Pb, Cd1

Fabric Filter $110,310,452 0.3108 354,947,491 $/ton

Hg, D/F ACI/FF2$691,599 0.00197 351,454,804 $/ton

CO3 RTO $28,898,682 1,112 25,990 $/ton

SO24 DIFF $109,618,852 23,331 4,698 $/ton

NOx SCR or SNCR series

4. Represents cost effectiveness to meet 95% SO2 reduction emission level from worst performing unit by applying DIFF to unit

with baseline emissions above this value. 

1. For Pb, Cd, calculations represent cost effectiveness to comply with the MACT floor emission limit, which is based on the 

representative detection level (RDL) for these pollutants. Since the limits are set at the quantification level of the EPA reference 

test method, further emission reductions cannot be quantified.

2. All but one unit would have already installed ACI/FF combination to meet limits for either D/F or Hg. The remaining unit alread

needs FF for metals/PM control, costed ACI component and FF improvement. Assumed 90% ACI factor and 90% emission 

reduction.

3. Cost effectiveness for beyond the floor CO measures considered only for preheater/precalciner kilns. (The limit for long kilns 

the same as it was for the 2011 final rule.) The average reduction yielded from units installing RTO to reach MACT floor limit wa

applied to units where RTO was assigned as a beyond-the-floor option. A 15% increase of MACT RTO TCI and TAC was adde

to units needing "robust" RTO's to meet the MACT floor to meet a lower BTF emission level.

Cost Effectiveness Units

Annual Reductions 

(TPY)*

Annual Control 

Control and Monitoring 

Pollutant(s) of 

Interest
Pollutant Reduction Total Reduction Units

PM 917.1 917.4 120,240 $/ton

CO is subcategorized based on kiln design, so only one of the subcategories is affected.

Since many kilns already have SNCR in place, additional NOx controls would likely require use of selective catalytic reduction, w

Additonal reductions from co-control Cost effectiveness 

for all controlled 

ming unit by applying DIFF to units 

n limit, which is based on the 

cation level of the EPA reference 

 or Hg. The remaining unit already

ACI factor and 90% emission 

ner kilns. (The limit for long kilns is 

RTO to reach MACT floor limit was 

CT RTO TCI and TAC was added 
elective catalytic reduction, which has not been adequately demonstrated on existing kilns in the U.S., or SNCR in series, which would requir
eries, which would require a reheat and second reaction chamber.
Secondary Impacts of Cement Kilns

FF ACI RTO SNCR WS Total

elec (Mw) 0 0 0 0

water (gal/yr) 0 0 0

ACI (lb/yr) 0 0

Dust (tpy) 0 0 0

Natural Gas (Mmscf/yr) 37 37

0

Emission Factors

Electrcitya

Pollutant (lb/Mw-hr) (lb/106

 scf) lb/ft3 ton/ft3

CO2 1,329 120,000 0.12 0.00006

CO - 84 0.000084 0.000000042

NOx 1.9366 100 0.0001 0.00000005

SO2 5.2589 - - -

a. National emission factors from Egrid for EGUs

b. Natural gas emission factors from AP 42

1288.1197

Natural Gasb
Secondary Emissions from Cement Kilns

CO2 CO SO2 NOx CO2 CO SO2

0 0 0 0.00 0.00

4,398,784 3,079 3,666 2,199.39 1.54

lbs: 4,398,784 3,079 0 3,666 2,199 2 0

tons: 2,199.4 1.54 0.0 1.8

2199.392114
NOx

0.00

1.83

2
Summary of MACT Compliance Costs for Cement Kilns

Total Capital 

Investment

($)

Total Annual 

Cost 

($/yr)

Total Capital 

Investment

($)

Total Annual 

Cost 

($/yr)

Total Capital 

Investment

($)

Total Annual 

Cost 

($/yr)

ALNationalCementRagland Kiln Electrostatic Precipitator ACI, fabric filter, wet scrubber, RTO $31,221,805 $10,609,773 $28,300 $21,300 $31,250,105 $10,631,073

CACAPortlandCementColton K-1

Collectors, Settling Chambers, 

Separators - General, Cyclone: 

Multiple (Multiclone), Fabric 

Filter improve fabric filter, RTO, ACI $10,899,897 $3,380,847 $18,000 $18,800 $10,917,897 $3,399,647

CACAPortlandCementColton K-2

Collectors, Settling Chambers, 

Separators - General, Cyclone: 

Multiple (Multiclone), Fabric 

Filter improve fabric filter, RTO, ACI $20,685,856 $6,367,525 $18,000 $18,800 $20,703,856 $6,386,325

CALehighSouthwestReddingPlant

In-Line Kiln/Raw Mill 

(S260) Fabric Filter

improve fabric filter, RTO, wet scrubber, ACI, 

$19,260,586 $6,221,708 $18,000 $19,600 $19,278,586 $6,241,308

FLCemexMiami Cement Kiln Fabric Filter

improve fabric filter, RTO, wet scrubber, ACI, 

SNCR $2,273,830 $2,473,322 $0 $0 $2,273,830 $2,473,322

IALafargeBuffalo Kiln 1 Fabric Filter improve fabric filter, wet scrubber, ACI $38,101,037 $10,254,048 $18,000 $17,800 $38,119,037 $10,271,848

IALehighCementMasonCity 302.203

Electrostatic Precipitator, Fabric 

Filter, Flue Gas Desulfurization 

(General), Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR)

wet scrubber, improve fabric filter, ACI

$41,618,144 $11,543,861 $0 $19,600 $41,618,144 $11,563,461

MILafargeMidwestAlpena 19 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet scrubber, ACI

$14,103,446 $4,171,782 $18,000 $17,500 $14,121,446 $4,189,282

MILafargeMidwestAlpena 20 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet scrubber, ACI

$14,567,998 $4,307,505 $18,000 $17,500 $14,585,998 $4,325,005

MILafargeMidwestAlpena 21 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet scrubber, ACI

$14,897,805 $4,403,860 $18,000 $17,500 $14,915,805 $4,421,360

MILafargeMidwestAlpena 22 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet scrubber, ACI

$24,698,458 $7,267,188 $18,000 $17,500 $24,716,458 $7,284,688

MILafargeMidwestAlpena 23 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet scrubber, ACI

$24,641,302 $7,250,490 $18,000 $17,500 $24,659,302 $7,267,990

PALafargeWhitehallPlant Kiln 2 Fabric Filter RTO, wet scrubber, ACI, improve fabric filter $11,896,627 $3,468,568 $18,000 $14,800 $11,914,627 $3,483,368

PALafargeWhitehallPlant Kiln 3 Fabric Filter RTO, wet scrubber, ACI, improve fabric filter $8,490,338 $2,378,888 $18,000 $13,000 $8,508,338 $2,391,888

PALehighCementEvansville 121

Cyclone: Single, Dry Limestone 

Injection, Fabric Filter wet scrubber, ACI, improve fabric filter $0 $0 $0 $0 $0 $0

PALehighCementEvansville 122

Cyclone: Single, Dry Limestone 

Injection, Fabric Filter wet scrubber, ACI, improve fabric filter $0 $0 $0 $0 $0 $0

PALehighCementYork 200 Electrostatic Precipitator RTO, fabric filter $7,535,045 $2,815,397 $18,000 $29,700 $7,553,045 $2,845,097

TXAshGroveMidlothian Kiln 1

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR) ACI, fabric filter, wet scrubber $8,602,408 $2,679,317 $18,000 $18,800 $8,620,408 $2,698,117

TXAshGroveMidlothian Kiln 2

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR) ACI, fabric filter, wet scrubber $10,464,251 $3,248,742 $18,000 $18,800 $10,482,251 $3,267,542

TXAshGroveMidlothian Kiln 3

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR) ACI, fabric filter, wet scrubber $10,808,134 $3,352,449 $18,000 $18,800 $10,826,134 $3,371,249

TXHolcimMidlothianPlant Kiln 1

Fabric Filter, Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR), Wet 

Scrubber improve fabric filter, RTO, ACI $46,779,173 $13,996,818 $28,300 $18,800 $46,807,473 $14,015,618

Control Costs Monitoring, Reporting, and 

Recordkeeping Costs Total MACT Floor Control, 

Monitoring, Reporting, and 

Recordkeeping Costs

FacilityID UnitID Existing Control Device Consolidated MACT Controls

1 of 2
TXHolcimMidlothianPlant Kiln 2

Fabric Filter, Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR), Wet 

Scrubber improve fabric filter, ACI, RTO $50,843,060 $15,491,625 $28,300 $19,600 $50,871,360 $15,511,225

UTHolcimDevilsSlide Kiln 1 Fabric Filter wet scrubber, ACI, improve fabric filter $47,102,025 $13,419,752 $18,000 $18,000 $47,120,025 $13,437,752

$459,491,225 $139,103,466 $372,900 $373,700 $459,864,125 $139,477,166

2 of 2
Table 2E. Waste-Burning Kilns: Costs to Meet MACT Floor (1 of 6)

Dust Elec Elec Water

TCI

($)

TCI 

($/dscfm)

TAC

($/yr)

TAC

($/yr/dscfm) tpy Mw

TAC

($/yr)

TAC

($/yr/dscfm)

TCI

($)

TCI 

($/dscfm)

TAC

($/yr)

TAC

($/yr/dscfm) Mw gal/yr

TCI

($)

ALNationalCementRagland Kiln Electrostatic Precipitator

ACI, fabric filter, wet scrubber, 

RTO $19,811,686 $109.73 $6,106,049 $33.82 66 7699 $11,475,207 $63.56 $2,424,376 $13.43 3907 28695230 $13,681,739.91

CACAPortlandCementColton K-1

Collectors, Settling Chambers, 

Separators - General, Cyclone: 

Multiple (Multiclone), Fabric Filter improve fabric filter, RTO, ACI $97,288 $1.40 $7,711,333.88

CACAPortlandCementColton K-2

Collectors, Settling Chambers, 

Separators - General, Cyclone: 

Multiple (Multiclone), Fabric Filter improve fabric filter, RTO, ACI $192,669 $1.40 $11,619,307.41

CALehighSouthwestReddingPlant

In-Line Kiln/Raw 

Mill (S260) Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI, $157,558 $1.35 $7,498,933 $64.31 $1,642,498 $14.09 2779 39568170 $10,525,135.87

FLCemexMiami Cement Kiln Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI, SNCR $256,694 $1.20 $13,567,471 $63.34 $2,859,134 $13.35 4599 61337109 $15,158,865.91

IALafargeBuffalo Kiln 1 Fabric Filter

improve fabric filter, wet scrubber, 

ACI $256,694 $1.53 $10,671,531 $63.66 $2,253,104 $13.44 3555 29473379

IALehighCementMasonCity 302.203

Electrostatic Precipitator, Fabric 

Filter, Flue Gas Desulfurization 

(General), Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR)

wet scrubber, improve fabric filter, 

ACI

$256,694 $1.38 $11,825,103 $63.52 $2,526,018 $13.57 4433 3498604

MILafargeMidwestAlpena 19 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI $136,319 $1.49 $5,950,923 $64.88 $1,295,363 $14.12 1882 22763503 $9,112,969.93

MILafargeMidwestAlpena 20 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI $141,481 $1.49 $6,151,889 $64.79 $1,337,341 $14.09 1948 23565525 $9,304,279.65

MILafargeMidwestAlpena 21 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI $145,267 $1.49 $6,294,564 $64.73 $1,367,143 $14.06 1995 24134916 $9,438,521.24

MILafargeMidwestAlpena 22 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI $247,736 $1.50 $10,534,345 $63.68 $2,252,758 $13.62 3391 41055160 $12,981,866.19

MILafargeMidwestAlpena 23 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI $247,765 $1.50 $10,509,620 $63.69 $2,247,593 $13.62 3383 40956484 $12,963,136.06

PALafargeWhitehallPlant Kiln 2 Fabric Filter

RTO, wet scrubber, ACI, improve 

fabric filter $87,653 $1.28 $4,500,370 $65.80 $945,391 $13.82 1119 14833599 $7,641,807.97

PALafargeWhitehallPlant Kiln 3 Fabric Filter

RTO, wet scrubber, ACI, improve 

fabric filter $87,653 $1.89 $3,129,998 $67.52 $653,314 $14.09 634 7047311 $6,051,508.73

PALehighCementEvansville 121

Cyclone: Single, Dry Limestone 

Injection, Fabric Filter

wet scrubber, ACI, improve fabric 

filter $132,160 $1.53 $5,628,143 $65.05 $1,239,723 $14.33 2068 24922614

PALehighCementEvansville 122

Cyclone: Single, Dry Limestone 

Injection, Fabric Filter

wet scrubber, ACI, improve fabric 

filter $132,160 $1.47 $5,828,632 $64.94 $1,282,236 $14.29 2146 28106277

PALehighCementYork 200 Electrostatic Precipitator RTO, fabric filter $5,523,925 $121.05 $1,775,068 $38.90 27 2168 $5,994,594.06

TXAshGroveMidlothian Kiln 1

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

$6,351,902 $118.84 $1,996,687 $37.36 12 2409 $3,571,164 $66.81 $801,028 $14.99 1,222 21,473,340

TXAshGroveMidlothian Kiln 2

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

$7,723,478 $116.31 $2,429,043 $36.58 46 2988 $4,376,600 $65.91 $967,421 $14.57 1,517 26,506,586

TXAshGroveMidlothian Kiln 3

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

$7,976,809 $115.95 $2,507,707 $36.45 17 3095 $4,525,365 $65.78 $998,293 $14.51 1,573 27,320,532

TXHolcimMidlothianPlant Kiln 1

Fabric Filter, Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR), Wet 

Scrubber improve fabric filter, RTO, ACI $256,694 $0.86 $18,542,581.76

TXHolcimMidlothianPlant Kiln 2

Fabric Filter, Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR), Wet 

Scrubber improve fabric filter, ACI, RTO $256,694 $0.79 $19,535,985.02

UTHolcimDevilsSlide Kiln 1 Fabric Filter

wet scrubber, ACI, improve fabric 

filter $256,694 $1.38 $11,774,867 $63.52 $2,486,339 $13.41 3979 50553387

$14,814,554 168 18,359 46,130 515,811,726

Add Packed Bed Scrubber

FacilityID UnitID ControlDevice Consolidated MACT Controls

Add Fabric Filter

 Improve Fabric Filter 

Performance
Table 2E. Waste-Burning Kilns: Costs to Meet MACT Floor (2 of 6)

ALNationalCementRagland Kiln Electrostatic Precipitator

ACI, fabric filter, wet scrubber, 

RTO

CACAPortlandCementColton K-1

Collectors, Settling Chambers, 

Separators - General, Cyclone: 

Multiple (Multiclone), Fabric Filter improve fabric filter, RTO, ACI

CACAPortlandCementColton K-2

Collectors, Settling Chambers, 

Separators - General, Cyclone: 

Multiple (Multiclone), Fabric Filter improve fabric filter, RTO, ACI

CALehighSouthwestReddingPlant

In-Line Kiln/Raw 

Mill (S260) Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI, 

FLCemexMiami Cement Kiln Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI, SNCR

IALafargeBuffalo Kiln 1 Fabric Filter

improve fabric filter, wet scrubber, 

ACI

IALehighCementMasonCity 302.203

Electrostatic Precipitator, Fabric 

Filter, Flue Gas Desulfurization 

(General), Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR)

wet scrubber, improve fabric filter, 

ACI

MILafargeMidwestAlpena 19 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 20 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 21 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 22 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 23 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

PALafargeWhitehallPlant Kiln 2 Fabric Filter

RTO, wet scrubber, ACI, improve 

fabric filter

PALafargeWhitehallPlant Kiln 3 Fabric Filter

RTO, wet scrubber, ACI, improve 

fabric filter

PALehighCementEvansville 121

Cyclone: Single, Dry Limestone 

Injection, Fabric Filter

wet scrubber, ACI, improve fabric 

filter

PALehighCementEvansville 122

Cyclone: Single, Dry Limestone 

Injection, Fabric Filter

wet scrubber, ACI, improve fabric 

filter

PALehighCementYork 200 Electrostatic Precipitator RTO, fabric filter

TXAshGroveMidlothian Kiln 1

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

TXAshGroveMidlothian Kiln 2

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

TXAshGroveMidlothian Kiln 3

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

TXHolcimMidlothianPlant Kiln 1

Fabric Filter, Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR), Wet 

Scrubber improve fabric filter, RTO, ACI

TXHolcimMidlothianPlant Kiln 2

Fabric Filter, Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR), Wet 

Scrubber improve fabric filter, ACI, RTO

UTHolcimDevilsSlide Kiln 1 Fabric Filter

wet scrubber, ACI, improve fabric 

filter

FacilityID UnitID ControlDevice Consolidated MACT Controls

Natural Gas

TCI 

($/dscfm)

TAC

($/yr)

TAC

($/yr/dscfm) Mmscf/yr

$75.78 $4,008,233.26 $22.20 131

$111.06 $1,997,011.59 $28.76 53

$84.50 $3,274,813.57 $23.82 105

$90.26 $2,901,799.88 $24.89 94

$70.77 $4,556,891.98 $21.28 155

$99.36 $2,437,625.33 $26.58 63

$97.99 $2,499,340.94 $26.32 66

$97.06 $2,542,867.82 $26.15 67

$78.48 $3,755,009.98 $22.70 114

$78.56 $3,748,293.75 $22.71 114

$111.74 $1,975,696.37 $28.89 38

$130.54 $1,502,737.56 $32.42 21

$131.37 $1,486,344.03 $32.57 37

$61.88 $5,883,521.91 $19.63 177

$59.76 $6,290,742.19 $19.24 208

1,444

Add RTO
Table 2E. Waste-Burning Kilns: Costs to Meet MACT Floor (3 of 6)

ALNationalCementRagland Kiln Electrostatic Precipitator

ACI, fabric filter, wet scrubber, 

RTO

CACAPortlandCementColton K-1

Collectors, Settling Chambers, 

Separators - General, Cyclone: 

Multiple (Multiclone), Fabric Filter improve fabric filter, RTO, ACI

CACAPortlandCementColton K-2

Collectors, Settling Chambers, 

Separators - General, Cyclone: 

Multiple (Multiclone), Fabric Filter improve fabric filter, RTO, ACI

CALehighSouthwestReddingPlant

In-Line Kiln/Raw 

Mill (S260) Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI, 

FLCemexMiami Cement Kiln Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI, SNCR

IALafargeBuffalo Kiln 1 Fabric Filter

improve fabric filter, wet scrubber, 

ACI

IALehighCementMasonCity 302.203

Electrostatic Precipitator, Fabric 

Filter, Flue Gas Desulfurization 

(General), Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR)

wet scrubber, improve fabric filter, 

ACI

MILafargeMidwestAlpena 19 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 20 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 21 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 22 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 23 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

PALafargeWhitehallPlant Kiln 2 Fabric Filter

RTO, wet scrubber, ACI, improve 

fabric filter

PALafargeWhitehallPlant Kiln 3 Fabric Filter

RTO, wet scrubber, ACI, improve 

fabric filter

PALehighCementEvansville 121

Cyclone: Single, Dry Limestone 

Injection, Fabric Filter

wet scrubber, ACI, improve fabric 

filter

PALehighCementEvansville 122

Cyclone: Single, Dry Limestone 

Injection, Fabric Filter

wet scrubber, ACI, improve fabric 

filter

PALehighCementYork 200 Electrostatic Precipitator RTO, fabric filter

TXAshGroveMidlothian Kiln 1

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

TXAshGroveMidlothian Kiln 2

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

TXAshGroveMidlothian Kiln 3

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

TXHolcimMidlothianPlant Kiln 1

Fabric Filter, Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR), Wet 

Scrubber improve fabric filter, RTO, ACI

TXHolcimMidlothianPlant Kiln 2

Fabric Filter, Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR), Wet 

Scrubber improve fabric filter, ACI, RTO

UTHolcimDevilsSlide Kiln 1 Fabric Filter

wet scrubber, ACI, improve fabric 

filter

FacilityID UnitID ControlDevice Consolidated MACT Controls

ACI Dust Elec Water Tune-up

TCI

($)

TCI 

($/dscfm)

TAC

($/yr)

TAC

($/yr/dscfm) lb/yr ton/yr

TCI

($)

TCI 

($/dscfm)

TAC

($/yr)

TAC

($/yr/dscfm) Mw gal/yr

TAC

($/yr)

