Summary of Impacts - Addition of In-Series Baghouse

Scenario Data sources ACFM

Inlet 

Temp

Bag 

material

Assumed 

Bag life Baghouse type Capital Cost

Annualized 

cost 

Emission 

Reduction 

(tpy) $/ton

Emission 

Reduction 

(tpy) $/ton

Scenario Using Average Emission Factor

1. Add on 1 FF to Main stack only Main - averaged over 7 tests 1,023,723 170 Standard 2 P-J (modular) $7,395,207 $1,529,730 57.4 $26,649 28.7 $53,245

Main - averaged over 7 tests 1,023,723 170 Standard 2 P-J (modular) $7,395,207 $1,529,730

7/8/9 - 2008 stack test 595,888 106 Standard 2 P-J (modular) $3,311,576 $849,750

 P-J (modular) $10,706,784 $2,379,480 58.8 $40,449 29.4 $80,818

3. Add on 1 FF to Main stack and 

 BHs 7/8/9 combined

Main - averaged over 7 tests

7/8/9 - 2008 stack test

1,619,611 170 Standard 2 P-J (modular) $11,274,855 $2,388,650 58.8 $40,605 29.4 $81,129

1

 Estimated removal efficiency b ased on standard baghouse performance.

2

 Estimated removal efficience based on reduction due to in-series configuration.

2. Add on 1 FF to Main stack and 

 1 FF to BHs 7/8/9 combined

Total Scenario 2

99.9% RE150% RE2
Draft Cost Estimates -Doe Run, Herculaneum

Add0on Control Technology - Fabric Filter

Based on AVERAGE Stack Flow Rate

Add-on BH for main stack only

Main stack

TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

COST BASE DATE: Third Quarter 1986 [2]

2008 575.4

 INPUT PARAMETERS:

-- Inlet stream flowrate (acfm): 1023723

-- Inlet stream temperature (oF): 170

-- Dust type: Blast furnace dust

-- Inlet dust loading (gr/ft3): 0.0018699

Dust mass median diameter (microns): 3.68

-- Filtration time (min): 10

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

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

 A: 2.5

 B: 1

 C: 1.2

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

 Material: 10

Application: 0.8

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

-- Fraction of bags cleaned (shaker & rev-air): 0

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

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

-- Bag material: Fiberglass w/PTFE 

Membranes (cost 

modifier at right)

1

-- Fabric effective residual drag (in. H2O/fpm): 1

-- Bag prices ($/ft2): [4]

 Mechanical shaker: 0 0 0 0

 Reverse-air $0.53 $0.69 $0.76 $0.99

 Pulse-jet $0.95 $1.08 $1.24 $1.29

DESIGN PARAMETERS

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

 Mechanical shaker: 2.7

 Reverse-air: 2.7

 Pulse-jet: 8.7

-- Net cloth area required (ft2):

 Mechanical shaker: 379157

 Reverse-air: 379157

 Pulse-jet: 117682

-- Gross cloth area required (ft2):

 Mechanical shaker: 394323

Reverse-air: 394323

 Pulse-jet: 117682

-- Area per bag/cage (ft2): 13

-- Number of bags/cages (pulse-jet only): 8772

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

 Mechanical shaker: 2.97

Reverse-air: 2.97

 Pulse-jet: 2.65

Page 2 of 36
Draft Cost Estimates -Doe Run, Herculaneum

Add0on Control Technology - Fabric Filter

Based on AVERAGE Stack Flow Rate

Add-on BH for main stack only

Main stack

TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

CAPITAL COSTS

Equipment Costs ($):

Item: Cost ($):

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

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

Baghouse 0 2,794,245 909,003 663,057

Bags 0 292,785 134,157 134,157

Insulation 0 316,588 247,660 110,990

Stainless 0 0 0 0

Cages 0 0 102,001 102,001

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

Total: 0 3,403,619 1,392,821 1,010,204

PEC($)-base: 0 4,016,270 1,643,528 1,192,041

 ' ' -esc.: 0 8,327,916 3,407,930 2,471,749

TCI ($): 0 18,071,577 7,395,207 5,363,696

 ($/acfm): 0 18 7 5

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

ANNUAL COST INPUTS:

Operating factor (hr/yr): 7920

Operating labor rate ($/hr): $15.82

Maintenance labor rate ($/hr): $17.40

Operating labor factor (hr/sh): 2.00

Maintenance labor factor (hr/sh): 1.00

Electricity price ($/kWhr): 0.062

Compressed air ($/1000 scf): 0.16

Dust disposal ($/ton): 20

Annual interest rate (fraction): 0.07

Control system life (years): 20

Capital recovery factor: 0.0944

Bag life (years): 5

Capital recovery factor (bags): 0.2439

Taxes, insurance, admin. factor: 4%

 ANNUAL COSTS ($/yr):

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

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

Oper. labor 0 31,324 31,324 31,324

Supv. labor 0 4,699 4,699 4,699

Maint. labor 0 17,228 17,228 17,228

Maint. matl. 0 17,228 17,228 17,228

Electricity 0 360,179 239,906 239,906

Compr. air 0 0 155,671 155,671

Bag repl. 0 92,012 42,783 42,783

Dust dispos. 0 1,299 1,299 1,299

Overhead 0 42,287 42,287 42,287

Tax,ins.,adm 0 722,863 295,808 214,548

Cap. recov. 0 1,670,218 681,497 489,737

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

Total Annual 0 2,959,336 1,529,730 1,256,709

Page 3 of 36
Draft Cost Estimates -Doe Run, Herculaneum

Add0on Control Technology - Fabric Filter

Based on AVERAGE Stack Flow Rate

Add-on BH for main stack only

Main stack

TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

ANNUAL COST WEIGHTING FACTORS:

