

the ACT costs for 200 and 500 tpd plants, which fall between $302,000 

and $709,000.

The SCR costs for plants producing greater than 501 tpd are lower than 

the ACT costs for 1,000 tpd plants, which are $1.1 million.

iv. Hydrogen Peroxide Injection

The average total facility annualized cost of H2O2 injection is $216,000 

per year for plants producing less than 500 tpd and $323,000 for plants 

producing greater than 501 tpd. The overall average is $270,000. No data 

were published in the ACT.
8

b. Normalized Costs

Normalized costs are summarized in Table 20.

i. NOX CEMS

The average total facility normalized cost of NOX CEMS is $1.03 for 

plants producing less than 500 tpd and $0.08 for plants producing greater 

than 501 tpd. The overall average is $0.20. No data were published in the 

ACT. The costs of NOX CEMS are most likely independent of plant 

production rate.

ii. NSCR

The NSCR costs for plants producing less than 500 tpd ($12.84 to $29.75) 

are much higher (a factor of 2.8) than the ACT costs for 200 and 500 tpd 

plants, which fall between $3.95 and $4.51.

The NSCR costs for plants producing greater than 501 tpd ($7.80) are 

much higher (a factor of 2.5) than the ACT costs for 1,000 tpd plants, 

which are $3.19.

The overall average total facility normalized cost of NSCR is $14.88. 

iii. SCR

The SCR costs for plants producing less than 500 tpd ($3.93) are a bit 

lower than the ACT costs for 200, 250, and 500 tpd plants, which fall 

between $3.95 and $4.51.

The SCR costs for plants producing greater than 501 tpd ($1.03 to $1.39) 

are lower (a factor of 3.0) than the ACT costs for 1,000 tpd plants, which 

are $3.19.

The overall average total facility normalized cost of SCR is $1.45

iv. Hydrogen Peroxide Injection

The average total facility normalized cost of hydrogen peroxide injection

is $2.06 for plants producing less than 500 tpd and $1.36 for plants 

producing greater than 501 tpd. The overall average is $1.58. No data 

were published in the ACT.
9

Table 1. Marshall and Swift Indices

Period Year Index

2nd quarter 2010 1493.51

1st quarter 2010 1481.81

annual 2009 1468.61

annual 2008 1449.31

annual 2007 1373.31

annual 2006 1302.31

annual 2005 1244.51

annual 2004 1178.51

annual 2003 1123.61

annual 2002 1104.21

annual 2000 10892

annual 1999 1068.32

annual 1997 1056.82

annual 1994 993.43

annual 1991 930.6

annual 1980 659.6

annual 1975 444.3

annual 1973 344.1

annual 1971 321.3

annual 1968 273.1

 

1 Marshall and Swift Index. Chemical Engineering. August 2010.

2 Marshall and Swift Index. Chemical Engineering. April 2001.

3 McKetta, John J. Encyclopedia of Chemical Processing and Design. Volume 61. 1997. Page xix.
10

Table 2. NOX CEMS testing costs

Company City

Production 

Line Description

Annual O & 

M Cost

Year of 

Cost Basis

Annualized Costs

($2010—2

nd quarter)

Nitric Acid 

Production (tpd)

El Dorado 

Nitrogen Baytown

Nitric Acid 

Plant CGAs and RATAs $7,605 $7,665 1,515

Agrium North Bend Line #1

audit labor and gases for 

RATA $10,000

2009

$10,170

288

JR Simplot Helm #1 Nitric Acid annual tests $10,950 $11,036 231

Coffeyville Coffeyville #1 Nitric Acid quarterly audits $23,200 $23,383 600

Agrium North Bend Line #1 RATA $30,000 2009 $30,509 288

PCS Nitrogen Geismar All trains CGAs and RATAs $1,000 $1,008 2,800

PCS Nitrogen Geismar All trains RATA $8,000 $8,063 2,800

Table 3. NOX CEMS calibration costs

Company City Production Line Annual O & M Cost

Year of Cost Basis Annualized Costs

($2010—2

nd quarter)