TAC

($/yr/dscfm)

TCI

($)

TCI 

($/dscfm)

$129,114 $0.72 $2,231,027 $12.36 1,543,578 772 $45,097,747 $250

$72,771 $1.05 $710,105 $10.23 472,737 236 $7,784,105 $112

$109,651 $0.80 $1,541,260 $11.21 1,055,637 528 $11,728,958 $85

$99,325 $0.85 $1,611,033 $13.82 1,108,312 554 $18,123,393 $155

$143,053 $0.67 $2,645,744 $12.35 1,835,904 918 $2,989,091 $13.96 $335,508 $1.57 53 12,798,000 $31,858,481 $149

$123,487 $0.74 $1,641,111 $9.79 1,123,349 562 $10,795,018 $64

$131,513 $0.71 $2,549,403 $13.69 1,769,477 885 $11,956,615 $64

$85,998 $0.94 $647,068 $7.06 424,430 212 $15,149,891 $165

$87,804 $0.92 $668,782 $7.04 439,384 220 $15,543,973 $164

$89,071 $0.92 $684,190 $7.04 450,000 225 $15,822,156 $163

$122,509 $0.74 $1,140,157 $6.89 765,482 383 $23,638,720 $143

$122,332 $0.74 $1,137,506 $6.89 763,642 382 $23,595,088 $143

$72,115 $1.05 $249,788 $3.65 146,787 73 $12,214,293 $179

$57,108 $1.23 $151,737 $3.27 82,912 41 $9,238,614 $199

$83,045 $0.96 $1,083,796 $12.53 736,240 368 $5,711,188 $66

$84,887 $0.95 $680,362 $7.58 446,884 223 $5,913,519 $66

$11,518,519 $252

$62,201 $1.16 $426,250 $7.97 273,007 137 $9,985,266 $187

$70,849 $1.07 $522,598 $7.87 339,155 170 $12,170,927 $183

$72,369 $1.05 $540,359 $7.85 351,372 176 $12,574,543 $183

$174,985 $0.58 $3,333,203 $11.12 2,319,648 1,160 $18,717,567 $62

$184,360 $0.56 $3,672,026 $11.23 2,558,372 1,279 $19,720,345 $60

$131,170 $0.71 $2,275,516 $12.28 1,574,836 787 $11,906,037 $64

$30,143,021 20,581,145 10,291 53 12,798,000

Add ACI SNCR Controls Subtotals
Table 2E. Waste-Burning Kilns: Costs to Meet MACT Floor (4 of 6)

ALNationalCementRagland Kiln Electrostatic Precipitator

ACI, fabric filter, wet scrubber, 

RTO

CACAPortlandCementColton K-1

Collectors, Settling Chambers, 

Separators - General, Cyclone: 

Multiple (Multiclone), Fabric Filter improve fabric filter, RTO, ACI

CACAPortlandCementColton K-2

Collectors, Settling Chambers, 

Separators - General, Cyclone: 

Multiple (Multiclone), Fabric Filter improve fabric filter, RTO, ACI

CALehighSouthwestReddingPlant

In-Line Kiln/Raw 

Mill (S260) Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI, 

FLCemexMiami Cement Kiln Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI, SNCR

IALafargeBuffalo Kiln 1 Fabric Filter

improve fabric filter, wet scrubber, 

ACI

IALehighCementMasonCity 302.203

Electrostatic Precipitator, Fabric 

Filter, Flue Gas Desulfurization 

(General), Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR)

wet scrubber, improve fabric filter, 

ACI

MILafargeMidwestAlpena 19 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 20 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 21 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 22 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 23 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

PALafargeWhitehallPlant Kiln 2 Fabric Filter

RTO, wet scrubber, ACI, improve 

fabric filter

PALafargeWhitehallPlant Kiln 3 Fabric Filter

RTO, wet scrubber, ACI, improve 

fabric filter

PALehighCementEvansville 121

Cyclone: Single, Dry Limestone 

Injection, Fabric Filter

wet scrubber, ACI, improve fabric 

filter

PALehighCementEvansville 122

Cyclone: Single, Dry Limestone 

Injection, Fabric Filter

wet scrubber, ACI, improve fabric 

filter

PALehighCementYork 200 Electrostatic Precipitator RTO, fabric filter

TXAshGroveMidlothian Kiln 1

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

TXAshGroveMidlothian Kiln 2

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

TXAshGroveMidlothian Kiln 3

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

TXHolcimMidlothianPlant Kiln 1

Fabric Filter, Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR), Wet 

Scrubber improve fabric filter, RTO, ACI

TXHolcimMidlothianPlant Kiln 2

Fabric Filter, Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR), Wet 

Scrubber improve fabric filter, ACI, RTO

UTHolcimDevilsSlide Kiln 1 Fabric Filter

wet scrubber, ACI, improve fabric 

filter

FacilityID UnitID ControlDevice Consolidated MACT Controls

Annual 

Stack Test

TAC

($/yr)

TAC

($/yr/dscf

m)

TCI

($)

TAC

($/yr)

TAC

($/yr)

TCI

($)

TAC

($/yr)

$14,769,685 $82 $40,667 $4,465 $40,667

$2,804,405 $40 $40,667 $4,465 $40,667

$5,008,742 $36 $40,667 $4,465 $40,667

$6,312,890 $54 $40,667 $4,465 $40,667

$10,653,972 $50 $40,667 $4,465 $40,667 $10,300 $3,200

$4,150,908 $25 $40,667 $4,465 $40,667

$5,332,115 $29 $40,667 $4,465 $40,667

$4,516,375 $49 $40,667 $4,465 $40,667

$4,646,944 $49 $40,667 $4,465 $40,667

$4,739,468 $49 $40,667 $4,465 $40,667

$7,395,660 $45 $40,667 $4,465 $40,667

$7,381,158 $45 $40,667 $4,465 $40,667

$3,258,529 $48 $40,667 $4,465 $40,667

$2,395,442 $52 $40,667 $4,465 $40,667

$2,455,679 $28 $40,667 $4,465 $40,667

$2,094,758 $23 $40,667 $4,465 $40,667

$3,261,412 $71 $40,667 $4,465 $40,667

$3,223,965 $60 $40,667 $4,465 $40,667

$3,919,062 $59 $40,667 $4,465 $40,667

$4,046,359 $59 $40,667 $4,465 $40,667

$9,473,418 $32 $40,667 $4,465 $40,667

$10,219,462 $31 $40,667 $4,465 $40,667

$5,018,549 $27 $40,667 $4,465 $40,667

Add SNCR 

Controls Subtotals Initial Stack Test Monitoring
Table 2E. Waste-Burning Kilns: Costs to Meet MACT Floor (5 of 6)

ALNationalCementRagland Kiln Electrostatic Precipitator

ACI, fabric filter, wet scrubber, 

RTO

CACAPortlandCementColton K-1

Collectors, Settling Chambers, 

Separators - General, Cyclone: 

Multiple (Multiclone), Fabric Filter improve fabric filter, RTO, ACI

CACAPortlandCementColton K-2

Collectors, Settling Chambers, 

Separators - General, Cyclone: 

Multiple (Multiclone), Fabric Filter improve fabric filter, RTO, ACI

CALehighSouthwestReddingPlant

In-Line Kiln/Raw 

Mill (S260) Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI, 

FLCemexMiami Cement Kiln Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI, SNCR

IALafargeBuffalo Kiln 1 Fabric Filter

improve fabric filter, wet scrubber, 

ACI

IALehighCementMasonCity 302.203

Electrostatic Precipitator, Fabric 

Filter, Flue Gas Desulfurization 

(General), Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR)

wet scrubber, improve fabric filter, 

ACI

MILafargeMidwestAlpena 19 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 20 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 21 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 22 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 23 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

PALafargeWhitehallPlant Kiln 2 Fabric Filter

RTO, wet scrubber, ACI, improve 

fabric filter

PALafargeWhitehallPlant Kiln 3 Fabric Filter

RTO, wet scrubber, ACI, improve 

fabric filter

PALehighCementEvansville 121

Cyclone: Single, Dry Limestone 

Injection, Fabric Filter

wet scrubber, ACI, improve fabric 

filter

PALehighCementEvansville 122

Cyclone: Single, Dry Limestone 

Injection, Fabric Filter

wet scrubber, ACI, improve fabric 

filter

PALehighCementYork 200 Electrostatic Precipitator RTO, fabric filter

TXAshGroveMidlothian Kiln 1

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

TXAshGroveMidlothian Kiln 2

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

TXAshGroveMidlothian Kiln 3

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

TXHolcimMidlothianPlant Kiln 1

Fabric Filter, Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR), Wet 

Scrubber improve fabric filter, RTO, ACI

TXHolcimMidlothianPlant Kiln 2

Fabric Filter, Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR), Wet 

Scrubber improve fabric filter, ACI, RTO

UTHolcimDevilsSlide Kiln 1 Fabric Filter

wet scrubber, ACI, improve fabric 

filter

FacilityID UnitID ControlDevice Consolidated MACT Controls

ACI 

Monitoringa

Annual 

Control 

Device 

Inspection

Reporting and 

Recordkeeping

TCI

($)

TAC

($/yr)

TCI

($)

TAC

($/yr)

TCI

($)

TAC

($/yr)

TCI

($)

TAC

($/yr)

TAC

($/yr)

TAC

($/yr)

TAC

($/yr)

TCI

($)

TAC

($/yr)

$25,500 $9,700 $24,300 $5,600 $231,000 $112,600 $158,000 $56,100 $9,100 $1,000 $2,989 $479,467 $242,221

$231,000 $112,600 $158,000 $56,100 $9,600 $1,000 $2,989 $429,667 $227,421

$231,000 $112,600 $158,000 $56,100 $9,600 $1,000 $2,989 $429,667 $227,421

$24,300 $5,600 $231,000 $112,600 $158,000 $56,100 $10,100 $1,000 $2,989 $453,967 $233,521

$24,300 $5,600 $231,000 $112,600 $158,000 $56,100 $9,100 $1,000 $2,989 $464,267 $235,721

$24,300 $5,600 $231,000 $112,600 $158,000 $56,100 $9,000 $1,000 $2,989 $453,967 $232,421

$24,300 $5,600 $231,000 $112,600 $158,000 $56,100 $10,100 $1,000 $2,989 $453,967 $233,521

$24,300 $5,600 $231,000 $112,600 $158,000 $56,100 $8,600 $1,000 $2,989 $453,967 $232,021

$24,300 $5,600 $231,000 $112,600 $158,000 $56,100 $8,600 $1,000 $2,989 $453,967 $232,021

$24,300 $5,600 $231,000 $112,600 $158,000 $56,100 $8,600 $1,000 $2,989 $453,967 $232,021

$24,300 $5,600 $231,000 $112,600 $158,000 $56,100 $8,600 $1,000 $2,989 $453,967 $232,021

$24,300 $5,600 $231,000 $112,600 $158,000 $56,100 $8,600 $1,000 $2,989 $453,967 $232,021

$24,300 $5,600 $231,000 $112,600 $158,000 $56,100 $6,900 $1,000 $2,989 $453,967 $230,321

$24,300 $5,600 $231,000 $112,600 $158,000 $56,100 $5,800 $1,000 $2,989 $453,967 $229,221

$24,300 $5,600 $231,000 $112,600 $158,000 $56,100 $10,100 $1,000 $2,989 $453,967 $233,521

$24,300 $5,600 $231,000 $112,600 $158,000 $56,100 $10,100 $1,000 $2,989 $453,967 $233,521

$25,500 $9,700 $231,000 $112,600 $158,000 $56,100 $0 $1,000 $2,989 $455,167 $227,521

$25,500 $9,700 $24,300 $5,600 $231,000 $112,600 $158,000 $56,100 $9,600 $1,000 $2,989 $479,467 $242,721

$25,500 $9,700 $24,300 $5,600 $231,000 $112,600 $158,000 $56,100 $9,600 $1,000 $2,989 $479,467 $242,721

$25,500 $9,700 $24,300 $5,600 $231,000 $112,600 $158,000 $56,100 $9,600 $1,000 $479,467 $239,732

$231,000 $112,600 $158,000 $56,100 $7,400 $1,000 $2,989 $429,667 $225,221

$231,000 $112,600 $158,000 $56,100 $8,000 $1,000 $2,989 $429,667 $225,821

$24,300 $5,600 $231,000 $112,600 $158,000 $56,100 $9,100 $1,000 $2,989 $453,967 $232,521

$48,500 $195,800

Bag Leak 

Detector

Add PBS 

Monitoring Hg CEMS PM CEMS/PM CPMS

Monitoring, Reporting, 

and Recordkeeping 

Subtotals
Table 2E. Waste-Burning Kilns: Costs to Meet MACT Floor (6 of 6)

ALNationalCementRagland Kiln Electrostatic Precipitator

ACI, fabric filter, wet scrubber, 

RTO

CACAPortlandCementColton K-1

Collectors, Settling Chambers, 

Separators - General, Cyclone: 

Multiple (Multiclone), Fabric Filter improve fabric filter, RTO, ACI

CACAPortlandCementColton K-2

Collectors, Settling Chambers, 

Separators - General, Cyclone: 

Multiple (Multiclone), Fabric Filter improve fabric filter, RTO, ACI

CALehighSouthwestReddingPlant

In-Line Kiln/Raw 

Mill (S260) Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI, 

FLCemexMiami Cement Kiln Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI, SNCR

IALafargeBuffalo Kiln 1 Fabric Filter

improve fabric filter, wet scrubber, 

ACI

IALehighCementMasonCity 302.203

Electrostatic Precipitator, Fabric 

Filter, Flue Gas Desulfurization 

(General), Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR)

wet scrubber, improve fabric filter, 

ACI

MILafargeMidwestAlpena 19 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 20 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 21 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 22 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 23 low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

PALafargeWhitehallPlant Kiln 2 Fabric Filter

RTO, wet scrubber, ACI, improve 

fabric filter

PALafargeWhitehallPlant Kiln 3 Fabric Filter

RTO, wet scrubber, ACI, improve 

fabric filter

PALehighCementEvansville 121

Cyclone: Single, Dry Limestone 

Injection, Fabric Filter

wet scrubber, ACI, improve fabric 

filter

PALehighCementEvansville 122

Cyclone: Single, Dry Limestone 

Injection, Fabric Filter

wet scrubber, ACI, improve fabric 

filter

PALehighCementYork 200 Electrostatic Precipitator RTO, fabric filter

TXAshGroveMidlothian Kiln 1

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

TXAshGroveMidlothian Kiln 2

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

TXAshGroveMidlothian Kiln 3

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

TXHolcimMidlothianPlant Kiln 1

Fabric Filter, Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR), Wet 

Scrubber improve fabric filter, RTO, ACI

TXHolcimMidlothianPlant Kiln 2

Fabric Filter, Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR), Wet 

Scrubber improve fabric filter, ACI, RTO

UTHolcimDevilsSlide Kiln 1 Fabric Filter

wet scrubber, ACI, improve fabric 

filter

FacilityID UnitID ControlDevice Consolidated MACT Controls

TCI

($)

TAC

($/yr)

$45,577,213 $15,011,906

$8,213,772 $3,031,826

$12,158,625 $5,236,163

$18,577,360 $6,546,410

$32,322,748 $10,889,692

$11,248,984 $4,383,329

$12,410,582 $5,565,636

$15,603,858 $4,748,396

$15,997,939 $4,878,965

$16,276,123 $4,971,489

$24,092,687 $7,627,681

$24,049,054 $7,613,178

$12,668,260 $3,488,850

$9,692,581 $2,624,662

$6,165,155 $2,689,200

$6,367,486 $2,328,279

$11,973,686 $3,488,933

$10,464,733 $3,466,686

$12,650,394 $4,161,783

$13,054,010 $4,286,091

$19,147,233 $9,698,639

$20,150,011 $10,445,283

$12,360,003 $5,251,070

$371,222,497 $132,434,143

Total MACT Floor Control, 

Monitoring, Reporting, and 

Recordkeeping Cost
Table 2E. Waste-Burning Kilns: Costs to Meet MACT Floor (1 of 5)

Elec Water

TCI

($)

TCI 

($/dscfm)

TAC

($/yr)

TAC

($/yr/dscfm)

TCI

($)

TCI 

($/dscfm)

TAC

($/yr)

TAC

($/yr/dscfm) Mw gal/yr

TCI

($)

ALNationalCementRagland Kiln

Precalciner/Prehea

ter Electrostatic Precipitator

ACI, fabric filter, wet scrubber, 

RTO

DIFF, robust RTO

$26,873,350 $148.85 $8,074,303 $45 $2,052,261

CACAPortlandCementColton K-1 Long kiln

Collectors, Settling Chambers, 

Separators - General, Cyclone: 

Multiple (Multiclone), Fabric Filter improve fabric filter, RTO, ACI DIFF $10,899,897 $156.99 $3,380,847 $49

CACAPortlandCementColton K-2 Long kiln

Collectors, Settling Chambers, 

Separators - General, Cyclone: 

Multiple (Multiclone), Fabric Filter improve fabric filter, RTO, ACI DIFF $20,685,856 $150.44 $6,367,525 $46

CALehighSouthwestReddingPlant

In-Line Kiln/Raw 

Mill (S260)

Precalciner/Prehea

ter Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI, 

DIFF, robust RTO

$17,681,816 $151.64 $4,806,550 $41 $1,578,770

FLCemexMiami Cement Kiln

Precalciner/Prehea

ter Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI, SNCR

robust RTO

$2,273,830

IALafargeBuffalo Kiln 1

Precalciner/Prehea

ter Fabric Filter

improve fabric filter, wet scrubber, 

ACI

RTO, DIFF

$25,015,576 $149.24 $6,461,834 $39 $13,085,462

IALehighCementMasonCity 302.203

Precalciner/Prehea

ter

Electrostatic Precipitator, Fabric 

Filter, Flue Gas Desulfurization 

(General), Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR)

wet scrubber, improve fabric filter, 

ACI

RTO, DIFF

$27,682,165 $148.69 $7,442,558 $40 $13,935,979

MILafargeMidwestAlpena 19 Long kiln low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

DIFF

$14,103,446 $153.77 $4,171,782 $45

MILafargeMidwestAlpena 20 Long kiln low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

DIFF

$14,567,998 $153.43 $4,307,505 $45

MILafargeMidwestAlpena 21 Long kiln low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

DIFF

$14,897,805 $153.20 $4,403,860 $45

MILafargeMidwestAlpena 22 Long kiln low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

DIFF

$24,698,458 $149.31 $7,267,188 $44

MILafargeMidwestAlpena 23 Long kiln low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

DIFF

$24,641,302 $149.33 $7,250,490 $44

PALafargeWhitehallPlant Kiln 2

Precalciner/Prehea

ter Fabric Filter

RTO, wet scrubber, ACI, improve 

fabric filter

DIFF, robust RTO 

$10,750,356 $157.19 $2,592,510 $38 $1,146,271

PALafargeWhitehallPlant Kiln 3

Precalciner/Prehea

ter Fabric Filter

RTO, wet scrubber, ACI, improve 

fabric filter

DIFF, robust RTO 

$7,582,611 $163.57 $1,756,661 $38 $907,726

PALehighCementEvansville 121 Long kiln

Cyclone: Single, Dry Limestone 

Injection, Fabric Filter

wet scrubber, ACI, improve fabric 

filter RTO

PALehighCementEvansville 122 Long kiln

Cyclone: Single, Dry Limestone 

Injection, Fabric Filter

wet scrubber, ACI, improve fabric 

filter RTO

PALehighCementYork 200 Long kiln Electrostatic Precipitator RTO, fabric filter ACI, DIFF, improve FF $7,478,474 $163.88 $2,133,898 $47

TXAshGroveMidlothian Kiln 1 Long kiln

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber RTO, DIFF

$8,602,408 $160.94 $2,679,317 $50

TXAshGroveMidlothian Kiln 2 Long kiln

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber RTO, DIFF

$10,464,251 $157.59 $3,248,742 $49

TXAshGroveMidlothian Kiln 3 Long kiln

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber RTO, DIFF

$10,808,134 $157.11 $3,352,449 $49

TXHolcimMidlothianPlant Kiln 1

Precalciner/Prehea

ter

Fabric Filter, Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR), Wet 

Scrubber improve fabric filter, RTO, ACI DIFF, robust RTO $43,997,785 $146.83 $10,615,062 $35 $2,781,387