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

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

Oper. labor 0.000 0.011 0.020 0.025

Supv. labor 0.000 0.002 0.003 0.004

Maint. labor 0.000 0.006 0.011 0.014

Maint. matl. 0.000 0.006 0.011 0.014

Overhead 0.000 0.014 0.028 0.034

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

S/T labor: 0.000 0.038 0.074 0.090

Compr. air 0.000 0.000 0.102 0.124

Bag repl. 0.000 0.031 0.028 0.034

Dust dispos. 0.000 0.000 0.001 0.001

Electricity 0.000 0.122 0.157 0.191

Tax,ins.,adm 0.000 0.244 0.193 0.171

Cap. recov. 0.000 0.564 0.446 0.390

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

S/T capital: 0.000 0.809 0.639 0.560

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

Total: 0.000 1.000 1.000 1.000

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

RELATIONSHIP BETWEEN GROSS AND NET CLOTH AREA

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

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

1 2.000

4001 1.500

12001 1.250

24001 1.170

36001 1.125

48001 1.110

60001 1.100

72001 1.090

84001 1.080

96001 1.070

108001 1.060

132001 1.050

180001 1.040

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

in Chapter 5 of the 'OAQPS Control Cost Manual'(4th edition).

[2] Base equipment costs reflect this date.

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

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

purchased equipment cost, and total capital investment have been

escalated to this date via VAPCCI and control equipment vendor data.

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

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

(See 'Manual,' Chapter 5, Table 5.7.)

Page 4 of 36
Draft Cost Estimates -Doe Run, Herculaneum

Add0on Control Technology - Fabric Filter

Based on AVERAGE Stack Flow Rate

Add-on 2 BHs - Main and 7,8 and 9 combined

BH 7, 8 and 9 combined

TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

COST BASE DATE: Third Quarter 1986 [2]

2008 575.4

 INPUT PARAMETERS:

-- Inlet stream flowrate (acfm): 595888

-- Inlet stream temperature (oF): 106

-- Dust type: Kettle refinery dust

-- Inlet dust loading (gr/ft3): 0.00006906

Dust mass median diameter (microns): 3.68

-- Filtration time (min): 10

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

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

 A: 2.5

 B: 1

 C: 1.2

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

 Material: 10

Application: 0.8

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

-- Fraction of bags cleaned (shaker & rev-air): 0

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

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

-- Bag material:

 Fiberglass w/PTFE 

Membranes (cost 

modifier at right)

1

-- Fabric effective residual drag (in. H2O/fpm): 1

-- Bag prices ($/ft2): [4]

 Mechanical shaker: 0 0 0 0

 Reverse-air $0.53 $0.69 $0.76 $0.99

 Pulse-jet $0.95 $1.08 $1.24 $1.29

DESIGN PARAMETERS

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

 Mechanical shaker: 2.7

 Reverse-air: 2.7

 Pulse-jet: 11.9

-- Net cloth area required (ft2):

 Mechanical shaker: 220699

 Reverse-air: 220699

 Pulse-jet: 50267

-- Gross cloth area required (ft2):

 Mechanical shaker: 229527

Reverse-air: 229527

 Pulse-jet: 50267

-- Area per bag/cage (ft2): 13

-- Number of bags/cages (pulse-jet only): 3747

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

 Mechanical shaker: 2.97

Reverse-air: 2.97

 Pulse-jet: 3.61

Page 5 of 36
Draft Cost Estimates -Doe Run, Herculaneum

Add0on Control Technology - Fabric Filter

Based on AVERAGE Stack Flow Rate

Add-on 2 BHs - Main and 7,8 and 9 combined

BH 7, 8 and 9 combined

TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

CAPITAL COSTS

Equipment Costs ($):

Item: Cost ($):

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

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

Baghouse 0 1,638,698 415,326 288,771

Bags 0 170,424 57,304 57,304

Insulation 0 184,752 107,505 48,227

Stainless 0 0 0 0

Cages 0 0 43,570 43,570

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

Total: 0 1,993,874 623,706 437,872

PEC($)-base: 0 2,352,771 735,973 516,689

 ' ' -esc.: 0 4,878,576 1,526,072 1,071,378

TCI ($): 0 10,586,510 3,311,576 2,324,889

 ($/acfm): 0 18 6 4

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

ANNUAL COST INPUTS:

Operating factor (hr/yr): 7920

Operating labor rate ($/hr): $15.82

Maintenance labor rate ($/hr): $17.40

Operating labor factor (hr/sh): 2.00

Maintenance labor factor (hr/sh): 1.00

Electricity price ($/kWhr): 0.062

Compressed air ($/1000 scf): 0.16

Dust disposal ($/ton): 20

Annual interest rate (fraction): 0.07

Control system life (years): 20

Capital recovery factor: 0.0944

Bag life (years): 5

Capital recovery factor (bags): 0.2439

Taxes, insurance, admin. factor: 4%

 ANNUAL COSTS ($/yr):