Nitric Acid Production (tpd)

Agrium North Bend Line #1 $24,000 2009 $24,407 288

PCS Nitrogen Geismar All trains $3,000 $3,024 2,800

Table 4. NOX CEMS maintenance and parts costs

Company City

Production 

Line Capital Cost

Year of 

Cost Basis

Annual O & 

M Cost

Year of 

Cost 

Basis

Annualized Costs

($2010—2

nd

quarter)

Nitric Acid 

Production 

(tpd)

JR Simplot Helm #1 Nitric Acid $1,567 $1,579

231

Agrium North Bend Line #1 $31,000 2009 $4,489 288

Agrium North Bend Line #1 $24,000 2009 $24,407 288

Agrium North Bend Line #1 $60,000 2009 $61,017 288

PCS 

Nitrogen Geismar All trains $5,000 $5,039 2,800
11

Table 5. NOX CEMS equipment costs

Company City Production Line

Capital 

Cost

Year of 

Cost 

Basis

Annual O & 

M Cost

Year of 

Cost Basis

Annualized Costs

($2010—2

nd

quarter)

Nitric Acid 

Production (tpd)

Dyno Nobel St. Helens Nitric Acid Plant $15,000 1991 $2,000 $5,443 41

Coffeyville Coffeyville #1 Nitric Acid $25,000 2000 $1,200 $6,091 600

JR Simplot Helm #1 Nitric Acid $49,894 1980 $11,700 $27,877 231

Agrium North Bend Line #1 $187,000 2009 $27,076 288

El Dorado 

Nitrogen Baytown Nitric Acid Plant $94,000

1999

$13,448

$32,265 1,515

Agrium Kennewick Plant 9 $75,000 2009 $50,000 $61,254 650

Agrium Sacramento Line #1 $125,338 2003 $44,200 2007 $71,789 236

Table 6. NSCR equipment costs

Company City Production Line Capital Cost

Yr of Cap 

Cost

Annual 

O & M Cost

Annualized Costs

($2010—2

nd quarter)

Nitric Acid Production 

(tpd)

JR Simplot Helm #1 Nitric Acid $450,000 2010 $49,798 231

PCS Nitrogen Geismar Train IV $1,495,000 2010 $165,439 550

Dyno Nobel St. Helens Nitric Acid Plant $1,560,000 1968 $263,874 $265,957

41

Dyno Nobel Cheyenne #2 Nitric Acid $1,606,264 1968 $1,311,188 $1,321,541 125

Dyno Nobel Cheyenne #1 Nitric Acid $1,700,981 1971 $1,346,596 $1,357,228 125

Table 7. NSCR fuel cost data

Company City

Production 

Line Fuel

Annual O & M 

Cost

Yr of cost 

basis

Annualized Costs

($2010—2

nd quarter)

Nitric Acid Production 

(tpd)

Agrium Sacramento Line #1 natural gas $242,050 2009 $246,154 236

JR Simplot Helm #1 Nitric Acid butane $1,025,000 2010 $1,033,093 231

PCS Nitrogen Geismar Train IV methane $1,300,000 $1,310,265 550
12

Table 8. NSCR catalyst costs

Company City

Production 

Line Annual O & M Cost Yr of cost basis

Annualized Costs

($2010—2

nd quarter) Nitric Acid Production (tpd)

PCS Nitrogen Geismar Train IV $67,600 $68,134 550

Agrium Sacramento Line #1 $203,400 2009 $206,849 236

Table 9. NSCR maintenance costs

Company City Production Line

Annual O & M 

Cost Yr of cost basis

Annualized Costs

($2010—2

nd quarter)

Nitric Acid 

Production (tpd)