TXHolcimMidlothianPlant Kiln 2

Precalciner/Prehea

ter

Fabric Filter, Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR), Wet 

Scrubber improve fabric filter, ACI, RTO DIFF, robust RTO $47,912,662 $146.57 $11,822,762 $36 $2,930,398

UTHolcimDevilsSlide Kiln 1

Precalciner/Prehea

ter Fabric Filter

wet scrubber, ACI, improve fabric 

filter RTO, DIFF $27,566,040 $148.72 $7,129,010 $38 $19,535,985

$109,264,852 0 0 $13,899,668

Consolidated MACT Controls

Add DIFF Add Packed Bed Scrubber Add RTO/

Beyond the Floor Control 

Options

FacilityID UnitID Kiln Type ControlDevice
Table 2E. Waste-Burning Kilns: Costs to Meet MACT Floor (2 of 5)

ALNationalCementRagland Kiln

Precalciner/Prehea

ter Electrostatic Precipitator

ACI, fabric filter, wet scrubber, 

RTO

CACAPortlandCementColton K-1 Long kiln

Collectors, Settling Chambers, 

Separators - General, Cyclone: 

Multiple (Multiclone), Fabric Filter improve fabric filter, RTO, ACI

CACAPortlandCementColton K-2 Long kiln

Collectors, Settling Chambers, 

Separators - General, Cyclone: 

Multiple (Multiclone), Fabric Filter improve fabric filter, RTO, ACI

CALehighSouthwestReddingPlant

In-Line Kiln/Raw 

Mill (S260)

Precalciner/Prehea

ter Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI, 

FLCemexMiami Cement Kiln

Precalciner/Prehea

ter Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI, SNCR

IALafargeBuffalo Kiln 1

Precalciner/Prehea

ter Fabric Filter

improve fabric filter, wet scrubber, 

ACI

IALehighCementMasonCity 302.203

Precalciner/Prehea

ter

Electrostatic Precipitator, Fabric 

Filter, Flue Gas Desulfurization 

(General), Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR)

wet scrubber, improve fabric filter, 

ACI

MILafargeMidwestAlpena 19 Long kiln low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 20 Long kiln low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 21 Long kiln low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 22 Long kiln low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 23 Long kiln low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

PALafargeWhitehallPlant Kiln 2

Precalciner/Prehea

ter Fabric Filter

RTO, wet scrubber, ACI, improve 

fabric filter

PALafargeWhitehallPlant Kiln 3

Precalciner/Prehea

ter Fabric Filter

RTO, wet scrubber, ACI, improve 

fabric filter

PALehighCementEvansville 121 Long kiln

Cyclone: Single, Dry Limestone 

Injection, Fabric Filter

wet scrubber, ACI, improve fabric 

filter

PALehighCementEvansville 122 Long kiln

Cyclone: Single, Dry Limestone 

Injection, Fabric Filter

wet scrubber, ACI, improve fabric 

filter

PALehighCementYork 200 Long kiln Electrostatic Precipitator RTO, fabric filter

TXAshGroveMidlothian Kiln 1 Long kiln

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

TXAshGroveMidlothian Kiln 2 Long kiln

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

TXAshGroveMidlothian Kiln 3 Long kiln

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

TXHolcimMidlothianPlant Kiln 1

Precalciner/Prehea

ter

Fabric Filter, Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR), Wet 

Scrubber improve fabric filter, RTO, ACI

TXHolcimMidlothianPlant Kiln 2

Precalciner/Prehea

ter

Fabric Filter, Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR), Wet 

Scrubber improve fabric filter, ACI, RTO

UTHolcimDevilsSlide Kiln 1

Precalciner/Prehea

ter Fabric Filter

wet scrubber, ACI, improve fabric 

filter

FacilityID UnitID Kiln Type ControlDevice Consolidated MACT Controls

TCI 

($/dscfm)

TAC

($/yr)

TAC

($/yr/dscfm)

$2,277,037

$1,415,159

$2,473,322

$78 $3,792,214 $23

$75 $4,101,303 $22

$876,059

$622,226

$3,381,757

$3,668,863

$60 $6,290,742 $19

$75 $28,898,682 $22

Add RTO/Adjust MACT RTO
Table 2E. Waste-Burning Kilns: Costs to Meet MACT Floor (3 of 5)

ALNationalCementRagland Kiln

Precalciner/Prehea

ter Electrostatic Precipitator

ACI, fabric filter, wet scrubber, 

RTO

CACAPortlandCementColton K-1 Long kiln

Collectors, Settling Chambers, 

Separators - General, Cyclone: 

Multiple (Multiclone), Fabric Filter improve fabric filter, RTO, ACI

CACAPortlandCementColton K-2 Long kiln

Collectors, Settling Chambers, 

Separators - General, Cyclone: 

Multiple (Multiclone), Fabric Filter improve fabric filter, RTO, ACI

CALehighSouthwestReddingPlant

In-Line Kiln/Raw 

Mill (S260)

Precalciner/Prehea

ter Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI, 

FLCemexMiami Cement Kiln

Precalciner/Prehea

ter Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI, SNCR

IALafargeBuffalo Kiln 1

Precalciner/Prehea

ter Fabric Filter

improve fabric filter, wet scrubber, 

ACI

IALehighCementMasonCity 302.203

Precalciner/Prehea

ter

Electrostatic Precipitator, Fabric 

Filter, Flue Gas Desulfurization 

(General), Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR)

wet scrubber, improve fabric filter, 

ACI

MILafargeMidwestAlpena 19 Long kiln low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 20 Long kiln low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 21 Long kiln low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 22 Long kiln low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 23 Long kiln low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

PALafargeWhitehallPlant Kiln 2

Precalciner/Prehea

ter Fabric Filter

RTO, wet scrubber, ACI, improve 

fabric filter

PALafargeWhitehallPlant Kiln 3

Precalciner/Prehea

ter Fabric Filter

RTO, wet scrubber, ACI, improve 

fabric filter

PALehighCementEvansville 121 Long kiln

Cyclone: Single, Dry Limestone 

Injection, Fabric Filter

wet scrubber, ACI, improve fabric 

filter

PALehighCementEvansville 122 Long kiln

Cyclone: Single, Dry Limestone 

Injection, Fabric Filter

wet scrubber, ACI, improve fabric 

filter

PALehighCementYork 200 Long kiln Electrostatic Precipitator RTO, fabric filter

TXAshGroveMidlothian Kiln 1 Long kiln

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

TXAshGroveMidlothian Kiln 2 Long kiln

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

TXAshGroveMidlothian Kiln 3 Long kiln

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

TXHolcimMidlothianPlant Kiln 1

Precalciner/Prehea

ter

Fabric Filter, Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR), Wet 

Scrubber improve fabric filter, RTO, ACI

TXHolcimMidlothianPlant Kiln 2

Precalciner/Prehea

ter

Fabric Filter, Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR), Wet 

Scrubber improve fabric filter, ACI, RTO

UTHolcimDevilsSlide Kiln 1

Precalciner/Prehea

ter Fabric Filter

wet scrubber, ACI, improve fabric 

filter

FacilityID UnitID Kiln Type ControlDevice Consolidated MACT Controls

Tune-up

TCI

($)

TCI 

($/dscfm)

TAC

($/yr)

TAC

($/yr/dscfm)

TCI

($)

TCI 

($/dscfm)

TAC

($/yr)

TAC

($/yr/dscfm)

TAC

($/yr)

TAC

($/yr/dscfm)

TCI

($)

TCI 

($/dscfm)

TAC

($/yr)

TAC

($/yr/dscf

m)

TCI

($)

$2,296,194 $33.07 $258,432 $3.72 $31,221,805 $182 $10,609,773 $48 $10,300

$10,899,897 $157 $3,380,847 $49

$20,685,856 $150 $6,367,525 $46

$19,260,586 $152 $6,221,708 $41

$2,273,830 $0 $2,473,322 $0

$38,101,037 $227 $10,254,048 $61

$41,618,144 $224 $11,543,861 $62

$14,103,446 $154 $4,171,782 $45

$14,567,998 $153 $4,307,505 $45

$14,897,805 $153 $4,403,860 $45

$24,698,458 $149 $7,267,188 $44

$24,641,302 $149 $7,250,490 $44

$11,896,627 $157 $3,468,568 $38

$8,490,338 $164 $2,378,888 $38

$0 $0 $0 $0

$0 $0 $0 $0

$56,571 $1.24 $681,499 $14.93 $7,535,045 $165 $2,815,397 $62

$8,602,408 $161 $2,679,317 $50

$10,464,251 $158 $3,248,742 $49

$10,808,134 $157 $3,352,449 $49

$46,779,173 $147 $13,996,818 $35 $10,300

$50,843,060 $147 $15,491,625 $36 $10,300

$47,102,025 $208 $13,419,752 $58

$681,499 $258,432

Add ACI SNCR/SCR Controls Subtotals

Add SNCR 

Monitoring
Table 2E. Waste-Burning Kilns: Costs to Meet MACT Floor (4 of 5)

ALNationalCementRagland Kiln

Precalciner/Prehea

ter Electrostatic Precipitator

ACI, fabric filter, wet scrubber, 

RTO

CACAPortlandCementColton K-1 Long kiln

Collectors, Settling Chambers, 

Separators - General, Cyclone: 

Multiple (Multiclone), Fabric Filter improve fabric filter, RTO, ACI

CACAPortlandCementColton K-2 Long kiln

Collectors, Settling Chambers, 

Separators - General, Cyclone: 

Multiple (Multiclone), Fabric Filter improve fabric filter, RTO, ACI

CALehighSouthwestReddingPlant

In-Line Kiln/Raw 

Mill (S260)

Precalciner/Prehea

ter Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI, 

FLCemexMiami Cement Kiln

Precalciner/Prehea

ter Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI, SNCR

IALafargeBuffalo Kiln 1

Precalciner/Prehea

ter Fabric Filter

improve fabric filter, wet scrubber, 

ACI

IALehighCementMasonCity 302.203

Precalciner/Prehea

ter

Electrostatic Precipitator, Fabric 

Filter, Flue Gas Desulfurization 

(General), Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR)

wet scrubber, improve fabric filter, 

ACI

MILafargeMidwestAlpena 19 Long kiln low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 20 Long kiln low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 21 Long kiln low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 22 Long kiln low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 23 Long kiln low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

PALafargeWhitehallPlant Kiln 2

Precalciner/Prehea

ter Fabric Filter

RTO, wet scrubber, ACI, improve 

fabric filter

PALafargeWhitehallPlant Kiln 3

Precalciner/Prehea

ter Fabric Filter

RTO, wet scrubber, ACI, improve 

fabric filter

PALehighCementEvansville 121 Long kiln

Cyclone: Single, Dry Limestone 

Injection, Fabric Filter

wet scrubber, ACI, improve fabric 

filter

PALehighCementEvansville 122 Long kiln

Cyclone: Single, Dry Limestone 

Injection, Fabric Filter

wet scrubber, ACI, improve fabric 

filter

PALehighCementYork 200 Long kiln Electrostatic Precipitator RTO, fabric filter

TXAshGroveMidlothian Kiln 1 Long kiln

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

TXAshGroveMidlothian Kiln 2 Long kiln

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

TXAshGroveMidlothian Kiln 3 Long kiln

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

TXHolcimMidlothianPlant Kiln 1

Precalciner/Prehea

ter

Fabric Filter, Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR), Wet 

Scrubber improve fabric filter, RTO, ACI

TXHolcimMidlothianPlant Kiln 2

Precalciner/Prehea

ter

Fabric Filter, Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR), Wet 

Scrubber improve fabric filter, ACI, RTO

UTHolcimDevilsSlide Kiln 1

Precalciner/Prehea

ter Fabric Filter

wet scrubber, ACI, improve fabric 

filter

FacilityID UnitID Kiln Type ControlDevice Consolidated MACT Controls

TAC

($/yr)

$3,200

$3,200

$3,200

$9,600

Add SNCR 

Monitoring
Table 2E. Waste-Burning Kilns: Costs to Meet MACT Floor (5 of 5)

ALNationalCementRagland Kiln

Precalciner/Prehea

ter Electrostatic Precipitator

ACI, fabric filter, wet scrubber, 

RTO

CACAPortlandCementColton K-1 Long kiln

Collectors, Settling Chambers, 

Separators - General, Cyclone: 

Multiple (Multiclone), Fabric Filter improve fabric filter, RTO, ACI

CACAPortlandCementColton K-2 Long kiln

Collectors, Settling Chambers, 

Separators - General, Cyclone: 

Multiple (Multiclone), Fabric Filter improve fabric filter, RTO, ACI

CALehighSouthwestReddingPlant

In-Line Kiln/Raw 

Mill (S260)

Precalciner/Prehea

ter Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI, 

FLCemexMiami Cement Kiln

Precalciner/Prehea

ter Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI, SNCR

IALafargeBuffalo Kiln 1

Precalciner/Prehea

ter Fabric Filter

improve fabric filter, wet scrubber, 

ACI

IALehighCementMasonCity 302.203

Precalciner/Prehea

ter

Electrostatic Precipitator, Fabric 

Filter, Flue Gas Desulfurization 

(General), Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR)

wet scrubber, improve fabric filter, 

ACI

MILafargeMidwestAlpena 19 Long kiln low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 20 Long kiln low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 21 Long kiln low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 22 Long kiln low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

MILafargeMidwestAlpena 23 Long kiln low-NOx burners, Fabric Filter

improve fabric filter, RTO, wet 

scrubber, ACI

PALafargeWhitehallPlant Kiln 2

Precalciner/Prehea

ter Fabric Filter

RTO, wet scrubber, ACI, improve 

fabric filter

PALafargeWhitehallPlant Kiln 3

Precalciner/Prehea

ter Fabric Filter

RTO, wet scrubber, ACI, improve 

fabric filter

PALehighCementEvansville 121 Long kiln

Cyclone: Single, Dry Limestone 

Injection, Fabric Filter

wet scrubber, ACI, improve fabric 

filter

PALehighCementEvansville 122 Long kiln

Cyclone: Single, Dry Limestone 

Injection, Fabric Filter

wet scrubber, ACI, improve fabric 

filter

PALehighCementYork 200 Long kiln Electrostatic Precipitator RTO, fabric filter

TXAshGroveMidlothian Kiln 1 Long kiln

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

TXAshGroveMidlothian Kiln 2 Long kiln

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

TXAshGroveMidlothian Kiln 3 Long kiln

Electrostatic Precipitator, 

Selective Non-Catalytic 

Reduction (NH3 Or Urea 

Injection) (SNCR)

ACI, fabric filter, wet scrubber

TXHolcimMidlothianPlant Kiln 1

Precalciner/Prehea

ter

Fabric Filter, Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR), Wet 

Scrubber improve fabric filter, RTO, ACI

TXHolcimMidlothianPlant Kiln 2

Precalciner/Prehea

ter

Fabric Filter, Selective NonCatalytic Reduction (NH3 Or 

Urea Injection) (SNCR), Wet 

Scrubber improve fabric filter, ACI, RTO

UTHolcimDevilsSlide Kiln 1

Precalciner/Prehea

ter Fabric Filter

wet scrubber, ACI, improve fabric 

filter

FacilityID UnitID Kiln Type ControlDevice Consolidated MACT Controls

ACI 

Monitoringa

TCI

($)

TAC

($/yr)

TAC

($/yr)

TCI

($)

TAC

($/yr)

TCI

($)

TAC

($/yr)

$18,000 $18,100 $28,300 $21,300 $31,250,105 $10,631,073

$18,000 $18,800 $18,000 $18,800 $10,917,897 $3,399,647

$18,000 $18,800 $18,000 $18,800 $20,703,856 $6,386,325

$18,000 $19,600 $18,000 $19,600 $19,278,586 $6,241,308

$0 $0 $2,273,830 $2,473,322

$18,000 $17,800 $18,000 $17,800 $38,119,037 $10,271,848

$19,600 $0 $19,600 $41,618,144 $11,563,461

$18,000 $17,500 $18,000 $17,500 $14,121,446 $4,189,282

$18,000 $17,500 $18,000 $17,500 $14,585,998 $4,325,005

$18,000 $17,500 $18,000 $17,500 $14,915,805 $4,421,360

$18,000 $17,500 $18,000 $17,500 $24,716,458 $7,284,688

$18,000 $17,500 $18,000 $17,500 $24,659,302 $7,267,990

$18,000 $14,800 $18,000 $14,800 $11,914,627 $3,483,368

$18,000 $13,000 $18,000 $13,000 $8,508,338 $2,391,888

$0 $0 $0 $0

$0 $0 $0 $0

$18,000 $19,600 $10,100 $18,000 $29,700 $7,553,045 $2,845,097

$18,000 $18,800 $18,000 $18,800 $8,620,408 $2,698,117

$18,000 $18,800 $18,000 $18,800 $10,482,251 $3,267,542

$18,000 $18,800 $18,000 $18,800 $10,826,134 $3,371,249

$18,000 $15,600 $28,300 $18,800 $46,807,473 $14,015,618

$18,000 $16,400 $28,300 $19,600 $50,871,360 $15,511,225

$18,000 $18,000 $18,000 $18,000 $47,120,025 $13,437,752

$354,000 $10,100 $459,864,125 $139,477,166

Total MACT Floor Control, 

Monitoring, Reporting, and 

Recordkeeping Cost

Monitoring, Reporting, 

and Recordkeeping 

DIFF Monitoring Subtotals
ALNationalCementRagland Kiln Waste-burning kiln 7920 416

million 

Btu/hr

CACAPortlandCementColton K-1 Waste-burning kiln 8322 260

million 

Btu/hr

CACAPortlandCementColton K-2 Waste-burning kiln 8322 260

million 

Btu/hr

CALehighSouthwestReddingPlant In-Line Kiln/Raw Mill (S260) Waste-burning kiln 8760 294.292825 million Btu/hr

FLCemexMiami Cement Kiln Waste-burning kiln 7900 485

million 

Btu/hr

IALafargeBuffalo Kiln 1 Waste-burning kiln 7800 356.5

million 

Btu/hr

IALehighCementMasonCity 302.203 Waste-burning kiln 8760 294.292825 million Btu/hr

MILafargeMidwestAlpena 19 Waste-burning kiln 7540 239 MMBtu/hr

MILafargeMidwestAlpena 20 Waste-burning kiln 7540 247 MMBtu/hr

MILafargeMidwestAlpena 21 Waste-burning kiln 7540 253 MMBtu/hr

MILafargeMidwestAlpena 22 Waste-burning kiln 7540 431 MMBtu/hr

MILafargeMidwestAlpena 23 Waste-burning kiln 7540 430 MMBtu/hr

PALafargeWhitehallPlant Kiln 2 Waste-burning kiln 6000 102

million 

Btu/hr

PALafargeWhitehallPlant Kiln 3 Waste-burning kiln 5000 102

million 

Btu/hr

PALehighCementEvansville 121 Waste-burning kiln 8760 260

million 

Btu/hr

PALehighCementEvansville 122 Waste-burning kiln 8760 260

million 

Btu/hr

PALehighCementYork 200 Waste-burning kiln 8760 180

million 

Btu/hr

TXAshGroveMidlothian Kiln 1 Waste-burning kiln 8322 221

million 

Btu/hr

TXAshGroveMidlothian Kiln 2 Waste-burning kiln 8322 217

million 

Btu/hr

TXAshGroveMidlothian Kiln 3 Waste-burning kiln 8322 216

million 

Btu/hr

TXHolcimMidlothianPlant Kiln 1 Waste-burning kiln 6437 294.292825 million Btu/hr

TXHolcimMidlothianPlant Kiln 2 Waste-burning kiln 6955 294.292825 million Btu/hr

UTHolcimDevilsSlide Kiln 1 Waste-burning kiln 7861.117647 294.292825 million Btu/hr

added 092711

Design 

Capacity

Design 

Capacity

Units

Operating Hours 

(hr/yr)

Subcategory

Data Gap: Assumed same as similar unit

Data Gap: Assumed average for subcategory

FacilityID UnitID

Data Gap: Filled using defaults previously used for proposal
PM and HCl baselines updated 8/20/12