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

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

Oper. labor 0 31,324 31,324 31,324

Supv. labor 0 4,699 4,699 4,699

Maint. labor 0 17,228 17,228 17,228

Maint. matl. 0 17,228 17,228 17,228

Electricity 0 209,638 190,090 190,090

Compr. air 0 0 90,613 90,613

Bag repl. 0 51,251 18,275 18,275

Dust dispos. 0 28 28 28

Overhead 0 42,287 42,287 42,287

Tax,ins.,adm 0 423,460 132,463 92,996

Cap. recov. 0 979,456 305,517 212,380

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

Total Annual 0 1,776,598 849,750 717,146

Page 6 of 36
Draft Cost Estimates -Doe Run, Herculaneum

Add0on Control Technology - Fabric Filter

Based on AVERAGE Stack Flow Rate

Add-on 2 BHs - Main and 7,8 and 9 combined

BH 7, 8 and 9 combined

TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

ANNUAL COST WEIGHTING FACTORS:

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

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

Oper. labor 0.000 0.018 0.037 0.044

Supv. labor 0.000 0.003 0.006 0.007

Maint. labor 0.000 0.010 0.020 0.024

Maint. matl. 0.000 0.010 0.020 0.024

Overhead 0.000 0.024 0.050 0.059

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

S/T labor: 0.000 0.063 0.133 0.157

Compr. air 0.000 0.000 0.107 0.126

Bag repl. 0.000 0.029 0.022 0.025

Dust dispos. 0.000 0.000 0.000 0.000

Electricity 0.000 0.118 0.224 0.265

Tax,ins.,adm 0.000 0.238 0.156 0.130

Cap. recov. 0.000 0.551 0.360 0.296

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

S/T capital: 0.000 0.790 0.515 0.426

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

Total: 0.000 1.000 1.000 1.000

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

RELATIONSHIP BETWEEN GROSS AND NET CLOTH AREA

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

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

1 2.000

4001 1.500

12001 1.250

24001 1.170

36001 1.125

48001 1.110

60001 1.100

72001 1.090

84001 1.080

96001 1.070

108001 1.060

132001 1.050

180001 1.040

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

in Chapter 5 of the 'OAQPS Control Cost Manual'(4th edition).

[2] Base equipment costs reflect this date.

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

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

purchased equipment cost, and total capital investment have been

escalated to this date via VAPCCI and control equipment vendor data.

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

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

(See 'Manual,' Chapter 5, Table 5.7.)

Page 7 of 36
Draft Cost Estimates -Doe Run, Herculaneum

Add0on Control Technology - Fabric Filter

Based on AVERAGE Stack Flow Rate

Add-on BH for main combined with 7, 8 and 9

All MACT sources

TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

COST BASE DATE: Third Quarter 1986 [2]

2008 575.4

 INPUT PARAMETERS:

-- Inlet stream flowrate (acfm): 1619611

-- Inlet stream temperature (oF): 170

-- Dust type:

blast furnace/kettel 

refinery dust

-- Inlet dust loading (gr/ft3): 0.0012510

Dust mass median diameter (microns): 3.68

-- Filtration time (min): 10

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

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

 A: 2.5

 B: 1

 C: 1.2

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

 Material: 10

Application: 0.8

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

-- Fraction of bags cleaned (shaker & rev-air): 0

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

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

-- Bag material: Fiberglass w/PTFE 

Membranes (cost 

modifier at right)

1

-- Fabric effective residual drag (in. H2O/fpm): 1

-- Bag prices ($/ft2): [4]

 Mechanical shaker: 0 0 0 0

 Reverse-air $0.53 $0.69 $0.76 $0.99

 Pulse-jet $0.95 $1.08 $1.24 $1.29

DESIGN PARAMETERS

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

 Mechanical shaker: 2.7

 Reverse-air: 2.7

 Pulse-jet: 8.9

-- Net cloth area required (ft2):

 Mechanical shaker: 599856

 Reverse-air: 599856

 Pulse-jet: 181730

-- Gross cloth area required (ft2):

 Mechanical shaker: 623850

Reverse-air: 623850

 Pulse-jet: 181730

-- Area per bag/cage (ft2): 13

-- Number of bags/cages (pulse-jet only): 13545

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

 Mechanical shaker: 2.97

Reverse-air: 2.97

 Pulse-jet: 2.72

Page 8 of 36
Draft Cost Estimates -Doe Run, Herculaneum

Add0on Control Technology - Fabric Filter

Based on AVERAGE Stack Flow Rate

Add-on BH for main combined with 7, 8 and 9

All MACT sources

TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

CAPITAL COSTS

Equipment Costs ($):

Item: Cost ($):

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

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

Baghouse 0 4,403,690 1,378,028 1,018,652

Bags 0 463,209 207,172 207,172

Insulation 0 500,210 380,816 170,619

Stainless 0 0 0 0

Cages 0 0 157,501 157,501

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

Total: 0 5,367,109 2,123,517 1,553,944

PEC($)-base: 0 6,333,189 2,505,750 1,833,654

 ' ' -esc.: 0 13,132,151 5,195,786 3,802,163

TCI ($): 0 28,496,767 11,274,855 8,250,694

 ($/acfm): 0 18 7 5

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

ANNUAL COST INPUTS:

Operating factor (hr/yr): 7920

Operating labor rate ($/hr): $15.82

Maintenance labor rate ($/hr): $17.40

Operating labor factor (hr/sh): 2.00

Maintenance labor factor (hr/sh): 1.00

Electricity price ($/kWhr): 0.062

Compressed air ($/1000 scf): 0.16

Dust disposal ($/ton): 20

Annual interest rate (fraction): 0.07

Control system life (years): 20

Capital recovery factor: 0.0944

Bag life (years): 2

Capital recovery factor (bags): 0.5531

Taxes, insurance, admin. factor: 4%

 ANNUAL COSTS ($/yr):

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

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

Oper. labor 0 31,324 31,324 31,324

Supv. labor 0 4,699 4,699 4,699

Maint. labor 0 17,228 17,228 17,228

Maint. matl. 0 17,228 17,228 17,228

Electricity 0 569,818 388,708 388,708

Compr. air 0 0 246,285 246,285

Bag repl. 0 328,840 149,826 149,826

Dust dispos. 0 1,375 1,375 1,375

Overhead 0 42,287 42,287 42,287

Tax,ins.,adm 0 1,139,871 450,994 330,028

Cap. recov. 0 2,633,772 1,038,697 753,237

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

Total Annual 0 4,786,441 2,388,650 1,982,224

Page 9 of 36
Draft Cost Estimates -Doe Run, Herculaneum

Add0on Control Technology - Fabric Filter

Based on AVERAGE Stack Flow Rate

Add-on BH for main combined with 7, 8 and 9

All MACT sources

TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

ANNUAL COST WEIGHTING FACTORS:

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

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

Oper. labor 0.000 0.007 0.013 0.016

Supv. labor 0.000 0.001 0.002 0.002

Maint. labor 0.000 0.004 0.007 0.009

Maint. matl. 0.000 0.004 0.007 0.009

Overhead 0.000 0.009 0.018 0.021

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

S/T labor: 0.000 0.024 0.047 0.057

Compr. air 0.000 0.000 0.103 0.124

Bag repl. 0.000 0.069 0.063 0.076

Dust dispos. 0.000 0.000 0.001 0.001

Electricity 0.000 0.119 0.163 0.196

Tax,ins.,adm 0.000 0.238 0.189 0.166

Cap. recov. 0.000 0.550 0.435 0.380

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

S/T capital: 0.000 0.788 0.624 0.546

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

Total: 0.000 1.000 1.000 1.000

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

RELATIONSHIP BETWEEN GROSS AND NET CLOTH AREA

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

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

1 2.000

4001 1.500

12001 1.250

24001 1.170

36001 1.125

48001 1.110

60001 1.100

72001 1.090

84001 1.080

96001 1.070

108001 1.060

132001 1.050

180001 1.040

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

in Chapter 5 of the 'OAQPS Control Cost Manual'(4th edition).

[2] Base equipment costs reflect this date.

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

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

purchased equipment cost, and total capital investment have been

escalated to this date via VAPCCI and control equipment vendor data.

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

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

(See 'Manual,' Chapter 5, Table 5.7.)

Page 10 of 36
Standard Cloth Bags

Baghouse 8

TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

COST BASE DATE: Third Quarter 1986 [2]

2008

 INPUT PARAMETERS:

-- Inlet stream flowrate (acfm):

-- Inlet stream temperature (oF):

-- Dust type:

-- Inlet dust loading (gr/ft3):

Dust mass median diameter (microns):

-- Filtration time (min):

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

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

 A:

 B:

 C:

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

 Material:

Application:

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

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

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

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

-- Bag material:

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

-- Bag prices ($/ft2): [4]

 Mechanical shaker: 0 0

 Reverse-air $0.53 $0.69

 Pulse-jet $0.95 $1.08

DESIGN PARAMETERS

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

 Mechanical shaker:

 Reverse-air:

 Pulse-jet:

-- Net cloth area required (ft2):

 Mechanical shaker:

 Reverse-air:

 Pulse-jet:

-- Gross cloth area required (ft2):

 Mechanical shaker:

Reverse-air:

 Pulse-jet:

-- Area per bag/cage (ft2):

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

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

 Mechanical shaker:

Reverse-air:

 Pulse-jet:

CAPITAL COSTS

Equipment Costs ($):

Item: Cost ($):

 Shaker Rev-air P-J (mod)

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

Baghouse 0 261,014 93,527

Bags 0 24,541 7,209

Insulation 0 27,572 16,146

Stainless 0 0 0

Cages 0 0 5,488

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

Total: 0 313,127 122,370

PEC($)-base: 0 369,490 144,397

 ' ' -esc.: 0 766,154 299,414

TCI ($): 0 1,662,553 649,728

 ($/acfm): 0 22 9

============================================================
Standard Cloth Bags

Baghouse 8

TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

COST BASE DATE: Third Quarter 1986 [2]

ANNUAL COST INPUTS:

Operating factor (hr/yr): 7920

Operating labor rate ($/hr): $15.82

Maintenance labor rate ($/hr): $17.40

Operating labor factor (hr/sh): 2.00

Maintenance labor factor (hr/sh): 1.00

Electricity price ($/kWhr): 0.062

Compressed air ($/1000 scf): 0.16

Dust disposal ($/ton): 20

Annual interest rate (fraction): 0.07

Control system life (years): 20

Capital recovery factor: 0.0944

Bag life (years): 5

Capital recovery factor (bags): 0.2439

Taxes, insurance, admin. factor: 4%

 ANNUAL COSTS ($/yr):

 Item Shaker Reverse-air P-J (mod)