PCS Nitrogen Geismar Train IV $22,425 $22,602 550

Agrium Sacramento Line #1 $86,500 2003 $114,977 236

Table 10. SCR equipment costs

Company City

Production 

Line

Capital 

Cost

Yr of Cap 

Cost

Annual 

O & M 

Cost

Yr of 

O&M 

cost

Annualized Costs

($2010—2

nd quarter)

Nitric Acid 

Production (tpd)

PCS Nitrogen Geismar Train III $1,235,000 2007 $147,465 650

Coffeyville Coffeyville

# 1 Nitric 

Acid $1,654,000 2009 $184,679

600

PCS Nitrogen Geismar Train V $1,820,000 2010 $201,404 1,600

El Dorado 

Nitrogen Baytown

Nitric Acid 

Plant $933,243 2009 $467,979 2008 $586,454

1,515

Table 11. SCR catalyst costs

Company City Production Line

Capital 

Cost

Yr of Cap 

Cost

Annual 

O & M Cost

Yr of 

O&M 

cost

Annualized Costs

($2010—2

nd

quarter)

Nitric Acid 

Production (tpd)

PCS Nitrogen Geismar Train V $54,300 $54,729 1,600

PCS Nitrogen Geismar Train III $71,735 $72,301 650

Coffeyville Coffeyville # 1 Nitric Acid $243,840 2008 $91,000 2009 $120,132

600
13

Table 12. SCR maintenance costs

Company City Production Line Technology

Capital 

Cost Yr of Cap Cost

Annual 

O & M Cost

Yr of 

O&M cost

Annualized 

Costs

($2010—

2

nd

quarter)

Nitric Acid 

Production 

(tpd)

PCS Nitrogen Geismar Train III SCR $18,500 $18,646 650

PCS Nitrogen Geismar Train V SCR $27,300 $27,516

1,600

Table 13. SCR ammonia costs

Company City

Production 

Line Technology

Capital 

Cost

Yr of Cap 

Cost

Annual 

O & M Cost

Yr of 

O&M cost

Annualized 

($2010—2

nd

quarter)Costs

Nitric Acid 

Production 

(tpd)

PCS 

Nitrogen Geismar Train III SCR $25,000 $25,197

650

PCS 

Nitrogen Geismar Train V SCR $315,000 $317,487

1,600

Agrium

North 

Bend Line #1 SCR $2,750,000 2009 $105,000 $412,884

288

Table 14. Hydrogen Peroxide Injection

Company City

Production 

Line Technology Capital Cost

Yr of 

Cap 

Cost

Annual 

O & M 

Cost

Yr of 

O&M 

cost

Annualized 

Costs

($2010—2

nd

quarter)

Nitric Acid 

Production 

(tpd)

Agrium North Bend Line #1 H2O2 Injection $165,000 1997 $189,000 $216,095

288

Agrium Kennewick Plant 9 H2O2 Injection $150,000 2004 $300,000 2010 $323,240

650
14

Table 15. Summary of Annualized Costs per Nitric Acid Train by Technology

Company City Production Line Technology Capital Cost Annual O & M Cost

Annualized Costs

($2010—2

nd quarter)

Nitric Acid 

Production (tpd)