PM Filt HCl

gr/dscf ppmvd

18 9.17 180543 213943 290674 273.00 0.26 0.0107255 5.982760939 0.85

19 9.17 69432 82277 111786 400 0.26 0.0107255 0.96417092 0.64

19 9.17 137503 162940 221380 400 0.26 0.0107255

0.96417092

0.73

19.33538749 116607 116607 181037.4742 400 0.26 0.0107255 14.865 0.85

14.00833333 12.56666667 214185.2813 128408.44 294945.7165 400 0.26 0.0107255 5.982760939 0.85

14.36 8.783333333 167620.3894 146115.14 294945.7165 296.877778 0.26 0.007131 5.982760939 0.68

16.17238095 12.46666667 186169.0947 112951.51 294945.7165 144.738889 0.26 0.0085787 5.982760939 0.85

4.5 9.17 91715.97758 108683.04 155834.7145 400 0.26 0.0107255 30.77905791 0.48

4.5 9.17 94947.38966 112512.25 161325.2101 400 0.26 0.0107255 30.77905791 0.48

4.5 9.17 97241.51133 115230.78 165223.1547 400 0.26 0.0107255 30.77905791 0.48

4.5 9.17 165414.5284 196015.51 281056 400 0.26 0.0107255 30.77905791 0.48

4.5 9.17 165016.9553 195544.39 280380.4831 400 0.26 0.0107255 30.77905791 0.48

13.76666667 68392 68392 100715.0685 400 0.26 0.0004479 5.982760939 0.28

13.76666667 46357.27273 46357.273 100715.0685 356.952381 0.26 0.0006787 5.982760939 0.28

20.27453416 6.69684739 86525.88582 88412.976 151854.3085 356.952381 0.26 0.0017715 5.982760939 0.76

19.71753086 6.766881092 89749.61061 91254.814 151854.3085 378.553398 0.26 0.004786 5.982760939 0.45

32.90024845 7.898947368 45632.9 42681.708 294945.7165 400 0.61 0.0159045 0.399364282 0.39

35.51314815 6.644827586 53450.94828 54816.725 87474.97499 400 0.61 0.0065373 2.100951474 0.48

35.1225 6.4796875 66401.85938 68887.451 101511.5234 400 0.61 0.0192853 0.589851696 0.48

34.78956835 7.117985612 68793.89928 68209.965 101162.2011 400 0.61 0.006935 0.472133909 0.48

19.33538749 299660 299660 294945.7165 400 0.26 0.0497977 0.280006443 0.95

19.33538749 326891.75 326891.75 294945.7165 400 0.26 0.0048187 0.280006443 0.89

10.16666667 185361.3333 185361.33 294945.7165 400 0.26 0.0231511 5.15 0.85

added 092711

Average 

Moisture (%)

Average O2 

(%)

ACI 

adjustm

ent 

factor

Stack Gas 

Temp 

(°F)

Fraction 

PM that is 

PM 2.5

Stack Gas 

Flow Rate 

(dscfm)

Stack Gas 

Flow Rate 

(acfm)

dscfm @ 

7% O2
 updated 8/20/12

SO2 PM baseline 

ppmvd

(mg/dscm)

741.3333333 24.54052581

741.3333333 24.54052581

741.3333333 24.54052581

15.79 24.54052581

0.30 24.54052581

5.00 16.31615658

0.39 19.62853987

741.3333333 24.54052581

741.3333333 24.54052581

741.3333333 24.54052581

741.3333333 24.54052581

741.3333333 24.54052581

2.11 1.024854088

2.11 1.552829783

0.32 4.053167326

0.11 10.95067978

120.88 (use SO2 value instead of HCl for scrubber algorithm) 36.39031576

741.3333333 14.95765076

741.3333333 44.12569525

741.33 15.86754213

2.19 113.9394988

3.23 11.02545206

0.93 52.97089577
Activated Carbon Injection Model Costs

Unit-specific field Unit-specific field Unit-specific field

Facility name Combustion equipment Annual operating 

hours (H)

hr/yr 

ALNationalCementRagland Kiln 7,920

CACAPortlandCementColton K-1 8,322

CACAPortlandCementColton K-2 8,322

CALehighSouthwestReddingPlant In-Line Kiln/Raw Mill (S260) 8,760

FLCemexMiami Cement Kiln 7,900

IALafargeBuffalo Kiln 1 7,800

IALehighCementMasonCity 302.203 8,760

MDLehighCementUnionBridge E02-001 8,322

MILafargeMidwestAlpena 19 7,540

MILafargeMidwestAlpena 20 7,540

MILafargeMidwestAlpena 21 7,540

MILafargeMidwestAlpena 22 7,540

MILafargeMidwestAlpena 23 7,540

PALafargeWhitehallPlant Kiln 2 6,000

PALafargeWhitehallPlant Kiln 3 5,000

PALehighCementEvansville 121 8,760

PALehighCementEvansville 122 8,760

PALehighCementYork 200 8,760

TXAshGroveMidlothian Kiln 1 8,322

TXAshGroveMidlothian Kiln 2 8,322

TXAshGroveMidlothian Kiln 3 8,322

TXHolcimMidlothianPlant Kiln 1 6,437

TXHolcimMidlothianPlant Kiln 2 6,955

UTHolcimDevilsSlide Kiln 1 7,861

Facility/Unit ID
Unit-specific field

Exhaust gas flow 

rate (Q)

Operating labor 

rate (LR)

Activated carbon 

cost (ACC)

Dust disposal cost 

(DDC)

dscfm $/hr $/lb $/ton

180,543 $34.60 $1.38 $34.29

69,432 $34.60 $1.38 $34.29

137,503 $34.60 $1.38 $34.29

116,607 $34.60 $1.38 $34.29

214,185 $34.60 $1.38 $34.29

167,620 $34.60 $1.38 $34.29

186,169 $34.60 $1.38 $34.29

267,395 $34.60 $1.38 $34.29

91,716 $34.60 $1.38 $34.29

94,947 $34.60 $1.38 $34.29

97,242 $34.60 $1.38 $34.29

165,415 $34.60 $1.38 $34.29

165,017 $34.60 $1.38 $34.29

68,392 $34.60 $1.38 $34.29

46,357 $34.60 $1.38 $34.29

86,526 $34.60 $1.38 $34.29

89,750 $34.60 $1.38 $34.29

45,633 $34.60 $1.38 $34.29

53,451 $34.60 $1.38 $34.29

66,402 $34.60 $1.38 $34.29

68,794 $34.60 $1.38 $34.29

299,660 $34.60 $1.38 $34.29

326,892 $34.60 $1.38 $34.29

185,361 $34.60 $1.38 $34.29
Unit-specific field

Capital recovery factor, 20-yr 

equipment life, 7% interest (CRF)

Cost Index 

2008

Cost Index 

1990

ACI Adjustment 

Factor (AF)

= [i x (1 + i)a] / [(1 + i)a - 1], where i = 

interest rate, a = equipment life

0.09439 575.4 361.3 0.85

0.09439 575.4 361.3 0.64

0.09439 575.4 361.3 0.73

0.09439 575.4 361.3 0.85

0.09439 575.4 361.3 0.85

0.09439 575.4 361.3 0.68

0.09439 575.4 361.3 0.85

0.09439 575.4 361.3 0.85

0.09439 575.4 361.3 0.48

0.09439 575.4 361.3 0.48

0.09439 575.4 361.3 0.48

0.09439 575.4 361.3 0.48

0.09439 575.4 361.3 0.48

0.09439 575.4 361.3 0.28

0.09439 575.4 361.3 0.28

0.09439 575.4 361.3 0.76

0.09439 575.4 361.3 0.45

0.09439 575.4 361.3 0.90

0.09439 575.4 361.3 0.48

0.09439 575.4 361.3 0.48

0.09439 575.4 361.3 0.48

0.09439 575.4 361.3 0.95

0.09439 575.4 361.3 0.89

0.09439 575.4 361.3 0.85
Total Unit cost Operating labor Supervisory

labor Maintenance

$ $/dscfm $/yr $/yr $/yr

= 4,500 x (Q/1,976)0.6 x (1.2 

retrofit factor) x (575.4/361.3) = $ / Q = (0.25 hr/8-hr 

shift) x H x LR

= 0.15 x 

(operating labor) = 0.2 x TCI

$129,114 $0.72 $8,564 $1,285 $25,823

$72,771 $1.05 $8,998 $1,350 $14,554

$109,651 $0.80 $8,998 $1,350 $21,930

$99,325 $0.85 $9,472 $1,421 $19,865

$143,053 $0.67 $8,542 $1,281 $28,611

$123,487 $0.74 $8,434 $1,265 $24,697

$131,513 $0.71 $9,472 $1,421 $26,303

$163,424 $0.61 $8,998 $1,350 $32,685

$85,998 $0.94 $8,153 $1,223 $17,200

$87,804 $0.92 $8,153 $1,223 $17,561

$89,071 $0.92 $8,153 $1,223 $17,814

$122,509 $0.74 $8,153 $1,223 $24,502

$122,332 $0.74 $8,153 $1,223 $24,466

$72,115 $1.05 $6,488 $973 $14,423

$57,108 $1.23 $5,406 $811 $11,422

$83,045 $0.96 $9,472 $1,421 $16,609

$84,887 $0.95 $9,472 $1,421 $16,977

$56,571 $1.24 $9,472 $1,421 $11,314

$62,201 $1.16 $8,998 $1,350 $12,440

$70,849 $1.07 $8,998 $1,350 $14,170

$72,369 $1.05 $8,998 $1,350 $14,474

$174,985 $0.58 $6,960 $1,044 $34,997

$184,360 $0.56 $7,520 $1,128 $36,872

$131,170 $0.71 $8,500 $1,275 $26,234

Capital Investment Direct Annual Costs
Activated carbon Dust disposal Overhead Property taxes, insurance, and 

administration

$/yr $/yr $/yr $/yr

= 0.00127 x Q x 

H x ACC x AF

= 0.00127 x Q x (1 ton/2,000 lb) 

x H x DDC x AF

= 0.6 x (labor + 

maintenance 

materials)

= 0.04 x TCI

$2,130,137 $26,465 $21,402 $5,165

$652,377 $8,105 $14,941 $2,911

$1,456,780 $18,099 $19,367 $4,386

$1,529,470 $19,002 $18,454 $3,973

$2,533,548 $31,477 $23,060 $5,722

$1,550,221 $19,260 $20,638 $4,939

$2,441,879 $30,338 $22,317 $5,261

$3,331,910 $41,395 $25,820 $6,537

$585,714 $7,277 $15,945 $3,440

$606,350 $7,533 $16,162 $3,512

$621,001 $7,715 $16,314 $3,563

$1,056,365 $13,124 $20,326 $4,900

$1,053,826 $13,093 $20,305 $4,893

$202,566 $2,517 $13,130 $2,885

$114,419 $1,422 $10,583 $2,284

$1,016,011 $12,623 $16,501 $3,322

$616,699 $7,662 $16,722 $3,395

$630,533 $7,834 $13,324 $2,263

$376,749 $4,681 $13,673 $2,488

$468,034 $5,815 $14,711 $2,834

$484,894 $6,024 $14,893 $2,895

$3,201,114 $39,770 $25,801 $6,999

$3,530,554 $43,863 $27,312 $7,374

$2,173,273 $27,001 $21,605 $5,247

Direct Annual Costs Indirect Annual Costs
Capital recovery

$/yr $/yr ($/yr) / dscfm ACI Dust

= CRF x TCI = Direct Annual Costs + 

Indirect Annual Costs = ($/yr) / Q

lb/yr ton/yr

$12,187 $2,231,027 $12.36 1,543,578 771.79

$6,869 $710,105 $10.23 472,737 236.37

$10,350 $1,541,260 $11.21 1,055,637 527.82

$9,376 $1,611,033 $13.82 1,108,312 554.16

$13,503 $2,645,744 $12.35 1,835,904 917.95

$11,656 $1,641,111 $9.79 1,123,349 561.67

$12,414 $2,549,403 $13.69 1,769,477 884.74

$15,426 $3,464,120 $12.96 2,414,427 1,207.21

$8,118 $647,068 $7.06 424,430 212.22

$8,288 $668,782 $7.04 439,384 219.69

$8,408 $684,190 $7.04 450,000 225.00

$11,564 $1,140,157 $6.89 765,482 382.74

$11,547 $1,137,506 $6.89 763,642 381.82

$6,807 $249,788 $3.65 146,787 73.39

$5,391 $151,737 $3.27 82,912 41.46

$7,839 $1,083,796 $12.53 736,240 368.12

$8,013 $680,362 $7.58 446,884 223.44

$5,340 $681,499 $14.93 456,908 228.45

$5,871 $426,250 $7.97 273,007 136.50

$6,688 $522,598 $7.87 339,155 169.58

$6,831 $540,359 $7.85 351,372 175.69

$16,517 $3,333,203 $11.12 2,319,648 1,159.82

$17,402 $3,672,026 $11.23 2,558,372 1,279.19

$12,382 $2,275,516 $12.28 1,574,836 787.42

Total cost

Total Annual Cost
3. Activated carbon cost: The Innovation Group. Chemical Profiles: Carbon, Activated. 2002. Assumed 20% price increase b

information from Norit, an activated carbon vendor.

4. Dust disposal cost: NSWMA’s 2005 Tip Fee Survey.
002. Assumed 20% price increase based on online
Packed Bed Scrubber Costs

Parameters/Costs Equation

ALNationalCem

entRagland

CACAPortland

CementColton

CACAPortland

CementColton

CALehighSouth

westReddingPl

ant FLCemexMiami IALafargeBuffalo

IALehighCementMaso

nCity

MDLehighCementUnionB

ridge

MILafargeMi

dwestAlpen

a

MILafargeMidwe

stAlpena

MILafargeMi

dwestAlpen

a MILafargeMidwestAlpena MILafargeMidwestAlpena

PALafarge

WhitehallPl

ant

PALafarge

WhitehallPl

ant

PALehighCe

mentEvansv

ille

PALehighCe

mentEvansvil

le

PALehighCe

mentYork

TXAshGrove

Midlothian

TXAshGrove

Midlothian

TXAshGrove

Midlothian

TXHolcimMi

dlothianPlan

t

TXHolcimMi

dlothianPlan

t

UTHolcimDevil

sSlide

Kiln K-1 K-2

In-Line 

Kiln/Raw Mill 

(S260) Cement Kiln Kiln 1 302.203 E02-001 19 20 21 22 23 Kiln 2 Kiln 3 121 122 200 Kiln 1 Kiln 2 Kiln 3 Kiln 1 Kiln 2 Kiln 1

A. Parameters

1. Incinerator capacity, lb/hr (C)

2. Temperature into quench, F (T1) 273 400 400 400 400 296.8777778 144.7388889 265.5 400 400 400 400 400 400 356.952381 356.952381 378.5533981 400 400 400 400 400 400 400

3. Temperature out of PB to ID fan, F (T2) 130 130 130 130 130 130 130 130 130 130 130 130 130 130 130 130 130 130 130 130 130 130 130 130

4. Annual operating hours, hr/yr (H) 7920 8322 8322 8760 7900 7800 8760 8322 7540 7540 7540 7540 7540 6000 5000 8760 8760 8760 8322 8322 8322 6437 6955 7861.117647

5. Exhaust gas flow rate, dscfm (Qd) 180543 69432 137503 116607 214185.2813 167620.3894 186169.0947 267394.9167 91715.9776 94947.38966 97241.5113 165414.5284 165016.9553 68392 46357.2727 86525.8858 89749.61061 45632.9 53450.9483 66401.8594 68793.8993 299660 326891.75 185361.3333

6. Assumed moisture content in gas entering 

quench, % (M) 18 19 19 19.33538749 14.00833333 14.36 16.17238095 13.09583333 4.5 4.5 4.5 4.5 4.5 13.7666667 13.7666667 20.2745342 19.71753086 32.9002484 35.5131481 35.1225 34.7895683 19.3353875 19.3353875 10.16666667

7. Exhaust gas flow rate, scfm (Qw) = (Qd) / (1 - M/100) 218,840 86,075 170,463 144,558 249,077 195,727 222,086 307,689 96,038 99,421 101,824 173,209 172,793 79,310 53,758 108,530 111,792 68,008 82,887 102,350 105,495 371,489 405,248 206,339

8. Water added in quench, scfm (Qh) = ((7.010 x (T1 - 77°F) - 6.958 x (T2 - 77°F)) 

x 0.9 + (8.154 x (T1 - 77°F) - 8.064 x (T2 - 

77°F)) x 0.1) x (lb-mole/385 scf) x Qw / 

(1,160 Btu/lb) / (18 lb/lb-mole) x (0.7302 ft3-

atm/lb-mol-°R) x 528°R / 1 atm

10,724 7,953 15,750 13,357 23,014 11,188 1,150 14,289 8,874 9,186 9,408 16,004 15,966 7,328 4,176 8,432 9,510 6,284 7,659 9,457 9,748 34,325 37,444 19,065

9. Actual flow out of PB, acfm (Qa) = (Qw + Qh) x (460°F + T2)/(528°R) 256,520 105,070 208,079 176,458 304,041 231,212 249,449 359,787 117,231 121,361 124,293 211,431 210,923 96,812 64,737 130,696 135,546 83,015 101,177 124,935 128,775 453,466 494,675 251,872

10. HCl concentration, ppmvd (HCl) 5.98 0.96 0.96 14.865 5.982760939 5.982760939 5.982760939 0.228770833 30.7790579 30.77905791 30.7790579 30.77905791 30.77905791 5.98276094 5.98276094 5.98276094 5.982760939 0.39936428 2.10095147 0.5898517 0.47213391 0.28000644 0.28000644 5.15

11. Operating 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 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60

12. Electricity cost, $/kWh (EC) $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 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07

13. Caustic cost, $/ton (CC) $357 $357 $357 $357 $357 $357 $357 $357 $357 $357 $357 $357 $357 $357 $357 $357 $357 $357 $357 $357 $357 $357 $357 $357

14. Sewage disposal cost, $/1,000 gal (SDC) $3.80 $3.80 $3.80 $3.80 $3.80 $3.80 $3.80 $3.80 $3.80 $3.80 $3.80 $3.80 $3.80 $3.80 $3.80 $3.80 $3.80 $3.80 $3.80 $3.80 $3.80 $3.80 $3.80 $3.80

15. Water cost, $/1,000 gal (WC) $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20

16. Assumed pressure drop through control 

system, inches of water (ΔP)

15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15

17. Surface area-to-volume ratio for 1" dia. 

Ceramic Raschig rings, ft2/ft3 (SAV)

58 58 58 58 58 58 58 58 58 58 58 58 58 58 58 58 58 58 58 58 58 58 58 58

18. Minimum packing wetting rate, ft2/hr (WR) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

19. Water density, lb/ft3 (Wd) 62.4 62.4 62.4 62.4 62.4 62.4 62.4 62.4 62.4 62.4 62.4 62.4 62.4 62.4 62.4 62.4 62.4 62.4 62.4 62.4 62.4 62.4 62.4 62.4

20. Water circulation flow rate, lb/hr-ft2 (Gs) = SAV x Wd x WR 4,705 4,705 4,705 4,705 4,705 4,705 4,705 4,705 4,705 4,705 4,705 4,705 4,705 4,705 4,705 4,705 4,705 4,705 4,705 4,705 4,705 4,705 4,705 4,705

21. Estimated column cross-sectional area from 

separate analysis, ft2 (A)

19.2 19.2 8.6 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 4.8 5.8 6.8 7.8 8.8 9.8 10.8 11.8 12.8 13.8 14.8

22. Water circulation rate, gpm (GPM) = Gs x A x (1 hr/60 min) x (1 gal/8.33 lb) 181 181 81 36 36 36 36 36 36 36 36 36 36 45 55 64 73 83 92 102 111 120 130 139

23. Water head, ft of water (Head) 60 60 60 60 60 60 60 60 60 60 60 60 60 61 62 63 64 65 66 67 68 69 70 71

24. Wastewater (blowdown) flow, gpm (B) = (HCl/1000000) x (Qd) x (lb-mole/385 ft3

) x 

(1 lb-mole NaCl/1 lb-mole HCl) x (58.2 lb 

NaCl/lb-mole NaCl) x (1 lb wastewater/0.1 lb 

NaCl) x (1 gal/8.33 lb)

0.196 0.012 0.024 0.315 0.233 0.182 0.202 0.011 0.512 0.530 0.543 0.924 0.922 0.074 0.050 0.094 0.097 0.003 0.020 0.007 0.006 0.015 0.017 0.173