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

Oper. labor 0 31,324 31,324

Supv. labor 0 4,699 4,699

Maint. labor 0 17,228 17,228

Maint. matl. 0 17,228 17,228

Electricity 0 27,687 24,757

Compr. air 0 0 11,599

Bag repl. 0 7,265 2,299

Dust dispos. 0 3 3

Overhead 0 42,287 42,287

Tax,ins.,adm 0 66,502 25,989

Cap. recov. 0 154,121 60,440

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

Total Annual 0 368,344 237,852

ANNUAL COST WEIGHTING FACTORS:

 Item Shaker Reverse-air P-J (mod)

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

Oper. labor 0.000 0.085 0.132

Supv. labor 0.000 0.013 0.020

Maint. labor 0.000 0.047 0.072

Maint. matl. 0.000 0.047 0.072

Overhead 0.000 0.115 0.178

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

S/T labor: 0.000 0.306 0.474

Compr. air 0.000 0.000 0.049

Bag repl. 0.000 0.020 0.010

Dust dispos. 0.000 0.000 0.000

Electricity 0.000 0.075 0.104

Tax,ins.,adm 0.000 0.181 0.109

Cap. recov. 0.000 0.418 0.254

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

S/T capital: 0.000 0.599 0.363

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

Total: 0.000 1.000 1.000

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

RELATIONSHIP BETWEEN GROSS AND NET CLOTH AREA

Net Cloth Area >/= (ft2):

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

1

4001

12001

24001

36001

48001

60001

72001

84001

96001

108001

132001
Standard Cloth Bags

Baghouse 8

TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

COST BASE DATE: Third Quarter 1986 [2]

180001

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

in Chapter 5 of the 'OAQPS Control Cost Manual'(4th edition).

[2] Base equipment costs reflect this date.

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

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

purchased equipment cost, and total capital investment have been

escalated to this date via VAPCCI and control equipment vendor data.

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

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

(See 'Manual,' Chapter 5, Table 5.7.)
Standard Cloth Bags

Baghouse 9 (BH 7 will be the same)

TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

COST BASE DATE: Third Quarter 1986 [2]

575.4 2008 575.4

 INPUT PARAMETERS:

76274 -- Inlet stream flowrate (acfm): 259807

107 -- Inlet stream temperature (oF): 107

Kettle refinery dust -- Dust type: Refinery bldg dust

0.0000490 -- Inlet dust loading (gr/ft3): 0.00007200

3.68 Dust mass median diameter (microns): 3.68

10 -- Filtration time (min): 10

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

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

2.5 A: 2.5

1 B: 1

1.2 C: 1.2

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

10 Material: 10

0.8 Application: 0.8

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

0 -- Fraction of bags cleaned (shaker & rev-air): 0

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

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

 Fiberglass w/PTFE 

Membranes (cost 

modifier at right)

1

-- Bag material:

 Fiberglass w/PTFE 

Membranes (cost 

modifier at right)

1

1 -- Fabric effective residual drag (in. H2O/fpm): 1

-- Bag prices ($/ft2): [4]

0 0 Mechanical shaker: 0 0 0 0

$0.76 $0.99 Reverse-air $0.53 $0.69 $0.76 $0.99

$1.24 $1.29 Pulse-jet $0.95 $1.08 $1.24 $1.29

DESIGN PARAMETERS

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

2.7 Mechanical shaker: 2.7

2.7 Reverse-air: 2.7

12.1 Pulse-jet: 11.8

-- Net cloth area required (ft2):

28250 Mechanical shaker: 96225

28250 Reverse-air: 96225

6323 Pulse-jet: 22044

-- Gross cloth area required (ft2):

33052 Mechanical shaker: 102961

33052 Reverse-air: 102961

6323 Pulse-jet: 22044

13 -- Area per bag/cage (ft2): 13

472 -- Number of bags/cages (pulse-jet only): 1644

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

2.97 Mechanical shaker: 2.97

2.97 Reverse-air: 2.97

3.68 Pulse-jet: 3.59

CAPITAL COSTS

Equipment Costs ($):

Item: Cost ($):

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

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

44,796 Baghouse 0 751,212 208,649 132,077

7,209 Bags 0 76,448 25,130 25,130

7,315 Insulation 0 83,498 48,830 21,951

0 Stainless 0 0 0 0

5,488 Cages 0 0 19,116 19,116

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

64,808 Total: 0 911,159 301,726 198,275

76,474 PEC($)-base: 0 1,075,168 356,036 233,964

158,572 ' ' -esc.: 0 2,229,408 738,257 485,136

344,101 TCI ($): 0 4,837,816 1,602,018 1,052,744

5 ($/acfm): 0 19 6 4

============================================================
Standard Cloth Bags

Baghouse 9 (BH 7 will be the same)

TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

COST BASE DATE: Third Quarter 1986 [2]

ANNUAL COST INPUTS:

Operating factor (hr/yr): 7920

Operating labor rate ($/hr): $15.82

Maintenance labor rate ($/hr): $17.40

Operating labor factor (hr/sh): 2.00

Maintenance labor factor (hr/sh): 1.00

Electricity price ($/kWhr): 0.062

Compressed air ($/1000 scf): 0.16

Dust disposal ($/ton): 20

Annual interest rate (fraction): 0.07

Control system life (years): 20

Capital recovery factor: 0.0944

Bag life (years): 5

Capital recovery factor (bags): 0.2439

Taxes, insurance, admin. factor: 4%

 ANNUAL COSTS ($/yr):