Dyno Nobel St. Helens Nitric Acid Plant CEMS $15,000 $2,000 $5,443 41

Coffeyville Coffeyville #1 Nitric Acid CEMS $25,000 $24,400 $29,474 600

PCS Nitrogen Geismar Train III CEMS $75,000 $17,000 $33,188 2,800

El Dorado Nitrogen Baytown Nitric Acid Plant CEMS $94,000 $21,053 $39,930 1,515

JR Simplot Helm Nitric Acid Plant CEMS $49,894 $24,217 $40,493 231

Agrium Kennewick Plant 9 CEMS $75,000 $50,000 $61.254 650

Agrium Sacramento Line #1 CEMS $125,338 $44,200 $71,789 236

Agrium North Bend Line #1 CEMS $218,000 $148,000 $182,074 288

Average $57,956 All

Average (without the lowest and the highest) $46,021 All

Agrium Kennewick Plant 9 H2O2 Injection $150,000 $300,000 $323,240 650

Agrium North Bend Line #1 H2O2 Injection $165,000 $189,000 $216,095 288

Average $269,667 All

JR Simplot Helm #1 Nitric Acid NSCR $450,000 $1,049,217 $1,082,891 231

Dyno Nobel St. Helens Nitric Acid Plant NSCR $1,560,000 $263,874 $265,957 41

Agrium Sacramento Line #1 NSCR $1,418,803 $1,505,192 236

PCS Nitrogen Geismar Train IV NSCR 1,495,000 $1,390,025 $1,566,439 550

Dyno Nobel Cheyenne #1 Nitric Acid NSCR $1,700981 $1,346,596 $1,357,228 125

Dyno Nobel Cheyenne #2 Nitric Acid NSCR $1606264 $1,311,188 $1,321,541 125

Average $1,183,208 All

PCS Nitrogen Geismar Train III SCR $1,235,000 $115,235 $263,609 650

Coffeyville Coffeyville # 1 Nitric Acid SCR $1,897,840 $91,000 $304,811 600

Agrium North Bend Line #1 SCR $2,750,000 $105,000 $412,884 288

El Dorado Nitrogen Baytown Nitric Acid Plant SCR $933,243 $467,979 $586,454 1,515

PCS Nitrogen Geismar Train V SCR $1,820,000 $396,600 $601,135 1,600

Average $433,779 All
15

Table 16. Normalized Costs for Plants producing less than 500 tons per day nitric acid

Company City

Production 

Line Technology Capital Cost

Annual O & M 

Cost

Annualized Costs

($2010—2

nd quarter)

Nitric Acid 

Production (tpy)

Annualized Costs 

per ton HNO3

Dyno 

Nobel St. Helens

Nitric Acid 

Plant CEMS $15,000 $2,000 $5,443 14,189 $0.37

JR Simplot Helm #1 Nitric Acid CEMS $49,894 $24,217 $40,493 84,315 $0.48

Agrium Sacramento Line #1 CEMS $125,338 $44,200 $71,789 86,031 $0.83

Agrium North Bend Line #1 CEMS $218,000 $148,000 $182,074 105,120 $1.73

Agrium North Bend Line #1

H2O2

Injection $165,000 $189,000 $216,095 105,120 $2.06

JR Simplot Helm #1 Nitric Acid NSCR $450,000 $1,049,217 $1,082,891 84,315 $12.84

Dyno 

Nobel St. Helens

Nitric Acid 

Plant NSCR $1,560,000 $263,874 $265,957 14,819 $17.95

Agrium Sacramento Line #1 NSCR $1,418,803 $1,505,192 86,031 $17.50

Dyno 

Nobel Cheyenne #1 Nitric Acid NSCR $1,700,981 $1,346,596 $1,357,228 45,625 $29.75

Dyno 

Nobel Cheyenne #2 Nitric Acid NSCR $1,606,264 $1,311,188 $1,321,541 45,625 $28.97

Agrium North Bend Line #1 SCR $2,750,000 $105,000 $412,884 105,120 $3.93
16

Table 17. Normalized Costs for Plants producing greater than 501 tons per day nitric acid

Company City

Production 

Line Technology

Capital 

Cost

Annual O & M 

Cost

Annualized Costs

($2010—2

nd quarter)

Nitric Acid 

Production (tpy)

Annualized Costs 

per ton HNO3

El Dorado 

Nitrogen Baytown

Nitric Acid 

Plant CEMS $94,000 $21,053 $39,930 552,975 $0.07

Coffeyville Coffeyville

#1 Nitric 

Acid CEMS $25,000 $24,400 $29,474 219,000 $0.13

PCS Nitrogen Geismar All trains CEMS $75,000 $17,000 $33,188 1,022,000 $0.03

Agrium Kennewick Plant 9 CEMS $75,000 $50,000 $61,254 237,250 $0.26

Agrium Kennewick Plant 9 H2O2 Injection $150,000 $300,000 $323,000 237,250 $1.36

PCS Nitrogen Geismar Train IV NSCR $1,495,000 $1,390,025 $1,566,439 200,750 $7.80