25. Capital recovery factor, 15-yr equipment life, 

7% interest (CRF)

= [i x (1 + i)a] / [(1 + i)a - 1], where i = interest 

rate, a = equipment life

0.10979 0.10979 0.10979 0.10979 0.10979 0.10979 0.10979 0.10979 0.10979 0.10979 0.10979 0.10979 0.10979 0.10979 0.10979 0.10979 0.10979 0.10979 0.10979 0.10979 0.10979 0.10979 0.10979 0.10979

26. Chemical Engineering plant cost index

 a. 2008 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4

 b. 1989 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5

B. Total Capital Investment

1. $ = (27.6 x Qd + 109,603) x (525.4/357.5) x 

(1.4 retrofit factor)

$11,475,207 $4,565,062 $8,798,486 $7,498,933 $13,567,471 $10,671,531 $11,825,103 $16,876,657 ######## $6,151,889 ######## $10,534,345 $10,509,620 ######## ######## ######## ######## ######## ######## ######## ######## ######## ######## $11,774,867

2. $/dscfm = $ / Qd $63.56 $65.75 $63.99 $64.31 $63.34 $63.66 $63.52 $63.12 $64.88 $64.79 $64.73 $63.68 $63.69 $65.80 $67.52 $65.05 $64.94 $67.60 $66.81 $65.91 $65.78 $63.02 $62.95 $63.52

C. Direct Annual Costs, $/yr

1. Operating labor = (if Qa < 20,000, then 0, otherwise 0.5 

hr/shift) x H x LR

$17,127 $17,996 $17,996 $18,944 $17,084 $16,868 $18,944 $17,996 $16,305 $16,305 $16,305 $16,305 $16,305 $12,975 $10,813 $18,944 $18,944 $18,944 $17,996 $17,996 $17,996 $13,920 $15,040 $17,000

2. Supervisory labor = 0.15 x (operating labor) $2,569 $2,699 $2,699 $2,842 $2,563 $2,530 $2,842 $2,699 $2,446 $2,446 $2,446 $2,446 $2,446 $1,946 $1,622 $2,842 $2,842 $2,842 $2,699 $2,699 $2,699 $2,088 $2,256 $2,550

3. Maintenance labor = (0.5 hr/8-hr shift) x H x (LR x 1.1) $18,840 $19,796 $19,796 $20,838 $18,792 $18,554 $20,838 $19,796 $17,936 $17,936 $17,936 $17,936 $17,936 $14,273 $11,894 $20,838 $20,838 $20,838 $19,796 $19,796 $19,796 $15,312 $16,544 $18,700

4. Maintenance materials = 0.02 x TCI $229,504 $91,301 $175,970 $149,979 $271,349 $213,431 $236,502 $337,533 $119,018 $123,038 $125,891 $210,687 $210,192 $90,007 $62,600 $112,563 $116,573 $61,699 $71,423 $87,532 $90,507 $377,665 $411,537 $235,497

5. Electricity = (0.000181 x Qa x ΔP x H x EC) + 

(0.000289 x GPM x Head x H x EC)

$260,988 $106,536 $208,313 $185,620 $307,203 $237,443 $296,136 $403,923 $125,731 $130,150 $133,287 $226,512 $225,968 $74,742 $42,364 $138,148 $143,383 $73,409 $81,651 $101,314 $105,044 $350,864 $413,553 $265,772

6. Caustic = HCl x (3.117E-9) x Q x H x CC $9,507 $619 $1,226 $16,874 $11,250 $8,693 $10,843 $566 $23,653 $24,487 $25,078 $42,660 $42,558 $2,728 $1,541 $5,039 $5,227 $177 $1,039 $362 $300 $600 $707 $8,339

7. Sewage disposal = B x (60 min/hr) x H x SDC $354 $23 $46 $628 $419 $324 $404 $21 $881 $912 $934 $1,588 $1,585 $102 $57 $188 $195 $7 $39 $13 $11 $22 $26 $311

8. Makeup water = (B + Qh x (lb-mole/385 scf) x (18 lb/lbmole) x (gal/8.33 lb)) x (60 min/hr) x H x WC$5,739 $4,459 $8,831 $7,914 $12,267 $5,895 $700 $8,010 $4,553 $4,713 $4,827 $8,211 $8,191 $2,967 $1,409 $4,985 $5,621 $3,708 $4,295 $5,301 $5,464 $14,882 $17,541 $10,111

D. Indirect Annual Costs, $/yr

1. Overhead = 0.6 x (labor + maintenance materials) $160,824 $79,076 $129,877 $115,561 $185,873 $150,829 $167,475 $226,815 $93,423 $95,835 $97,547 $148,424 $148,128 $71,521 $52,157 $93,111 $95,517 $62,593 $67,149 $76,814 $78,599 $245,391 $267,226 $164,248

2. Property taxes, insurance, and administration = 0.04 x TCI $459,008 $182,602 $351,939 $299,957 $542,699 $426,861 $473,004 $675,066 $238,037 $246,076 $251,783 $421,374 $420,385 $180,015 $125,200 $225,126 $233,145 $123,398 $142,847 $175,064 $181,015 $755,331 $823,074 $470,995

3. Capital recovery = CRF x TCI $1,259,916 $501,219 $966,026 $823,342 $1,489,635 $1,171,677 $1,298,333 $1,852,966 $653,379 $675,444 $691,109 $1,156,614 $1,153,900 $494,116 $343,657 $617,940 $639,952 $338,711 $392,095 $480,527 $496,861 ######## ######## $1,292,817

E. Total Annual Cost

1. $/yr = Direct Annual Costs + Indirect Annual 

Costs

$2,424,376 $1,006,328 $1,882,719 $1,642,498 $2,859,134 $2,253,104 $2,526,018 $3,545,392 ######## $1,337,341 ######## $2,252,758 $2,247,593 $945,391 $653,314 ######## ######## $706,324 $801,028 $967,421 $998,293 ######## ######## $2,486,339

2. ($/yr) /dscfm = ($/yr) / Qd $13.43 $14.49 $13.69 $14.09 $13.35 $13.44 $13.57 $13.26 $14.12 $14.09 $14.06 $13.62 $13.62 $13.82 $14.09 $14.33 $14.29 $15.48 $14.99 $14.57 $14.51 $12.85 $12.93 $13.41

Sources:

1. Cost equations: Hospital/Medical/Infectious Waste Incinerators (HMIWI) [EPA-HQ-OAR-2006-0534]-Model Plant Description and Cost Report (II-A-112); and Wet Scrubber Cost Memorandum (IV-B-30).

2. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2008 National Industry-Specific

 Occupational Employment and Wage Estimates.

3. Electricity cost: Energy Information Administration. Average Industrial Retail Price of Electricity: October 2009.

4. Caustic cost: Purchasing.com. Caustic soda price hike is on the horizon. August 29, 2007.

5. Sewage disposal cost, water cost: Air Compliance Advisor, version 7.5.

0.0054 0.0054

Elec(mw) 3907.00193 1594.84899 3118.4569 2778.74463 4598.853269 3554.535221 4433.167758 6046.744273 1882.204 1948.354469 1995.318 3390.894312 3382.755554 1118.885 634.1915 2068.089 2146.448 1098.937 1222.327 1516.682 1572.512 5252.461 6190.918 3978.62782

Water (gal/yr) 28695230.1 22294903.2 44152654 39568169.5 61337109.3 29473379.34 3498603.848 40051515.34 22763503 23565525.39 24134916 41055159.94 40956484.05 14833599 7047311 24922614 28106277 18538893 21473340 26506586 27320532 74412408 87706982 50553386.6
Regenerative Thermal Oxidizer Estimated Costs (Source "Summary of Environmental and Cost Impacts 

Facility Name Combustor ID

Exhaust gas flow 

rate, dscfm

Annual operating 

hours, hr/yr

ALNationalCementRaglan

d Kiln 180543 7920

CACAPortlandCementColt

on K-1 69432 8322

CACAPortlandCementColt

on K-2 137503 8322

CALehighSouthwestReddi

ngPlant In-Line Kiln/Raw Mill (S260) 116607 8760

FLCemexMiami Cement Kiln 214185 7900

IALafargeBuffalo Kiln 1 167620 7800

IALehighCementMasonCit

y 302.203 186169 8760

MDLehighCementUnionBr

idge E02-001 267395 8322

MILafargeMidwestAlpena 19 91716 7540

MILafargeMidwestAlpena 20 94947 7540

MILafargeMidwestAlpena 21 97242 7540

MILafargeMidwestAlpena 22 165415 7540

MILafargeMidwestAlpena 23 165017 7540

PALafargeWhitehallPlant Kiln 2 68392 6000

PALafargeWhitehallPlant Kiln 3 46357 5000

PALehighCementEvansvill

e 121 86526 8760

PALehighCementEvansvill

e 122 89750 8760

PALehighCementYork 200 45633 8760

TXAshGroveMidlothian Kiln 1 53451 8322

TXAshGroveMidlothian Kiln 2 66402 8322

TXAshGroveMidlothian Kiln 3 68794 8322

TXHolcimMidlothianPlant Kiln 1 299660 6437

TXHolcimMidlothianPlant Kiln 2 326892 6955

UTHolcimDevilsSlide Kiln 1 185361 7861
ary of Environmental and Cost Impacts of Final Amendments to Portland Cement NESHAP")

TCI ($)

Adjusted Incremental 

TCI ($) TCI ($)/dscfm TAC ($)

13,681,740 2,052,261 76 4,008,233

7,711,334 111 1,997,012

11,619,307 85 3,274,814

10,525,136 1,578,770 90 2,901,800

15,158,866 2,273,830 71 4,556,892

13,085,462 78 3,792,214

13,935,979 75 4,101,303

17,317,485 65 5,392,264

9,112,970 99 2,437,625

9,304,280 98 2,499,341

9,438,521 97 2,542,868

12,981,866 78 3,755,010

12,963,136 79 3,748,294

7,641,808 1,146,271 112 1,975,696

6,051,509 907,726 131 1,502,738

8,799,957 102 2,337,454

8,995,234 100 2,399,830

5,994,594 131 1,486,344

6,591,226 123 1,660,059

7,507,599 113 1,934,699

7,668,720 111 1,983,941

18,542,582 2,781,387 62 5,883,522

19,535,985 2,930,398 60 6,290,742

13,899,668 75 4,087,975
Adjusted Incremental TAC ($) TAC ($)/dscfm

NG Fuel 

Requirement 

(scfm)

Annual NG 

requirement 

(MMscf/yr)

2,277,037 22 276 131.122

29 106 52.986

24 210 104.932

1,415,159 25 178 93.669

2,473,322 21 327 155.162

23 256 119.892

22 285 149.548

20 409 204.056

27 140 63.414

26 145 65.648

26 149 67.235

23 253 114.371

23 252 114.096

876,059 29 105 37.629

622,226 32 71 21.255

27 132 69.506

27 137 72.095

33 70 36.657

31 82 40.790

29 101 50.673

29 105 52.498

3,381,757 20 458 176.881

3,668,863 19 500 208.483

22 283 133.620
Fabric Filter Costs

Parameters/Costs Equation

ALNationalCe

mentRagland

CACAPortland

CementColton

CACAPortland

CementColton

CALehighSout

hwestRedding

Plant

FLCemexMiam

i

IALafargeBuffal

o

IALehighCeme

ntMasonCity

MDLehighCem

entUnionBridge

MILafargeMidw

estAlpena

MILafargeMidw

estAlpena

MILafargeMidw

estAlpena

MILafargeMidw

estAlpena

MILafargeMid

westAlpena

PALafargeW

hitehallPlant

PALafargeW

hitehallPlant

PALehighCe

mentEvansvi

lle

PALehighCe

mentEvansvi

lle

PALehighCe

mentYork

TXAshGrove

Midlothian

TXAshGrove

Midlothian

TXAshGrove

Midlothian

TXHolcimMi

dlothianPlan

t

TXHolcimMi

dlothianPlan

t

UTHolcimDe

vilsSlide

Kiln K-1 K-2

In-Line 

Kiln/Raw Mill 

(S260) Cement Kiln Kiln 1 302.203 E02-001 19 20 21 22 23 Kiln 2 Kiln 3 121 122 200 Kiln 1 Kiln 2 Kiln 3 Kiln 1 Kiln 2 Kiln 1

A. Parameters

1. Incinerator capacity, lb/hr (C)

2. Annual operating hours, hr/yr (H) 7,920 8,322 8,322 8,760 7,900 7,800 8,760 8,322 7,540 7,540 7,540 7,540 7,540 6000 5000 8760 8760 8760 8322 8322 8322 6437 6955 7861.118

3. Exhaust gas flow rate, dscfm (Q) 180,543 69,432 137,503 116,607 214,185 167,620 186,169 267,395 91,716 94,947 97,242 165,415 165,017 68392 46357.27 86525.89 89749.61 45632.9 53450.95 66401.86 68793.9 299660 326891.8 185361.3

4. PM concentration, gr/dscf (PM) 0.011 0.011 0.011 0.011 0.011 0.007 0.009 0.000 0.011 0.011 0.011 0.011 0.011 0.000448 0.000679 0.001771 0.004786 0.015905 0.006537 0.019285 0.006935 0.049798 0.004819 0.023151

5. Water vapor in gas from incinerator (10% by 

weight)

 a. lb/min = Q / (385 ft3

/lb-mol) x (29 lb/lb-mol) x moisture content (0.10) 1,359.9 523.0 1,035.7 878.3 1,613.3 1,262.6 1,402.3 2,014.1 690.8 715.2 732.5 1,246.0 1,243.0 515.2 349.2 651.8 676.0 343.7 402.6 500.2 518.2 2,257.2 2,462.3 1,396.2

 b. scfm = (lb/min) / (18 lb/lb-mol) x (385 ft3

/lb-mol) 29,087 11,186 22,153 18,787 34,508 27,006 29,994 43,080 14,776 15,297 15,667 26,650 26,586 11,019 7,469 13,940 14,460 7,352 8,612 10,698 11,083 48,279 52,666 29,864

6. Enthalpy change in quench (1800°F to 

300°F)

 a. Dry gas from incinerator, Btu/lb air = [7.010 x (300°F - 77°F) - 7.554 x (1800°F - 77°F)] / (29 lb/lb-mol) 395 395 395 395 395 395 395 395 395 395 395 395 395 395 395 395 395 395 395 395 395 395 395 395

 b. Water vapor from incinerator, Btu/lb water 

vapor

= [8.154 x (300°F - 77°F) - 9.215 x (1800°F - 77°F)] / (18 lb/lb-mol) 781 781 781 781 781 781 781 781 781 781 781 781 781 781 781 781 781 781 781 781 781 781 781 781

 c. Total gas stream, Btu/yr = [(Btu/lb air) x Q / (385 ft3/lb-mol) x (29 lb/lb-mol) x (60 min/hr) x H] + 

[(Btu/lb water vapor) x Q x (0.00753 lb water vapor/ft3) x (60 min/hr) x H]

3.06E+12 1.24E+12 2.45E+12 2.18E+12 3.62E+12 2.79E+12 3.49E+12 4.76E+12 1.48E+12 1.53E+12 1.57E+12 2.67E+12 2.66E+12 8.77E+11 4.95E+11 1.62E+12 1.68E+12 8.55E+11 9.51E+11 1.18E+12 1.22E+12 4.12E+12 4.86E+12 3.11E+12

 d. Cooling water

 i. Heat of vaporization at 77°F, Btu/lb 1,050 1,050 1,050 1,050 1,050 1,050 1,050 1,050 1,050 1,050 1,050 1,050 1,050 1,050 1,050 1,050 1,050 1,050 1,050 1,050 1,050 1,050 1,050 1,050

 ii. Sensible heat for vapor, Btu/lb 85 85 85 85 85 85 85 85 85 85 85 85 85 85 85 85 85 85 85 85 85 85 85 85

 iii. Total, Btu/lb water 1,135 1,135 1,135 1,135 1,135 1,135 1,135 1,135 1,135 1,135 1,135 1,135 1,135 1,135 1,135 1,135 1,135 1,135 1,135 1,135 1,135 1,135 1,135 1,135

7. Cooling water evaporated, lb/yr

 a. lb/yr = [enthalpy change (total gas stream, Btu/yr)] / [enthalpy change (cooling 

water, Btu/lb)]

2.69E+09 1.09E+09 2.16E+09 1.92E+09 3.19E+09 2.46E+09 3.07E+09 4.19E+09 1.30E+09 1.35E+09 1.38E+09 2.35E+09 2.34E+09 7.73E+08 4.37E+08 1.43E+09 1.48E+09 7.53E+08 8.38E+08 1.04E+09 1.08E+09 3.63E+09 4.28E+09 2.74E+09

 b. scfm = [cooling water evaporated (lb/yr)] / (18 lb/lb-mol) x (385 ft3/lb-mol) / (H 

* 60 min/hr)

121,216 46,617 92,319 78,290 143,803 112,540 124,993 179,528 61,578 63,747 65,288 111,059 110,792 45,918 31,124 58,093 60,258 30,638 35,887 44,582 46,188 201,191 219,474 124,451

8. Actual gas flow into fabric filter, acfm (AQ) = [Q + (water vapor in gas from incinerator, scfm) + (water vapor added 

in quench, i.e., cooling water evaporated, scfm)] x [(300°F + 

460°F)/528°R]

476,219 183,141 362,692 307,574 564,957 442,133 491,059 705,308 241,919 250,443 256,494 436,314 435,265 180,398 122,277 228,229 236,733 120,366 140,988 175,148 181,458 790,414 862,243 488,928

9. Operating 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 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60

10. Electricity cost, $/kWh (EC) $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 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07 $0.07

11. Water cost, $/1,000 gal (WC) $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20 $0.20

12. Compressed air cost, $/1,000 ft3 (CAC) $0.24 $0.24 $0.24 $0.24 $0.24 $0.24 $0.24 $0.24 $0.24 $0.24 $0.24 $0.24 $0.24 $0.24 $0.24 $0.24 $0.24 $0.24 $0.24 $0.24 $0.24 $0.24 $0.24 $0.24

13. Dust disposal cost, $/ton (DDC) $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29

14. Capital recovery factors = [i x (1 + i)a

] / [(1 + i)a - 1], where i = interest rate, a = equipment life

 a. Bag CRF, 2-yr life, 7% interest 0.55309 0.55309 0.55309 0.55309 0.55309 0.55309 0.55309 0.55309 0.55309 0.55309 0.55309 0.55309 0.55309 0.55309 0.55309 0.55309 0.55309 0.55309 0.55309 0.55309 0.55309 0.55309 0.55309 0.55309

 b. Cage CRF, 4-yr life, 7% interest 0.29523 0.29523 0.29523 0.29523 0.29523 0.29523 0.29523 0.29523 0.29523 0.29523 0.29523 0.29523 0.29523 0.29523 0.29523 0.29523 0.29523 0.29523 0.29523 0.29523 0.29523 0.29523 0.29523 0.29523

 c. Equipment CRF, 20-yr life, 7% interest 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439

15. Cost index

 a. 2008 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4

 b. 1989 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5 357.5

B. Total Capital Investment

1. $ = (47.0 x Q + 306,720) x (1.4 retrofit cost factor) x (525.4/357.5) $19,811,686 $8,044,409 $15,253,501 $13,040,493 $23,374,598 $18,443,106 $20,407,522 $29,009,807 $10,404,390 $10,746,615 $10,989,576 $18,209,493 ######### ######## ######## ######## ######## ######## ######## ######## ######## ######## ######## ########

2. $/dscfm = $ / Q $109.73 $115.86 $110.93 $111.83 $109.13 $110.03 $109.62 $108.49 $113.44 $113.18 $113.01 $110.08 $110.09 $116.01 $120.81 $113.89 $113.61 $121.05 $118.84 $116.31 $115.95 $108.21 $108.02 $109.63

C. Direct Annual Operating Costs, $/yr

1. Electricity = (0.746 kW/hp) x hp (0.0072 x Q + 3.20) x H x EC $514,306 $208,645 $411,898 $367,899 $608,366 $470,348 $586,536 $799,742 $249,324 $258,066 $264,272 $448,702 $447,627 $148,190 $83,961 $273,352 $283,485 $144,824 $160,926 $199,596 $206,739 $693,112 $816,844 $524,072