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

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

31,324 Oper. labor 0 31,324 31,324 31,324

4,699 Supv. labor 0 4,699 4,699 4,699

17,228 Maint. labor 0 17,228 17,228 17,228

17,228 Maint. matl. 0 17,228 17,228 17,228

24,757 Electricity 0 92,073 82,399 82,399

11,599 Compr. air 0 0 39,507 39,507

2,299 Bag repl. 0 22,928 8,015 8,015

3 Dust dispos. 0 13 13 13

42,287 Overhead 0 42,287 42,287 42,287

13,764 Tax,ins.,adm 0 193,513 64,081 42,110

31,591 Cap. recov. 0 447,782 148,117 96,270

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

196,778 Total Annual 0 869,073 454,897 381,078

ANNUAL COST WEIGHTING FACTORS:

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

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

0.159 Oper. labor 0.000 0.036 0.069 0.082

0.024 Supv. labor 0.000 0.005 0.010 0.012

0.088 Maint. labor 0.000 0.020 0.038 0.045

0.088 Maint. matl. 0.000 0.020 0.038 0.045

0.215 Overhead 0.000 0.049 0.093 0.111

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

0.573 S/T labor: 0.000 0.130 0.248 0.296

0.059 Compr. air 0.000 0.000 0.087 0.104

0.012 Bag repl. 0.000 0.026 0.018 0.021

0.000 Dust dispos. 0.000 0.000 0.000 0.000

0.126 Electricity 0.000 0.106 0.181 0.216

0.070 Tax,ins.,adm 0.000 0.223 0.141 0.111

0.161 Cap. recov. 0.000 0.515 0.326 0.253

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

0.230 S/T capital: 0.000 0.738 0.466 0.363

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

1.000 Total: 0.000 1.000 1.000 1.000

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

RELATIONSHIP BETWEEN GROSS AND NET CLOTH AREA

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

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

2.000 1 2.000

1.500 4001 1.500

1.250 12001 1.250

1.170 24001 1.170

1.125 36001 1.125

1.110 48001 1.110

1.100 60001 1.100

1.090 72001 1.090

1.080 84001 1.080

1.070 96001 1.070

1.060 108001 1.060

1.050 132001 1.050
Standard Cloth Bags

Baghouse 9 (BH 7 will be the same)

TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

COST BASE DATE: Third Quarter 1986 [2]

1.040 180001 1.040

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

in Chapter 5 of the 'OAQPS Control Cost Manual'(4th edition).

[2] Base equipment costs reflect this date.

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

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

purchased equipment cost, and total capital investment have been

escalated to this date via VAPCCI and control equipment vendor data.

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

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

(See 'Manual,' Chapter 5, Table 5.7.)



Membrane Bags

Baghouse 8

TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

COST BASE DATE: Third Quarter 1986 [2]

2008 575.4

 INPUT PARAMETERS:

-- Inlet stream flowrate (acfm): 76274

-- Inlet stream temperature (oF): 104

-- Dust type: Kettle refinery dust

-- Inlet dust loading (gr/ft3): 0.0000490

Dust mass median diameter (microns): 3.68

-- Filtration time (min): 10

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

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

 A: 2.5

 B: 1

 C: 1.2

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

 Material: 10

Application: 0.8

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

-- Fraction of bags cleaned (shaker & rev-air): 0

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

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

-- Bag material: Fiberglass w/PTFE 

Membranes (cost 

modifier at right)

3.75

-- Fabric effective residual drag (in. H2O/fpm): 1

-- Bag prices ($/ft2): [4]

 Mechanical shaker: 0 0 0 0

 Reverse-air $1.99 $2.59 $2.85 $3.71

 Pulse-jet $3.56 $4.05 $4.65 $4.84

DESIGN PARAMETERS

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

 Mechanical shaker: 2.7

 Reverse-air: 2.7

 Pulse-jet: 12.1

-- Net cloth area required (ft2):

 Mechanical shaker: 28250

 Reverse-air: 28250

 Pulse-jet: 6282

-- Gross cloth area required (ft2):

 Mechanical shaker: 33052

Reverse-air: 33052

 Pulse-jet: 6282

-- Area per bag/cage (ft2): 13

-- Number of bags/cages (pulse-jet only): 469

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

 Mechanical shaker: 2.97

Reverse-air: 2.97

 Pulse-jet: 3.70

CAPITAL COSTS

Equipment Costs ($):

Item: Cost ($):

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

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

Baghouse 0 261,014 93,220 44,564

Bags 0 92,029 26,854 26,854

Insulation 0 27,572 16,059 7,276

Stainless 0 0 0 0

Cages 0 0 5,454 5,454

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

Total: 0 380,615 141,587 84,147

PEC($)-base: 0 449,126 167,073 99,294

 ' ' -esc.: 0 931,282 346,433 205,890

TCI ($): 0 2,020,883 751,760 446,781

 ($/acfm): 0 26 10 6

============================================================
Membrane Bags

Baghouse 8

TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

COST BASE DATE: Third Quarter 1986 [2]

ANNUAL COST INPUTS:

Operating factor (hr/yr): 7920

Operating labor rate ($/hr): $15.82

Maintenance labor rate ($/hr): $17.40

Operating labor factor (hr/sh): 2.00

Maintenance labor factor (hr/sh): 1.00

Electricity price ($/kWhr): 0.062

Compressed air ($/1000 scf): 0.16

Dust disposal ($/ton): 20

Annual interest rate (fraction): 0.07

Control system life (years): 20

Capital recovery factor: 0.0944

Bag life (years): 5

Capital recovery factor (bags): 0.2439

Taxes, insurance, admin. factor: 4%

 ANNUAL COSTS ($/yr):