El Dorado 

Nitrogen Baytown

Nitric Acid 

Plant SCR $933,243 $467,979 $586,454 552,975 $1.06

PCS Nitrogen Geismar Train V SCR $1,820,000 $396,600 $601,135 584,000 $1.03

PCS Nitrogen Geismar Train III SCR $1,235,000 $115,235 $263,609 237,250 $1.11

Coffeyville Coffeyville

# 1 Nitric 

Acid SCR $1,897,840 $91,000 $304,811 219,000 $1.39

Table 18. Summary of Data from ACT

Plant size 

(ton/day)

Uncontrolled 

NOX emissions 

(tpy)

Control 

technique

NOX

removed 

(tpy)

ACT 

Annualized 

Cost from 

($1991)

Cost 

Effectiveness

($1991)

Annualized costs 

($2010—2

nd

quarter)

Cost Effectiveness 

($/ton NOX)

($2010—2

nd

quarter)

Normalized costs 

($/ton HNO3)

($2010—2

nd

quarter)

200 718 NSCR 701 $501,000 $714 $804,044 $1,120 $11.20

500 1800 NSCR 1759 $1,020,000 $580 $1,636,976 $930 $9.12

1000 3590 NSCR 3507 $1,780,000 $507 $2,856,684 $815 $7.96

200 718 SCR 617 $188,000 $304 $301,717 $489 $4.20

500 1800 SCR 1548 $442,000 $286 $709,356 $460 $3.95

1000 3590 SCR 3087 $714,000 $231 $1,145,883 $370 $3.19

250 898 SCR 873 $252,000 $289 $404,429 $465 $4.51
17

Table 19. Summary of Annualized Costs by Plant Size

Tech

Overall

($2010—2

nd quarter)

0-500 tpd

($2010—2

nd quarter)

>501 tpd

($2010—2

nd quarter)

ACT

($2010—2

nd quarter)

min max avg min max avg min max avg min max avg

CEMS $5,400 $182,000 $58,000 $5,400 $182,000 $75,000 $29,000 $61,000 $41,000 ---- ---- ----

NSCR $266,000 $1,570,000 $1,180,000 $266,000 $1,505,000 $1,110,000 $1,570,000 $1,570,000 $1,570,000

$804,000 $2,900,000 $1,770,000

SCR $264,000 $601,000 $434,000 $413,000 $413,000 $413,000 $264,000 $586,000 $385,000

$301,000 $1,150,000 $640,000

H2O2 $216,000 $323,000 $270,000 $216,000 $216,000 $216,000 $323,000 $323,000 $323,000 ---- ---- ----

Table 20. Summary of Normalized Costs by Model Plant ($/ton nitric acid)

Tech

Overall

($2010—2

nd quarter)

0-500 tpd

($2010—2

nd quarter)

>501 tpd

($2010—2

nd quarter)

ACT

($2010—2

nd quarter)

min max avg min max avg min max avg min max avg

CEMS $0.03 $1.73 $0.20 $0.37 $1.73 $1.03 $0.03 $0.26 $0.08 ---- ---- ----

NSCR $7.80 $29.75 $14.88 $12.84 $29.75 $20.02 $7.80 $7.80 $7.80 $7.96 $11.20 $8.68

SCR $1.03 $3.93 $1.28 $3.93 $3.93 $3.93 $1.03 $1.39 $1.10 $3.19 $4.51 $3.65

H2O2 $1.36 $2.06 $1.58 $2.06 $2.06 $2.06 $1.36 $1.36 $1.36 ---- ---- ----