3. Evaporative cooler water = (0.1007 x Q + 23.1506) gal/min x (60 min/hr) x H x WC $1,730,092 $700,543 $1,385,084 $1,236,787 $2,046,884 $1,582,076 $1,973,142 $2,691,317 $837,750 $867,192 $888,095 $1,509,242 $1,505,620 $497,536 $281,480 $918,361 $952,486 $485,484 $539,831 $670,069 $694,124 ######## ######## ########

4. Operating labor = (1 hr/shift) x (1 shift/8 hr) x H x LR $34,254 $35,993 $35,993 $37,887 $34,168 $33,735 $37,887 $35,993 $32,611 $32,611 $32,611 $32,611 $32,611 $25,950 $21,625 $37,887 $37,887 $37,887 $35,993 $35,993 $35,993 $27,840 $30,080 $33,999

5. Supervisory labor = 0.15 x (operating labor) $5,138 $5,399 $5,399 $5,683 $5,125 $5,060 $5,683 $5,399 $4,892 $4,892 $4,892 $4,892 $4,892 $3,893 $3,244 $5,683 $5,683 $5,683 $5,399 $5,399 $5,399 $4,176 $4,512 $5,100

6. Maintenance labor = (0.5 hr/shift) x (1 shift/8 hr) x H x (LR x 1.1) $18,840 $19,796 $19,796 $20,838 $18,792 $18,554 $20,838 $19,796 $17,936 $17,936 $17,936 $17,936 $17,936 $14,273 $11,894 $20,838 $20,838 $20,838 $19,796 $19,796 $19,796 $15,312 $16,544 $18,700

7. Maintenance materials = 0.02 x TCI $396,234 $160,888 $305,070 $260,810 $467,492 $368,862 $408,150 $580,196 $208,088 $214,932 $219,792 $364,190 $363,348 $158,685 $112,013 $197,095 $203,923 $110,479 $127,038 $154,470 $159,536 $648,537 $706,217 $406,440

8. Compressed air = AQ x (2 ft3

 air/1,000 ft3 filtered) x (60 min/hr) x H x CAC $108,624 $43,894 $86,928 $77,597 $128,539 $99,321 $123,888 $169,044 $52,533 $54,384 $55,698 $94,746 $94,519 $31,173 $17,608 $57,580 $59,725 $30,367 $33,791 $41,978 $43,491 $146,531 $172,711 $110,693

9. Dust disposal = (PM gr/dscf x Q x 60 min/hr x 1 lb/7,000 gr) x (1 ton/2,000 lb) x H x 

DDC

$2,254 $911 $1,804 $1,610 $2,667 $1,370 $2,056 $109 $1,090 $1,128 $1,156 $1,966 $1,961 $27 $23 $197 $553 $934 $427 $1,566 $583 $14,116 $1,610 $4,958

10. Bag replacement

 a. Bag cost = AQ x ($2.5/ft2

) x (525.4/317.4) x (1.08 taxes and freight ratio)/(3.5 

ft/min G/C ratio)

$608,114 $233,865 $463,145 $392,762 $721,430 $564,588 $627,064 $900,653 $308,922 $319,807 $327,534 $557,158 $555,819 $230,361 $156,143 $291,441 $302,299 $153,703 $180,036 $223,658 $231,715 ######## ######## $624,344

 b. Bag replacement labor cost = AQ x (0.15 hr/bag)/(18 ft2

 bag area)/(3.5 ft/min G/C ratio) x LR $39,231 $15,087 $29,879 $25,338 $46,542 $36,423 $40,454 $58,104 $19,930 $20,632 $21,130 $35,944 $35,858 $14,861 $10,073 $18,802 $19,502 $9,916 $11,615 $14,429 $14,949 $65,115 $71,032 $40,278

 c. Bag replacement cost = Bag CRF x [(total bag cost) + (bag replacement labor cost)] $358,042 $137,694 $272,687 $231,248 $424,759 $332,414 $369,199 $530,281 $181,885 $188,294 $192,843 $328,040 $327,251 $135,631 $91,933 $171,593 $177,986 $90,496 $106,001 $131,684 $136,428 $594,267 $648,271 $367,597

11. Cage replacement

 a. Number of bags = AQ/(3.5 ft/min G/C ratio)/(18 ft2

 bag area) $7,559 $2,907 $5,757 $4,882 $8,968 $7,018 $7,795 $11,195 $3,840 $3,975 $4,071 $6,926 $6,909 $2,863 $1,941 $3,623 $3,758 $1,911 $2,238 $2,780 $2,880 $12,546 $13,686 $7,761

 b. Cage replacement labor cost = bag replacement labor cost $39,231 $15,087 $29,879 $25,338 $46,542 $36,423 $40,454 $58,104 $19,930 $20,632 $21,130 $35,944 $35,858 $14,861 $10,073 $18,802 $19,502 $9,916 $11,615 $14,429 $14,949 $65,115 $71,032 $40,278

 c. Cage replacement cost = Cage CRF x [single-cage cost (4.941+ 0.163 x 18 ft2

 bag area) x 

(number of bags) x (525.4/317.4) + (cage replacement labor cost)]

$40,673 $15,642 $30,977 $26,269 $48,252 $37,762 $41,941 $60,239 $20,662 $21,390 $21,907 $37,265 $37,175 $15,407 $10,443 $19,493 $20,219 $10,280 $12,042 $14,959 $15,498 $67,508 $73,643 $41,759

D. Indirect Annual Costs, $/yr

1. Overhead = 0.6 x (labor + maintenance materials) $272,679 $133,245 $219,755 $195,131 $315,346 $255,727 $283,535 $384,830 $158,115 $162,222 $165,138 $251,777 $251,271 $121,680 $89,265 $156,901 $160,998 $104,932 $112,935 $129,394 $132,434 $417,519 $454,412 $278,543

2. Property taxes, insurance, and administration = 0.04 x TCI $792,467 $321,776 $610,140 $521,620 $934,984 $737,724 $816,301 $1,160,392 $416,176 $429,865 $439,583 $728,380 $726,696 $317,370 $224,026 $394,189 $407,846 $220,957 $254,076 $308,939 $319,072 ######## ######## $812,879

3. Capital recovery = Equipment CRF x (TCI - bag replacement cost - cage replacement 

cost)

$1,832,447 $744,862 $1,411,159 $1,206,623 $2,161,748 $1,705,957 $1,887,517 $2,682,580 $962,982 $994,612 $1,017,067 $1,684,365 $1,680,474 $734,680 $518,997 $912,180 $943,734 $511,907 $588,432 $715,200 $738,614 ######## ######## ########

E. Total Annual Cost

1. $/yr = Direct Annual Costs + Indirect Annual Costs $6,106,049 $2,529,287 $4,796,688 $4,190,001 $7,197,122 $5,648,911 $6,556,674 $9,119,917 $3,144,042 $3,247,523 $3,320,988 $5,504,110 $5,491,379 ######## ######## ######## ######## ######## ######## ######## ######## ######## ######## ########

2. ($/yr) / dscfm = ($/yr) / Q $33.82 $36.43 $34.88 $35.93 $33.60 $33.70 $35.22 $34.11 $34.28 $34.20 $34.15 $33.27 $33.28 $32.23 $31.63 $36.58 $36.49 $38.90 $37.36 $36.58 $36.45 $30.89 $31.67 $33.70

Sources:

1. Cost equations: Hospital/Medical/Infectious Waste Incinerators (HMIWI) [EPA-HQ-OAR-2006-0534] Model Plant Description and Cost Report (II-A-112); and Dry Injection Fabric Filter Cost Memorandum (IV-B-32).

2. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2008 National Industry-Specific Occupational Employment and Wage Estimates

3. Electricity cost: Energy Information Administration. Average Industrial Retail Price of Electricity: October 2009.

4. Water cost: Air Compliance Advisor, version 7.5.

5. Compressed air cost: P2Pays.org. Energy Tips – Compressed Air. Compressed Air Tip Sheet #1. August 2004.

6. Dust disposal cost: NSWMA’s 2005 Tip Fee Survey

Elec(mw) 7699.18851 3123.42513 6166.13026 5507.47085 9107.27154 7041.13672 8780.4865 11972.1855 3732.39092 3863.25939 3956.16867 6717.09733 6700.9961 2218.406 1256.907 4092.103 4243.785 2168.018 2409.077 2987.971 3094.893 10375.94 12228.2 7845.395

Dust disposal cost ($/yr) $2,254 $911 $1,804 $1,610 $2,667 $1,370 $2,056 $109 $1,090 $1,128 $1,156 $1,966 $1,961 $27 $23 $197 $553 $934 $427 $1,566 $583 $14,116 $1,610 $4,958

Dust disposal unit cost ($/ton) $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29 $34.29

Dust amount (tpy) 65.73 26.56 52.60 46.95 77.78 39.96 59.96 3.18 31.79 32.91 33.70 57.33 57.19 0.79 0.67 5.75 16.13 27.25 12.46 45.67 17.02 411.67 46.95 144.58
Energy Recovery Unit Selective Noncatalytic Reduction Costs

Facility Name Combustion Equipment 

Unit Heat 

Input Capacity

(HI)

Annual operating 

hours (H)

Exhaust gas 

flow rate (Q) NOX

MMBtu/hr hr/yr dscfm lb/MMBtu

CACAPortlandCement

Colton K-1 260.00 8322 69432.20373 0.28

CACAPortlandCement

Colton K-2 260.00 8322 137503 0.28

CALehighSouthwestR

eddingPlant In-Line Kiln/Raw Mill (S260) 294.29 8760 116607 0.28

FLCemexMiami Cement Kiln 485.00 7900 214185.2813 0.28

IALafargeBuffalo Kiln 1 356.50 7800 167620.3894 0.28

IALehighCementMaso

nCity 302.203 294.29 8760 186169.0947 0.28

MDLehighCementUnio

nBridge E02-001 1246.29 8322 267394.9167 0.28

MILafargeMidwestAlp

ena 19 238.97 7540 91715.97758 0.28

MILafargeMidwestAlp

ena 20 247.39 7540 94947.38966 0.28

MILafargeMidwestAlp

ena 21 253.37 7540 97241.51133 0.28

MILafargeMidwestAlp

ena 22 431.00 7540 165414.5284 0.28

MILafargeMidwestAlp

ena 23 429.96 7540 165016.9553 0.28

PALafargeWhitehallPl

ant Kiln 2 102.00 6000 68392 0.28

PALafargeWhitehallPl

ant Kiln 3 102.00 5000 46357.27273 0.28

PALehighCementEvan

sville 121 260.00 8760 86525.88582 0.28

PALehighCementEvan

sville 122 260.00 8760 89749.61061 0.28

PALehighCementYork 200 180.00 8760 45632.9 0.28

TXAshGroveMidlothia

n Kiln 1 221.00 8322 53450.94828 0.28

TXAshGroveMidlothia

n Kiln 2 217.00 8322 66401.85938 0.28

TXAshGroveMidlothia

n Kiln 3 216.00 8322 68793.89928 0.28

TXHolcimMidlothianPl

ant Kiln 1 294.29 6437 299660 0.28

TXHolcimMidlothianPl

ant Kiln 2 294.29 6955 326891.75 0.28

Facility/Unit ID
UTHolcimDevilsSlide Kiln 1 294.29 7861.117647 185361.3333 0.28
Urea solution 

cost (U)

Electricity

cost (EC)

Water 

cost (WC)

Capital recovery factor, 20-yr 

equipment life, 7% interest (CRF)

Cost Index - 

2008

Cost Index - 

1998

$/gal $/kWh $/1000 gal

= [i x (1 + i)a] / [(1 + i)a - 1], where i 

= interest rate, a = equipment life

$0.85 $0.07 $0.20 0.09439 575.4 390.6

$0.85 $0.07 $0.20 0.09439 575.4 390.6

$0.85 $0.07 $0.20 0.09439 575.4 390.6

$0.85 $0.07 $0.20 0.09439 575.4 390.6

$0.85 $0.07 $0.20 0.09439 575.4 390.6

$0.85 $0.07 $0.20 0.09439 575.4 390.6

$0.85 $0.07 $0.20 0.09439 575.4 390.6

$0.85 $0.07 $0.20 0.09439 575.4 390.6

$0.85 $0.07 $0.20 0.09439 575.4 390.6

$0.85 $0.07 $0.20 0.09439 575.4 390.6

$0.85 $0.07 $0.20 0.09439 575.4 390.6

$0.85 $0.07 $0.20 0.09439 575.4 390.6

$0.85 $0.07 $0.20 0.09439 575.4 390.6

$0.85 $0.07 $0.20 0.09439 575.4 390.6

$0.85 $0.07 $0.20 0.09439 575.4 390.6

$0.85 $0.07 $0.20 0.09439 575.4 390.6

$0.85 $0.07 $0.20 0.09439 575.4 390.6

$0.85 $0.07 $0.20 0.09439 575.4 390.6

$0.85 $0.07 $0.20 0.09439 575.4 390.6

$0.85 $0.07 $0.20 0.09439 575.4 390.6

$0.85 $0.07 $0.20 0.09439 575.4 390.6

$0.85 $0.07 $0.20 0.09439 575.4 390.6

Parameters
$0.85 $0.07 $0.20 0.09439 575.4 390.6
Total Direct Capital Cost (DC) Indirect Installation 

Costs (IC)

Other Capital 

Costs (OC)

$ $ $

= [$950/(MMBtu/hr)] x (HI) x [2,375 MMBtu/hr / HI]0.577 x (0.66 

+ 0.85 x 45% NOX removal efficiency) x (1.2 retrofit factor) x 

(575.4/390.6)

= 0.2 x DC

= [0.173 x (DC 

+ IC)] + (119.3 

gal x U)

$1,631,211 $326,242 $338,741

$1,631,211 $326,242 $338,741

$1,718,978 $343,796 $356,961

$2,123,465 $424,693 $440,933

$1,864,222 $372,844 $387,114

$1,718,978 $343,796 $356,961

$3,165,366 $633,073 $657,231

$1,574,048 $314,810 $326,874

$1,597,272 $319,454 $331,695

$1,613,485 $322,697 $335,061

$2,020,042 $404,008 $419,462

$2,017,986 $403,597 $419,035

$1,098,030 $219,606 $228,052

$1,098,030 $219,606 $228,052

$1,631,211 $326,242 $338,741

$1,631,211 $326,242 $338,741

$1,396,229 $279,246 $289,959

$1,522,840 $304,568 $316,243

$1,511,120 $302,224 $313,810

$1,508,170 $301,634 $313,198

$1,718,978 $343,796 $356,961

$1,718,978 $343,796 $356,961

Total Capital Investment (TCI)
$1,718,978 $343,796 $356,961
Total Capital 

Investment

Total Capital 

Investment/dscfm Maintenance Reagent Electricity

$ $/dscfm $/yr $/yr $/yr

= DC + IC + OC = $ / Q = 0.015 x TCI = (0.36 gal/hr) x H 

x U

= kW [0.47 x NOX x HI / 106] / 

9.5 x H x EC

$2,296,194 $33.07 $34,443 $2,547 $2,002

$2,296,194 $16.70 $34,443 $2,547 $2,002

$2,419,734 $20.75 $36,296 $2,681 $2,386

$2,989,091 $13.96 $44,836 $2,417 $3,546

$2,624,180 $15.66 $39,363 $2,387 $2,573

$2,419,734 $13.00 $36,296 $2,681 $2,386

$4,455,671 $16.66 $66,835 $2,547 $9,597

$2,215,731 $24.16 $33,236 $2,307 $1,667

$2,248,422 $23.68 $33,726 $2,307 $1,726

$2,271,243 $23.36 $34,069 $2,307 $1,768

$2,843,512 $17.19 $42,653 $2,307 $3,007

$2,840,619 $17.21 $42,609 $2,307 $3,000

$1,545,689 $22.60 $23,185 $1,836 $566

$1,545,689 $33.34 $23,185 $1,530 $472

$2,296,194 $26.54 $34,443 $2,681 $2,108

$2,296,194 $25.58 $34,443 $2,681 $2,108

$1,965,434 $43.07 $29,482 $2,681 $1,459

$2,143,651 $40.11 $32,155 $2,547 $1,702

$2,127,154 $32.03 $31,907 $2,547 $1,671

$2,123,002 $30.86 $31,845 $2,547 $1,663

$2,419,734 $8.07 $36,296 $1,970 $1,753

$2,419,734 $7.40 $36,296 $2,128 $1,894

Direct Annual Costs
$2,419,734 $13.05 $36,296 $2,406 $2,141
Indirect Capital Costs

Water Capital recovery

$/yr $/yr $/yr ($/yr) / dscfm

= (1.62 gal/hr) x H x 

WC = CRF x TCI

= Direct Annual Costs 

+ Indirect Annual 

Costs

= ($/yr) / Q

$2,696 $216,744 $258,432 $3.72

$2,696 $216,744 $258,432 $1.88

$2,838 $228,406 $272,606 $2.34

$2,560 $282,149 $335,508 $1.57

$2,527 $247,704 $294,554 $1.76

$2,838 $228,406 $272,606 $1.46

$2,696 $420,584 $502,259 $1.88

$2,443 $209,149 $248,803 $2.71

$2,443 $212,235 $252,438 $2.66

$2,443 $214,389 $254,976 $2.62

$2,443 $268,407 $318,817 $1.93

$2,443 $268,134 $318,494 $1.93

$1,944 $145,902 $173,434 $2.54

$1,620 $145,902 $172,709 $3.73

$2,838 $216,744 $258,814 $2.99

$2,838 $216,744 $258,814 $2.88

$2,838 $185,523 $221,982 $4.86

$2,696 $202,346 $241,445 $4.52

$2,696 $200,788 $239,610 $3.61

$2,696 $200,396 $239,148 $3.48

$2,086 $228,406 $270,510 $0.90

$2,253 $228,406 $270,978 $0.83

Total Annual Costs

Total cost
$2,547 $228,406 $271,795 $1.47
Elec Water

Mw gal/yr

3.00E+01 13,481,640.00 2. Hospital/Medical/Infectious Waste Incinerators 

3.00E+01 13,481,640.00 3. Electricity cost: Energy Information Administra

3.57E+01 14,191,200.00 Sources:

5.31E+01 12,798,000.00 1. Cost equations, urea solution cost: OAQPS Co

3.85E+01 12,636,000.00 2. Hospital/Medical/Infectious Waste Incinerators 

3.57E+01 14,191,200.00 3. Electricity cost: Energy Information Administra

1.44E+02 13,481,640.00

2.50E+01 12,214,800.00

2.58E+01 12,214,800.00

2.65E+01 12,214,800.00

4.50E+01 12,214,800.00

4.49E+01 12,214,800.00

8.48E+00 9,720,000.00 4. Water cost: Air Compliance Advisor, version 7

7.06E+00 8,100,000.00 5. NOX removal efficiency: Clean Air Technology 

3.16E+01 14,191,200.00 November 1999.

3.16E+01 14,191,200.00

2.18E+01 14,191,200.00

2.55E+01 13,481,640.00

2.50E+01 13,481,640.00

2.49E+01 13,481,640.00

2.62E+01 10,427,940.00

2.84E+01 11,267,100.00
3.20E+01 12,735,010.59
nfectious Waste Incinerators (HMIWI) [EPA-HQ-OAR-2006-0534] Heating value: Process Description Report (II-A-110).

ergy Information Administration. Average Industrial Retail Price of Electricity: October 2009.

ea solution cost: OAQPS Control Cost Manual. Section 4.2: NOX Post-Combustion, Chapter 1: Selective Noncatalytic Reduction.

nfectious Waste Incinerators (HMIWI) [EPA-HQ-OAR-2006-0534] Heating value: Process Description Report (II-A-110).

ergy Information Administration. Average Industrial Retail Price of Electricity: October 2009.

mpliance Advisor, version 7.5.

ency: Clean Air Technology Center. EPA Technical Bulletin: Nitrogen Oxides (NOX)--Why and How They Are Controlled. 456/F-99-006R.

eport (II-A-110).

e Noncatalytic Reduction.

eport (II-A-110).

ey Are Controlled. 456/F-99-006R.
Energy Recovery Unit Incremental Control Model Costs

Facility name

Combustion 

equipment 

Annual 

operating hours 

(H)

Exhaust gas 

flow rate to FF 

(Qff)

Exhaust gas 

flow rate (Q)

Unc. HCl 

concentration 

(HClu)*

hr/yr acfm dscfm ppmvd

Used for bag 

replacement 

only

ALNationalCement

Ragland Kiln 7920 290674.23 180543 6.630095546

CACAPortlandCem

entColton K-1 8322 111785.848 69432.20373 0.96417092

CACAPortlandCem

entColton K-2 8322 221379.83 137503 0.96417092

CALehighSouthwest

ReddingPlant

In-Line Kiln/Raw Mill 

(S260) 8760 181037.4742 116607 3

FLCemexMiami Cement Kiln 7900 294945.7165 214185.2813 3

IALafargeBuffalo Kiln 1 7800 294945.7165 167620.3894 3

IALehighCementMa

sonCity 302.203 8760 294945.7165 186169.0947 3

MDLehighCementU

nionBridge E02-001 8322 430528.3333 267394.9167 6.630095546

MILafargeMidwestAl

pena 19 7540 155834.7145 91715.97758 30.77905791

MILafargeMidwestAl

pena 20 7540 161325.2101 94947.38966 30.77905791

MILafargeMidwestAl

pena 21 7540 165223.1547 97241.51133 30.77905791

MILafargeMidwestAl

pena 22 7540 281056 165414.5284 30.77905791

MILafargeMidwestAl

pena 23 7540 280380.4831 165016.9553 30.77905791

PALafargeWhitehall

Plant Kiln 2 6000 100715.0685 68392 3

PALafargeWhitehall

Plant Kiln 3 5000 100715.0685 46357.27273 3

PALehighCementEv

ansville 121 8760 151854 86526 3

PALehighCementEv

ansville 122 8760 151854.3085 89749.61061 3

PALehighCementY

ork 200 8760 294945.7165 45632.9 0.399364282

TXAshGroveMidloth

ian Kiln 1 8322 87474.97499 53450.94828 2.101

TXAshGroveMidloth

ian Kiln 2 8322 101511.5234 66401.85938 0.595

TXAshGroveMidloth

ian Kiln 3 8322 101162.2011 68793.89928 0.472

TXHolcimMidlothian

Plant Kiln 1 6437 294945.7165 299660 3

Facility/Unit ID
TXHolcimMidlothian

Plant Kiln 2 6955 294945.7165 326891.753

UTHolcimDevilsSlid e Kiln 1 7861 294945.7165 185361.3333

3
Cont. HCl 

concentration 

(HClc)**

Operating 

labor rate 

(LR)

Wastewater 

(blowdown) flow 

(B)

Caustic 

cost (CC)

Sewage 

disposal cost 

(SDC)

Water cost 

(WC)

Lime cost 

(LC)

Sodium

bicarbonate 

cost (SBC)

ppmvd $/hr gpm $/ton $/1,000 gal $/1,000 gal $/ton $/ton

6.630095546

$34.60 0.217 $357 $3.80 $0.20 $95 $440

0.96417092

$34.60 0.012 $357 $3.80 $0.20 $95 $440

0.96417092

$34.60 0.024 $357 $3.80 $0.20 $95 $440

3

$34.60 0.063 $357 $3.80 $0.20 $95 $440

3 $34.60 0.117 $357 $3.80 $0.20 $95 $440

3 $34.60 0.091 $357 $3.80 $0.20 $95 $440

3

$34.60 0.101 $357 $3.80 $0.20 $95 $440

6.630095546

$35.60 0.322 $357 $3.80 $0.20 $95 $440

30.77905791

$36.60 0.512 $357 $3.80 $0.20 $95 $440

30.77905791

$37.60 0.530 $357 $3.80 $0.20 $95 $440

30.77905791

$38.60 0.543 $357 $3.80 $0.20 $95 $440

30.77905791

$39.60 0.924 $357 $3.80 $0.20 $95 $440

30.77905791

$40.60 0.922 $357 $3.80 $0.20 $95 $440

3

$34.60 0.037 $357 $3.80 $0.20 $95 $440

3

$34.60 0.025 $357 $3.80 $0.20 $95 $440

3

$34.60 0.047 $357 $3.80 $0.20 $95 $440

3

$34.60 0.049 $357 $3.80 $0.20 $95 $440

0.399364282

$34.60 0.003 $357 $3.80 $0.20 $95 $440

2.101

$35.60 0.020 $357 $3.80 $0.20 $95 $440

0.595

$36.60 0.007 $357 $3.80 $0.20 $95 $440

0.472

$37.60 0.006 $357 $3.80 $0.20 $95 $440

3

$34.60 0.163 $357 $3.80 $0.20 $95 $440
3

$34.60 0.178 $357 $3.80 $0.20 $95 $440

3

$34.60 0.101 $357 $3.80 $0.20 $95 $440
Dust disposal 

cost (DDC)

Activated 

carbon cost 

(ACC)

Natural gas 

cost (NGC)

Electricity

cost (EC) Total bag cost

$/ton $/lb $/1,000 ft3 $/kWh

Bag CRF, 2-yr 

life, 7% interest

Cage CRF, 4-yr life, 

7% interest $/yr

$42.14 $1.38 $9.58 $0.07 0.55309 0.29523 $406,504

$42.14 $1.38 $9.58 $0.07 0.55309 0.29523 $156,331

$43.14 $1.38 $9.58 $0.07 0.55309 0.29523 $309,597

$42.14 $1.38 $9.58 $0.07 0.55309 0.29523 $253,179

$42.14 $1.38 $9.58 $0.07 0.55309 0.29523 $412,478

$42.14 $1.38 $9.58 $0.07 0.55309 0.29523 $412,478

$42.14 $1.38 $9.58 $0.07 0.55309 0.29523 $412,478

$43.14 $1.38 $9.58 $0.07 0.55309 0.29523 $602,089

$44.14 $1.38 $9.58 $0.07 0.55309 0.29523 $217,933

$45.14 $1.38 $9.58 $0.07 0.55309 0.29523 $225,611

$46.14 $1.38 $9.58 $0.07 0.55309 0.29523 $231,063

$47.14 $1.38 $9.58 $0.07 0.55309 0.29523 $393,053

$48.14 $1.38 $9.58 $0.07 0.55309 0.29523 $392,109

$43.14 $1.38 $9.58 $0.07 0.55309 0.29523 $140,849

$44.14 $1.38 $9.58 $0.07 0.55309 0.29523 $140,849

$45.14 $1.38 $9.58 $0.07 0.55309 0.29523 $212,366

$46.14 $1.38 $9.58 $0.07 0.55309 0.29523 $212,366

$47.14 $1.38 $9.58 $0.07 0.55309 0.29523 $412,478

$48.14 $1.38 $9.58 $0.07 0.55309 0.29523 $122,333

$49.14 $1.38 $9.58 $0.07 0.55309 0.29523 $141,963

$50.14 $1.38 $9.58 $0.07 0.55309 0.29523 $141,474

$48.14 $1.38 $9.58 $0.07 0.55309 0.29523 $412,478

Capital recovery factors

= [i x (1 + i)a] / [(1 + i)a - 1], where i = 

interest rate, a = equipment life
$49.14 $1.38 $9.58 $0.07 0.55309 0.29523 $412,478

$50.14 $1.38 $9.58 $0.07 0.55309 0.29523 $412,478
Bag replacement 

labor cost 

Total cage 

cost 

Cage 

replacement 

labor cost

Urea solution 

cost (U) Caustic Sewage disposal

Makeup 

water

$/yr $/yr $/yr $/gal

= HCl x 

(3.117E9) x Q x H 

x CC

= B x (60 

min/hr) x H x 

SDC

= B x (60 

min/hr) x H x 

WC

$23,946

$26,516

$23,946 $0.85 $10,535 $392 $21

$9,209

$10,197

$9,209 $0.85 $619 $23 $1

$18,237

$20,195

$18,237 $1.85 $1,226 $46 $2

$14,914

$16,515

$14,914 $0.85 $3,405 $127 $7

$24,298 $26,906 $24,298 $0.85 $5,641 $210 $11

$24,298 $26,906 $24,298 $0.85 $4,359 $162 $9

$24,298

$26,906

$24,298 $1.85 $5,437 $202 $11

$36,492

$39,576

$36,492 $2.85 $16,395 $610 $32

$13,580

$14,435

$13,580 $3.85 $23,653 $881 $46

$14,442

$15,057

$14,442 $4.85 $24,487 $912 $48

$15,185

$15,537

$15,185 $5.85 $25,078 $934 $49

$26,500

$26,626

$26,500 $6.85 $42,660 $1,588 $84

$27,103

$26,759

$27,103 $7.85 $42,558 $1,585 $83

$8,297

$9,187

$8,297 $8.85 $1,368 $51 $3

$8,297

$9,187

$8,297 $9.85 $773 $29 $2

$12,510

$13,852

$12,510 $10.85 $2,527 $94 $5

$12,510

$13,852

$12,510 $11.85 $2,621 $98 $5

$24,298

$26,906

$24,298 $12.85 $177 $7 $0

$7,415

$8,041

$7,415 $13.85 $1,039 $39 $2

$8,846

$9,403

$8,846 $14.85 $365 $14 $1

$9,056

$9,442

$9,056 $15.85 $300 $11 $1

$24,298

$26,906

$24,298 $6.85 $6,431 $239 $13

Increase Caustic Flow 
$24,298

$26,906

$24,298 $7.85 $7,580 $282 $15

$24,298

$26,906

$24,298 $8.85 $4,858 $181 $10
Makeup lime Dust disposal

$/yr ($/yr) / dscfm $/yr

= Caustic + 

Sewage disposal + 

Makeup water

= ($/yr) / Q

= (2.4E-7 lb/dscf) x HCl x 

Q x (1 ton/2000 lb) x (60 

min/hr) x H x LC

= HCl x Q x (60 min/hr) x 

(2.86E-7 lb/dscf) x (1 

ton/2,000 lb) x H x DDC

= Makeup lime + 

Dust disposal

$10,948 $0.06 $6,485 $3,428 $9,912

$643 $0.01 $381 $201 $582

$1,274 $0.01 $755 $408 $1,163

$3,539 $0.03 $2,096 $1,108 $3,204

$5,862 $0.027 $3,472 $1,835 $5,307

$4,530 $0.027 $2,683 $1,418 $4,101

$5,650 $0.03 $3,346 $1,769 $5,115

$17,038 $0.06 $10,092 $5,461 $15,552

$24,580 $0.27 $14,559 $8,061 $22,620

$25,447 $0.27 $15,072 $8,534 $23,606

$26,061 $0.27 $15,436 $8,934 $24,370

$44,332 $0.27 $26,258 $15,527 $41,784

$44,226 $0.27 $26,195 $15,818 $42,012

$1,422 $0.02 $842 $456 $1,298

$803 $0.02 $476 $263 $739

$2,626 $0.03 $1,555 $881 $2,436

$2,724 $0.03 $1,613 $934 $2,547

$184 $0.00 $109 $65 $174

$1,079 $0.02 $639 $386 $1,025

$380 $0.01 $225 $139 $364

$312 $0.00 $185 $116 $301

$6,683 $0.02 $3,958 $2,390 $6,348

Total cost

Increase Lime Flow 

Total cost

ncrease Caustic Flow 
$7,877 $0.02 $4,665 $2,876 $7,541

$5,048 $0.03 $2,990 $1,881 $4,871
Makeup NaHCO3 Dust disposal

($/yr) / dscfm $/yr

= ($/yr) / Q

= (2.73E-7 lb/dscf x HCl x Q) x 

(1 ton/2000 lb) x (60 min/hr) x H 

x SBC

= [(HCl x Q x 60 min/hr x 2.10E-7 

lb/dscf)] x (1 ton/2,000 lb) x H x 

DDC

= Makeup NaHCO3 + 

Dust disposal

$0.05 $34,163 $2,517 $36,680

$0.01 $2,008 $148 $2,156

$0.01 $3,976 $300 $4,276

$0.03 $11,043 $814 $11,857

$0.02 $18,293 $1,348 $19,640

$0.02 $14,134 $1,041 $15,176

$0.03 $17,631 $1,299 $18,930

$0.06 $53,166 $4,010 $57,176

$0.25 $76,702 $5,919 $82,621

$0.25 $79,405 $6,266 $85,671

$0.25 $81,323 $6,560 $87,883

$0.25 $138,337 $11,401 $149,737

$0.25 $138,004 $11,615 $149,619

$0.02 $4,436 $335 $4,771

$0.02 $2,506 $193 $2,699

$0.03 $8,194 $647 $8,841

$0.03 $8,500 $686 $9,185

$0.00 $575 $47 $623

$0.02 $3,368 $283 $3,651

$0.01 $1,185 $102 $1,287

$0.00 $974 $85 $1,059

$0.02 $20,853 $1,755 $22,608

Increase NaHCO3 Flow

Total cost Total Cost
$0.02 $24,579 $2,112 $26,690

$0.03 $15,753 $1,381 $17,134
Activated carbon Dust disposal

($/yr) / dscfm $/yr

($/yr) / 

dscfm

= ($/yr) / Q = (1.27E-3) x Q x 

H x ACC

= (1.27E-3) x Q x (1 

ton/2,000 lb) x H x DDC

= Activated carbon + 

Dust disposal

= ($/yr) / 

Q

$0.20 $2,506,044 $38,263 $2,544,306 $14.09

$0.03 $1,012,678 $15,462 $1,028,140 $14.81

$0.03 $2,005,500 $31,347 $2,036,847 $14.81

$0.10 $1,790,241 $27,334 $1,817,575 $15.59

$0.09 $2,965,511 $45,278 $3,010,789 $14.06

$0.09 $2,291,418 $34,986 $2,326,403 $13.88

$0.10 $2,858,212 $43,640 $2,901,852 $15.59

$0.21 $3,899,992 $60,959 $3,960,950 $14.81

$0.90 $1,211,990 $19,383 $1,231,373 $13.43

$0.90 $1,254,692 $20,521 $1,275,213 $13.43

$0.90 $1,285,008 $21,482 $1,306,490 $13.44

$0.91 $2,185,887 $37,334 $2,223,222 $13.44

$0.91 $2,180,634 $38,035 $2,218,668 $13.45

$0.07 $719,183 $11,241 $730,424 $10.68

$0.06 $406,229 $6,497 $412,725 $8.90

$0.10 $1,328,413 $21,726 $1,350,139 $15.60

$0.10 $1,377,906 $23,035 $1,400,941 $15.61

$0.01 $700,592 $11,966 $712,558 $15.61

$0.07 $779,589 $13,598 $793,187 $14.84

$0.02 $968,480 $17,243 $985,723 $14.84

$0.02 $1,003,368 $18,228 $1,021,596 $14.85

$0.08 $3,380,610 $58,965 $3,439,575 $11.48

Total cost

Increase Carbon Flow

Total Cost
$0.08 $3,984,592 $70,943 $4,055,535 $12.41

$0.09 $2,553,796 $46,394 $2,600,190 $14.03
Fan electricity

$/yr ($/yr) / dscfm

= (0.32 Btu/lb/°F) x (28.5 lb/lbmole) x (100°F) x 

(lbmole/385 ft3) x (ft3/1,000 Btu) x (Q/0.9) x (60 min/hr) x H 

x NGC

= ($/yr) / Q = 0.746 x (0.0205 x 

Q) x H x EC

$2,163,287 $11.98 $1,460,747

$874,172 $12.59 $590,280

$1,731,204 $12.59 $1,168,985

$1,545,386 $13.25 $1,043,513

$2,559,912 $11.95 $1,728,566

$1,978,016 $11.80 $1,335,644

$2,467,289 $13.25 $1,666,022

$3,366,582 $12.59 $2,273,265

$1,046,224 $11.41 $706,457

$1,083,085 $11.41 $731,347

$1,109,255 $11.41 $749,018

$1,886,919 $11.41 $1,274,131

$1,882,384 $11.41 $1,271,069

$620,819 $9.08 $419,204

$350,668 $7.56 $236,787

$1,146,723 $13.25 $774,318

$1,189,447 $13.25 $803,167

$604,770 $13.25 $408,368

$672,963 $12.59 $454,415

$836,019 $12.59 $564,517

$866,136 $12.59 $584,853

$2,918,238 $9.74 $1,970,523

Natural gas

Increase Natural Gas
$3,439,612 $10.52 $2,322,578

$2,204,509 $11.89 $1,488,581
Pump electricity Bag replacement

$/yr

($/yr) / 

dscfm

=0.746 x (0.00267 x Q 

+ 4.554) x H x EC

= Fan electricity + 

pump electricity

= ($/yr) / 

Q

= Bag CRF x [(total bag cost) + (bag 

replacement labor cost)]

$192,051 $1,652,798 $9.15 $238,079

$78,769 $669,049 $9.64 $91,559

$154,142 $1,323,127 $9.62 $181,323

$137,899 $1,181,412 $10.13 $148,280

$226,928 $1,955,494 $9.13 $241,577

$175,730 $1,511,373 $9.02 $241,577

$218,977 $1,885,000 $10.13 $241,577

$297,967 $2,571,232 $9.62 $353,194

$93,723 $800,179 $8.72 $128,048

$96,965 $828,312 $8.72 $132,772

$99,266 $848,284 $8.72 $136,197

$167,659 $1,441,790 $8.72 $232,051

$167,260 $1,438,329 $8.72 $231,863

$55,960 $475,165 $6.95 $82,491

$31,975 $268,761 $5.80 $82,491

$102,838 $877,156 $10.14 $124,377

$106,596 $909,763 $10.14 $124,377

$55,175 $463,543 $10.16 $241,577

$61,073 $515,488 $9.64 $71,762

$75,413 $639,931 $9.64 $83,411

$78,062 $662,915 $9.64 $83,257

$258,109 $2,228,632 $7.44 $241,577

Increase Scrubber Horsepower

Total cost
$304,080 $2,626,658 $8.04 $241,577

$195,663 $1,684,244 $9.09 $241,577
Cage replacement

 $/yr ($/yr) / dscfm $/yr ($/yr)/dscfm

= Cage CRF x [(total cage cost) + 

(cage replacement labor cost)]

= Bag replacement + Cage 

replacement = ($/yr) / Q = (0.36 gal/hr) x H x U = ($/yr) / Q

$14,898 $252,976 $1.40 $2,424 $0.01

$5,729 $97,288 $1.40 $2,547 $0.04

$11,346 $192,669 $1.40 $5,542 $0.04

$9,279 $157,558 $1.35 $2,681 $0.02

$15,117 $256,694 $1.20 $2,417 $0.01

$15,117 $256,694 $1.53 $2,387 $0.01

$15,117 $256,694 $1.38 $5,834 $0.03

$22,458 $375,651 $1.40 $8,538 $0.03

$8,271 $136,319 $1.49 $10,450 $0.11

$8,709 $141,481 $1.49 $13,165 $0.14

$9,070 $145,267 $1.49 $15,879 $0.16

$15,684 $247,736 $1.50 $18,594 $0.11

$15,902 $247,765 $1.50 $21,308 $0.13

$5,162 $87,653 $1.28 $19,116 $0.28

$5,162 $87,653 $1.89 $17,730 $0.38

$7,783 $132,160 $1.53 $34,217 $0.40

$7,783 $132,160 $1.47 $37,370 $0.42

$15,117 $256,694 $5.63 $40,524 $0.89

$4,563 $76,325 $1.43 $41,493 $0.78

$5,388 $88,799 $1.34 $44,489 $0.67

$5,461 $88,718 $1.29 $47,485 $0.69

$15,117 $256,694 $0.86 $15,874 $0.05

Increase NOX Reagent

Reagent

Improve FF Performance

Total cost
$15,117 $256,694 $0.79 $19,655 $0.06

$15,117 $256,694 $1.38 $25,046 $0.14
Secondary IMPACTS

2. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2008 National Industr

2. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2008 National Industr

and Wage Estimates.

Sources:

1. Cost equations: Hospital/Medical/Infectious Waste Incinerators (HMIWI) [EPA-HQ-OAR-2006-0534] Model Plan

Memorandum (IV-B-32); and Secondary Chamber Retrofit Cost Memorandum (IV-B-33).

2. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2008 National Industr

and Wage Estimates.

3. Lime cost: U.S. Geological Survey. Mineral Commodity Summaries 2008. Hydrated Lime Average Value, 2007

4. Dust disposal cost: NSWMA’s 2005 Tip Fee Survey.

5. Natural gas cost: Energy Information Administration. Natural Gas Prices: 2008.

6. Electricity cost: Energy Information Administration. Average Industrial Retail Price of Electricity: October 2009.

7. Water cost, sewage disposal cost: Air Compliance Advisor, version 7.5.
8. Activated carbon cost: The Innovation Group. Chemical Profiles: Carbon, Activated. 2002. Assumed 20% price 

from Norit, an activated carbon vendor.
Statistics, May 2008 National Industry-Specific Occupational Employment

Statistics, May 2008 National Industry-Specific Occupational Employment

PA-HQ-OAR-2006-0534] Model Plant Description and Cost Report (II-A-112); Wet Scrubber Cost Memorandum (IV-B-30); Dry Injection Fab

Statistics, May 2008 National Industry-Specific Occupational Employment

Hydrated Lime Average Value, 2007.

l Price of Electricity: October 2009.
ctivated. 2002. Assumed 20% price increase based on online information
randum (IV-B-30); Dry Injection Fabric Filter Cost
Recording lime/carbon 

flow, min/4-hr period

Annual operating 

hours, hr/yr (H)

Operating labor wage 

rate, $/hr (LR)

CACAPortlandCementColton K-1 5 8,322 34.6

CACAPortlandCementColton K-2 5 8,322 34.6

CALehighSouthwestReddingPl

ant

In-Line 

Kiln/Raw Mill 

(S260) 5

8,760

34.6

FLCemexMiami Cement Kiln 5 7,900 34.6

IALafargeBuffalo Kiln 1 5 7,800 34.6

IALehighCementMasonCity 302.203 5 8,760 34.6

MDLehighCementUnionBridge E02-001 5

8,322

34.6

MILafargeMidwestAlpena 19 5 7,540 34.6

MILafargeMidwestAlpena 20 5 7,540 34.6

MILafargeMidwestAlpena 21 5 7,540 34.6

MILafargeMidwestAlpena 22 5 7,540 34.6

MILafargeMidwestAlpena 23 5 7,540 34.6

PALafargeWhitehallPlant Kiln 2 5 6,000 34.6

PALafargeWhitehallPlant Kiln 3 5 5,000 34.6

PALehighCementEvansville 121 5 8,760 34.6

PALehighCementEvansville 122 5 8,760 34.6

PALehighCementYork 200 5 8,760 34.6

TXAshGroveMidlothian Kiln 1 5 8,322 34.6

TXAshGroveMidlothian Kiln 2 5 8,322 34.6

TXAshGroveMidlothian Kiln 3 5 8,322 34.6

TXHolcimMidlothianPlant Kiln 1 5 6,437 34.6

TXHolcimMidlothianPlant Kiln 2 5 6,955 34.6

UTHolcimDevilsSlide Kiln 1 5 7,861 34.6

FacilityID UnitID

Input Parameters
Operating labor ($/yr) Overhead ($/yr) Total Annual Cost ($/yr)

= (5 min to record lime/carbon 

flow/4-hr period) x (1 hr/60 min) 

x H x LR

= 0.6 x (labor + 

maintenance materials)

=Operating labor + Overhead

$6,000 $3,600 $9,600

$6,000 $3,600 $9,600

$6,300 $3,800 $10,100

$5,700 $3,400 $9,100

$5,600 $3,400 $9,000

$6,300 $3,800 $10,100

$6,000 $3,600 $9,600

$5,400 $3,200 $8,600

$5,400 $3,200 $8,600

$5,400 $3,200 $8,600

$5,400 $3,200 $8,600

$5,400 $3,200 $8,600

$4,300 $2,600 $6,900

$3,600 $2,200 $5,800

$6,300 $3,800 $10,100

$6,300 $3,800 $10,100

$6,300 $3,800 $10,100

$6,000 $3,600 $9,600

$6,000 $3,600 $9,600

$6,000 $3,600 $9,600

$4,600 $2,800 $7,400

$5,000 $3,000 $8,000

$5,700 $3,400 $9,100
Monitoring Costs

Parameters/Costs Equation FF WS SNCR

Bag leak 

detector

CO 

CEMS

HCl 

CEMS PM CEMS

Hg 

CEMS

Multimetal 

CEMS

Dioxin or Hg 

sorbent trap 

biweekly

monitoring

A. Parameters

1. Recording lime/carbon flow, min/4-hr 

period

2. Annual operating hours, hr/yr (H)

3. Cost index

 a. 2008 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4

 b. 2006 499.6 499.6 499.6 499.6 499.6 499.6 499.6 499.6 499.6 499.6

 c. 1997 386.5 386.5 386.5 386.5 386.5 386.5 386.5 386.5 386.5 386.5

 d. 1993 359.2 359.2 359.2 359.2 359.2 359.2 359.2 359.2 359.2 359.2

 e. 1992 358.2 358.2 358.2 358.2 358.2 358.2 358.2 358.2 358.2 358.2

4. Operating labor wage rate, $/hr (LR) $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60

5. Capital recovery factor, 20-yr 

equipment life, 7% interest (CRF)

= [i x (1 + i)a] / [(1 + i)a - 1], where i = 

interest rate, a = equipment life

0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439

B. Total Capital Investment, $ (TCI)

1. Planning $700 $700 $700 $800 $4,000 $3,300 $900 $3,300

2. Select type of equipment $400 $400 $400 $4,500 $10,000 $16,100 $12,200 $16,100

3. Provide support facilities $1,500 $1,500 $1,500 $500 $20,600 $20,600 $500 $20,600

4. Purchased equipment cost (PEC) $13,000 $19,300 $5,300 $14,100 $48,400 $51,900 $73,500 $109,900

5. Install and check equipment $1,000 $1,000 $1,000 $4,800 $18,200 $19,300 $19,500 $21,500

6. Perf. spec. tests (certif.) $700 $700 $700 $0 $15,700 $12,800 $35,500 $42,300

7. Prepare QA/QC plan $700 $700 $700 $800 $17,500 $17,500 $15,400 $17,500

8. Total capital cost = Planning + selecting equipment + 

support facilities + PEC + installation + 

perf. spec. tests + QA/QC plan

$18,000 $24,300 $10,300 $25,500 $134,000 $142,000 $158,000 $231,000 $230,000 $115,000

C. Annual Costs, $/yr

1. Operating labor = (5 min to record lime/carbon flow/4-hr 

period) x (1 hr/60 min) x H x LR

2. Maintenance materials = 0.02 x TCI $400 $500 $200

3. Operation & maintenance = Day-to-day activities + annual RATA 

+ CGA + annual QA + O&M review and 

update

$6,000 $27,600 $24,600 $27,300 $78,100

4. Recordkeeping and reporting = $1,000 x (525.4/386.5) $1,500 $1,500 $1,500 $200 $1,200 $1,600 $6,300 $1,600

5. Overhead = 0.6 x (labor + maintenance materials) $200 $300 $100

6. Property taxes, insurance, and 

administration

= 0.04 x TCI $700 $1,000 $400

7. Capital recovery = CRF x TCI $1,700 $2,300 $1,000 $3,500 $12,600 $20,200 $22,500 $32,900

8. Total annual cost = Operating labor + maintenance 

materials + recordkeeping and reporting 

+ overhead + property taxes, insurance, 

and administration + capital recovery

$4,500 $5,600 $3,200 $9,700 $41,400 $46,400 $56,100 $112,600 $63,300 $41,500

All model sizes
Notes:

1. Monitoring costs have been rounded to the nearest $100 to be consistent with level of rounding in original costs.

2. Costs to be replaced include: (a) bag leak detector replacing opacity test; (b) CO CEMS replacing CO test and secondary chamber temperature monitor;

(c) HCl CEMS replacing HCl test, HCl sorbent monitor (dry scrubbers) and scrubber liquor pH monitor (wet scrubbers); (d) PM CEMS replacing PM and

opacity tests and and pressure drop monitor (wet scrubbers); (e) multi-metal/Hg CEMS replacing flue gas temperature monitor (wet scrubbers); (f) dioxin

sorbent trap biweekly monitoring replacing fabric filter inlet temperature monitor; and (g) Hg sorbent trap biweekly monitoring replacing flue gas temperature

monitor (wet scrubbers).

Sources:

1. Hospital/Medical/Infectious Waste Incinerators (HMIWI) [EPA-HQ-OAR-2006-0534] Testing and Monitoring Options and Costs Memo (IV-B-66).

2. E-mail and attachment from Peter Westlin, EPA, to Mary Johnson, EPA. August 19, 2008. Monitoring Options for SNCR on Medical Waste Incinerators.

3. E-mail from Dan Bivins, EPA, to Mary Johnson, EPA. September 27, 2006. Cost of CO CEMS.

4. E-mail from Dan Bivins, EPA, to Mary Johnson, EPA. July 28, 2006. Some Preliminary Thoughts on the HWI Monitoring.
Monitoring Costs

Parameters/Costs

A. Parameters

1. Recording lime/carbon flow, min/4-hr 

period

2. Annual operating hours, hr/yr (H)

3. Cost index

 a. 2008

 b. 2006

 c. 1997

 d. 1993

 e. 1992

4. Operating labor wage rate, $/hr (LR)

5. Capital recovery factor, 20-yr 

equipment life, 7% interest (CRF)

B. Total Capital Investment, $ (TCI)

1. Planning

2. Select type of equipment

3. Provide support facilities

4. Purchased equipment cost (PEC)

5. Install and check equipment

6. Perf. spec. tests (certif.)

7. Prepare QA/QC plan

8. Total capital cost

C. Annual Costs, $/yr

1. Operating labor

2. Maintenance materials

3. Operation & maintenance

4. Recordkeeping and reporting

5. Overhead

6. Property taxes, insurance, and 

administration

7. Capital recovery

8. Total annual cost

ACI ACI

ALNational

CementRag

land

CACAPortla

ndCementC

olton

CACAPortlan

dCementColt

on

CALehighSo

uthwestReddi

ngPlant

FLCemexMia

mi

IALafargeBuf

falo

IALehighCe

mentMasonC

ity

MDLehighCe

mentUnionBri

dge

MILafargeMi

dwestAlpena

MILafargeMi

dwestAlpena

MILafargeMi

dwestAlpena

MILafargeMi

dwestAlpena

MILafargeMi

dwestAlpena

PALafargeW

hitehallPlant

Kiln K-1 K-2

In-Line 

Kiln/Raw Mill 

(S260) Cement Kiln Kiln 1 302.203 E02-001 19 20 21 22 23 Kiln 2

5 5 5 5 5 5 5 5 5 5 5 5 5 5

7920 8322 8322 8760 7900 7800 8760 8322 7540 7540 7540 7540 7540 6000

575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4

499.6 499.6 499.6 499.6 499.6 499.6 499.6 499.6 499.6 499.6 499.6 499.6 499.6 499.6

386.5 386.5 386.5 386.5 386.5 386.5 386.5 386.5 386.5 386.5 386.5 386.5 386.5 386.5

359.2 359.2 359.2 359.2 359.2 359.2 359.2 359.2 359.2 359.2 359.2 359.2 359.2 359.2

358.2 358.2 358.2 358.2 358.2 358.2 358.2 358.2 358.2 358.2 358.2 358.2 358.2 358.2

$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

0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439

$5,700 $6,000 $6,000 $6,300 $5,700 $5,600 $6,300 $6,000 $5,400 $5,400 $5,400 $5,400 $5,400 $4,300

$3,400 $3,600 $3,600 $3,800 $3,400 $3,400 $3,800 $3,600 $3,200 $3,200 $3,200 $3,200 $3,200 $2,600

$9,100 $9,600 $9,600 $10,100 $9,100 $9,000 $10,100 $9,600 $8,600 $8,600 $8,600 $8,600 $8,600 $6,900
Notes:

1. Monitoring costs have been rounded to the nearest $100 to be consistent with level of rounding in original costs.

2. Costs to be replaced include: (a) bag leak detector replacing opacity test; (b) CO CEMS replacing CO test and secondary chamber temperature monitor;

(c) HCl CEMS replacing HCl test, HCl sorbent monitor (dry scrubbers) and scrubber liquor pH monitor (wet scrubbers); (d) PM CEMS replacing PM and

opacity tests and and pressure drop monitor (wet scrubbers); (e) multi-metal/Hg CEMS replacing flue gas temperature monitor (wet scrubbers); (f) dioxin

sorbent trap biweekly monitoring replacing fabric filter inlet temperature monitor; and (g) Hg sorbent trap biweekly monitoring replacing flue gas temperature

monitor (wet scrubbers).

Sources:

1. Hospital/Medical/Infectious Waste Incinerators (HMIWI) [EPA-HQ-OAR-2006-0534] Testing and Monitoring Options and Costs Memo (IV-B-66).

2. E-mail and attachment from Peter Westlin, EPA, to Mary Johnson, EPA. August 19, 2008. Monitoring Options for SNCR on Medical Waste Incinerators.

3. E-mail from Dan Bivins, EPA, to Mary Johnson, EPA. September 27, 2006. Cost of CO CEMS.

4. E-mail from Dan Bivins, EPA, to Mary Johnson, EPA. July 28, 2006. Some Preliminary Thoughts on the HWI Monitoring.
Monitoring Costs

Parameters/Costs

A. Parameters

1. Recording lime/carbon flow, min/4-hr 

period

2. Annual operating hours, hr/yr (H)

3. Cost index

 a. 2008

 b. 2006

 c. 1997

 d. 1993

 e. 1992

4. Operating labor wage rate, $/hr (LR)

5. Capital recovery factor, 20-yr 

equipment life, 7% interest (CRF)

B. Total Capital Investment, $ (TCI)

1. Planning

2. Select type of equipment

3. Provide support facilities

4. Purchased equipment cost (PEC)

5. Install and check equipment

6. Perf. spec. tests (certif.)

7. Prepare QA/QC plan

8. Total capital cost

C. Annual Costs, $/yr

1. Operating labor

2. Maintenance materials

3. Operation & maintenance

4. Recordkeeping and reporting

5. Overhead

6. Property taxes, insurance, and 

administration

7. Capital recovery

8. Total annual cost

PALafargeW

hitehallPlant

PALehighCe

mentEvansvil

le

PALehighCe

mentEvansvil

le

PALehighCe

mentYork

TXAshGrove

Midlothian

TXAshGrove

Midlothian

TXAshGrove

Midlothian

TXHolcimMid

lothianPlant

TXHolcimMid

lothianPlant

UTHolcimDe

vilsSlide

Kiln 3 121 122 200 Kiln 1 Kiln 2 Kiln 3 Kiln 1 Kiln 2 Kiln 1

5 5 5 5 5 5 5 5 5 5

5000 8760 8760 8760 8322 8322 8322 6437 6955 7861.118

575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4 575.4

499.6 499.6 499.6 499.6 499.6 499.6 499.6 499.6 499.6 499.6

386.5 386.5 386.5 386.5 386.5 386.5 386.5 386.5 386.5 386.5

359.2 359.2 359.2 359.2 359.2 359.2 359.2 359.2 359.2 359.2

358.2 358.2 358.2 358.2 358.2 358.2 358.2 358.2 358.2 358.2

$34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60 $34.60

0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439 0.09439

$3,600 $6,300 $6,300 $6,300 $6,000 $6,000 $6,000 $4,600 $5,000 $5,700

$2,200 $3,800 $3,800 $3,800 $3,600 $3,600 $3,600 $2,800 $3,000 $3,400

$5,800 $10,100 $10,100 $10,100 $9,600 $9,600 $9,600 $7,400 $8,000 $9,100
Notes:

1. Monitoring costs have been rounded to the nearest $100 to be consistent with level of rounding in original costs.

2. Costs to be replaced include: (a) bag leak detector replacing opacity test; (b) CO CEMS replacing CO test and secondary chamber temperature monitor;

(c) HCl CEMS replacing HCl test, HCl sorbent monitor (dry scrubbers) and scrubber liquor pH monitor (wet scrubbers); (d) PM CEMS replacing PM and

opacity tests and and pressure drop monitor (wet scrubbers); (e) multi-metal/Hg CEMS replacing flue gas temperature monitor (wet scrubbers); (f) dioxin

sorbent trap biweekly monitoring replacing fabric filter inlet temperature monitor; and (g) Hg sorbent trap biweekly monitoring replacing flue gas temperature

monitor (wet scrubbers).

Sources:

1. Hospital/Medical/Infectious Waste Incinerators (HMIWI) [EPA-HQ-OAR-2006-0534] Testing and Monitoring Options and Costs Memo (IV-B-66).

2. E-mail and attachment from Peter Westlin, EPA, to Mary Johnson, EPA. August 19, 2008. Monitoring Options for SNCR on Medical Waste Incinerators.

3. E-mail from Dan Bivins, EPA, to Mary Johnson, EPA. September 27, 2006. Cost of CO CEMS.

4. E-mail from Dan Bivins, EPA, to Mary Johnson, EPA. July 28, 2006. Some Preliminary Thoughts on the HWI Monitoring.
Stack Testing Costs

Parameters/Costs Equation Values

A. Parameters

1. Cost index

 a. 2008 575.4

 d. 1992 358.2

B. Testing Costs, $

1. Method 5 (PM) = $8,000 x (575.4/358.2) $12,000

2. Method 9 (opacity) = $1,000 x (575.4/358.2) + $1,500 $2,500

3. Method 10 (CO) = $4,000 x (575.4/358.2) + $1,000 $7,000

4. Method 26 (HCl) = $5,000 x (575.4/358.2) $7,000

5. Method 29 (metals) = $8,000 x (575.4/358.2) + $2,000 $14,000

6. Method 23 (CDD/CDF) = $21,000 x (575.4/358.2) - $5,000 $26,000

7. Method 7E (NOX) = $5,000 x (575.4/358.2) $7,000

8. Method 6C (SO2) = $5,000 x (575.4/358.2) $7,000

Note:

1. Initial testing costs to be annualized over 15 years at 7% interest.

2. Testing costs have been rounded to the nearest $1,000 (except for opacity) to be

consistent with level of rounding in original costs; costs also adjusted based on

additional information from EPA.

3. Multiple test costs adjusted by 2/3 in nationwide cost estimates to account for travel,

accommodations, methods/sampling trains, etc. common to the tests.

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 for SNCR & Test Cost Questions.

CRF (15 yr, 7%): 0.10979
Initial Test annualized (TAC)

Annual PM, HCl, opacity; $14,333

Annual everything except PM, Hg, HCl, and opacity $40,667 $4,465

Annual PM, HCl, CO, Nox, SO2, opacity: $28,333

All pollutants: $55,000
Cost Factor (in 2008$) Reference/Note Year of Costs

Advanced Combustion Controls (Linkageless Boiler Management System) -- cost is per boiler - TCI

LBMS costs are based on a 2008 quote provided 

to the U.S. Department of Energy. The installed 

cost for a LBMS on a 20 mmBtu/hr unit was are 

$19,127. The DOE noted that costs are relatively 

fixed, regardless of the size of the unit. 

Assumed to represent $2008, since that was the 

year the quote was obtained.

Activated Carbon Injection

Received spreadsheet of HMIWI model costs 

from Tom Holloway of RTI International. Originally $2004

Received spreadsheet of HMIWI model costs 

from Tom Holloway of RTI International. Originally $2004

Packed Scrubber

Received spreadsheet of HMIWI model costs 

from Tom Holloway of RTI International. Originally $2004

Secondary Chamber/Afterburner Retrofit

Received spreadsheet of HMIWI model costs 

from Tom Holloway of RTI International. Originally $2004

Selective Non-Catalytic Reduction

Received spreadsheet of HMIWI model costs 

from Tom Holloway of RTI International. Originally $2004

Catalytic Oxidizer

Used catalytic oxidizer costing for all sizes, 

though some fell outside the appropriate sizerange for the equation. Originally $2004

Hospital/Medical/Infectious Waste Incinerators (HMIWI). [EPAHQ-OAR-2006-0534]

$ 19,127

Fabric Filter

Hospital/Medical/Infectious Waste Incinerators (HMIWI). [EPAHQ-OAR-2006-0534]

EPA Air Pollution Control Cost Manual, Sixth Edition EPA 452/B-02-

001

Hospital/Medical/Infectious Waste Incinerators (HMIWI). [EPAHQ-OAR-2006-0534]

Hospital/Medical/Infectious Waste Incinerators (HMIWI). [EPAHQ-OAR-2006-0534]

Hospital/Medical/Infectious Waste Incinerators (HMIWI). [EPAHQ-OAR-2006-0534]