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

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

Oper. labor 0 31,324 31,324 31,324

Supv. labor 0 4,699 4,699 4,699

Maint. labor 0 17,228 17,228 17,228

Maint. matl. 0 17,228 17,228 17,228

Electricity 0 27,687 24,922 24,922

Compr. air 0 0 11,599 11,599

Bag repl. 0 25,037 7,471 7,471

Dust dispos. 0 3 3 3

Overhead 0 42,287 42,287 42,287

Tax,ins.,adm 0 80,835 30,070 17,871

Cap. recov. 0 181,067 68,069 39,281

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

Total Annual 0 427,394 254,899 213,912

ANNUAL COST WEIGHTING FACTORS:

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

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

Oper. labor 0.000 0.073 0.123 0.146

Supv. labor 0.000 0.011 0.018 0.022

Maint. labor 0.000 0.040 0.068 0.081

Maint. matl. 0.000 0.040 0.068 0.081

Overhead 0.000 0.099 0.166 0.198

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

S/T labor: 0.000 0.264 0.442 0.527

Compr. air 0.000 0.000 0.046 0.054

Bag repl. 0.000 0.059 0.029 0.035

Dust dispos. 0.000 0.000 0.000 0.000

Electricity 0.000 0.065 0.098 0.117

Tax,ins.,adm 0.000 0.189 0.118 0.084

Cap. recov. 0.000 0.424 0.267 0.184

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

S/T capital: 0.000 0.613 0.385 0.267

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

Total: 0.000 1.000 1.000 1.000

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

RELATIONSHIP BETWEEN GROSS AND NET CLOTH AREA RELATIONSHIP BETWEEN GROSS AND NET CLOTH AREA

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

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

1 2.000

4001 1.500

12001 1.250

24001 1.170

36001 1.125

48001 1.110

60001 1.100

72001 1.090

84001 1.080

96001 1.070

108001 1.060

132001 1.050
Membrane Bags

Baghouse 8

TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

COST BASE DATE: Third Quarter 1986 [2]

180001 1.040

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

in Chapter 5 of the 'OAQPS Control Cost Manual'(4th edition).

[2] Base equipment costs reflect this date.

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

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

purchased equipment cost, and total capital investment have been

escalated to this date via VAPCCI and control equipment vendor data.

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

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

(See 'Manual,' Chapter 5, Table 5.7.)
Membrane Bags

Baghouse 9 (BH 7 will be the same)

TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

COST BASE DATE: Third Quarter 1986 [2]

2008 575.4

 INPUT PARAMETERS:

-- Inlet stream flowrate (acfm): 259807

-- Inlet stream temperature (oF): 107

-- Dust type: Refinery bldg dust

-- Inlet dust loading (gr/ft3): 0.00007200

Dust mass median diameter (microns): 3.68

-- Filtration time (min): 10

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

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

 A: 2.5

 B: 1

 C: 1.2

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

 Material: 10

Application: 0.8

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

-- Fraction of bags cleaned (shaker & rev-air): 0

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

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

-- Bag material:

 Fiberglass w/PTFE 

Membranes (cost modifier 

at right)

3.75

-- Fabric effective residual drag (in. H2O/fpm): 1

-- Bag prices ($/ft2): [4]

 Mechanical shaker: 0 0 0 0

 Reverse-air $1.99 $2.59 $2.85 $3.71

 Pulse-jet $3.56 $4.05 $4.65 $4.84

DESIGN PARAMETERS

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

 Mechanical shaker: 2.7

 Reverse-air: 2.7

 Pulse-jet: 11.8

-- Net cloth area required (ft2):

 Mechanical shaker: 96225

 Reverse-air: 96225

 Pulse-jet: 22044

-- Gross cloth area required (ft2):

 Mechanical shaker: 102961

Reverse-air: 102961

 Pulse-jet: 22044

-- Area per bag/cage (ft2): 13

-- Number of bags/cages (pulse-jet only): 1644

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

 Mechanical shaker: 2.97

Reverse-air: 2.97

 Pulse-jet: 3.59

CAPITAL COSTS

Equipment Costs ($):

Item: Cost ($):

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

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

Baghouse 0 751,212 208,649 132,077

Bags 0 286,681 94,239 94,239

Insulation 0 83,498 48,830 21,951

Stainless 0 0 0 0

Cages 0 0 19,116 19,116

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

Total: 0 1,121,392 370,834 267,383

PEC($)-base: 0 1,323,242 437,584 315,512

 ' ' -esc.: 0 2,743,802 907,351 654,229

TCI ($): 0 5,954,050 1,968,951 1,419,676

 ($/acfm): 0 23 8 5

============================================================
Membrane Bags

Baghouse 9 (BH 7 will be the same)

TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

COST BASE DATE: Third Quarter 1986 [2]

ANNUAL COST INPUTS:

Operating factor (hr/yr): 7920

Operating labor rate ($/hr): $15.82

Maintenance labor rate ($/hr): $17.40

Operating labor factor (hr/sh): 2.00

Maintenance labor factor (hr/sh): 1.00

Electricity price ($/kWhr): 0.062

Compressed air ($/1000 scf): 0.16

Dust disposal ($/ton): 20

Annual interest rate (fraction): 0.07

Control system life (years): 20

Capital recovery factor: 0.0944

Bag life (years): 5

Capital recovery factor (bags): 0.2439

Taxes, insurance, admin. factor: 4%

 ANNUAL COSTS ($/yr):

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

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

Oper. labor 0 31,324 31,324 31,324

Supv. labor 0 4,699 4,699 4,699

Maint. labor 0 17,228 17,228 17,228

Maint. matl. 0 17,228 17,228 17,228

Electricity 0 92,073 82,399 82,399

Compr. air 0 0 39,507 39,507

Bag repl. 0 78,303 26,218 26,218

Dust dispos. 0 13 13 13

Overhead 0 42,287 42,287 42,287

Tax,ins.,adm 0 238,162 78,758 56,787

Cap. recov. 0 531,715 175,708 123,860

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

Total Annual 0 1,053,031 515,368 441,549

ANNUAL COST WEIGHTING FACTORS:

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

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

Oper. labor 0.000 0.030 0.061 0.071

Supv. labor 0.000 0.004 0.009 0.011

Maint. labor 0.000 0.016 0.033 0.039

Maint. matl. 0.000 0.016 0.033 0.039

Overhead 0.000 0.040 0.082 0.096

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

S/T labor: 0.000 0.107 0.219 0.255

Compr. air 0.000 0.000 0.077 0.089

Bag repl. 0.000 0.074 0.051 0.059

Dust dispos. 0.000 0.000 0.000 0.000

Electricity 0.000 0.087 0.160 0.187

Tax,ins.,adm 0.000 0.226 0.153 0.129

Cap. recov. 0.000 0.505 0.341 0.281

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

S/T capital: 0.000 0.731 0.494 0.409

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

Total: 0.000 1.000 1.000 1.000

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

RELATIONSHIP BETWEEN GROSS AND NET CLOTH AREA

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

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

1 2.000

4001 1.500

12001 1.250

24001 1.170

36001 1.125

48001 1.110

60001 1.100

72001 1.090

84001 1.080

96001 1.070

108001 1.060

132001 1.050
Membrane Bags

Baghouse 9 (BH 7 will be the same)

TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

COST BASE DATE: Third Quarter 1986 [2]

180001 1.040

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

in Chapter 5 of the 'OAQPS Control Cost Manual'(4th edition).

[2] Base equipment costs reflect this date.

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

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

purchased equipment cost, and total capital investment have been

escalated to this date via VAPCCI and control equipment vendor data.

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

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

(See 'Manual,' Chapter 5, Table 5.7.)
Total Cost 

Investment

Total 

Annualized 

Cost

2008 Baseline 

Pb Emissions 

(tpy)

Emission Reduction 

from upgrade* 

(tpy)

CE 

($/ton)

Furnace area, BH 7 81,548 27,591 1.81 0.95 29,043

Refining, BH 8 102,032 17,048 0.45 0.21 81,179

Refining BH 9 366,932 60,471 2.03 1.3 45,467

*We estimate removal efficiency for membrane bag update to be between 50 and 70 percent.

Total Cost 

Investment

Total 

Annualized 

Cost

2008 Baseline 

Pb Emissions 

(tpy)

Emission Reduction 

from upgrade* 

(tpy)

CE 

($/ton)

Main Stack 1,958,851 322,823 13.31 8.0 40,424

*We estimate removal efficiency for membrane bag update to be between 50 and 70 percent.

Cost of Upgrade to

Membrane Bags

Cost of Upgrade to

Membrane Bags

Table 3.1 - Cost Effectiveness of Upgrading Baghouses to Membrane Bags for Baghouses 7, 8 and 9

Table 3.3 - Cost Effectiveness of Upgrading Baghouses to Membrane Bags for Main Stack

Impacts

Impacts
Process Source

Emission Reduction 

Required to Reduce 

Risks? Control Added TCI ($) TAC ($)

Baseline 

Emissions 

(tpy)

Emission 

Reduction 

(tpy)

Cost 

Effectiveness 

($/ton)

Smelter

Main Stack No None 0 0 13.31 0 0

BH 7 Yes Membrane bags 366,932 60,471 1.81 0.95 63,654

Refining

BH8 Yes Membrane bags 102,032 17,048

BH 9 Yes Membrane bags 366,932 60,471

Total refining Yes 468,964 77,519 2.74 1.8 43,066

Total Process 835,897 137,990 17.86 2.75 50,178

Cost Effectiveness of Additional Controls for Primary Lead Smelting NESHAP
Main Stack - Standard Bags

Main stack Dec. 20, 2010

TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

COST BASE DATE: Third Quarter 1986 [2]

2008 575.4

 INPUT PARAMETERS:

-- Inlet stream flowrate (acfm): 1023723

-- Inlet stream temperature (oF): 170

-- Dust type: Blast furnace dust

-- Inlet dust loading (gr/ft3): 0.0018699

Dust mass median diameter (microns): 3.68

-- Filtration time (min): 10

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

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

 A: 2.5

 B: 1

 C: 1.2

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

 Material: 10

Application: 0.8

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

-- Fraction of bags cleaned (shaker & rev-air): 0

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

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

-- Bag material: Fiberglass w/PTFE 

Membranes (cost 

modifier at right)

1

-- Fabric effective residual drag (in. H2O/fpm): 1

-- Bag prices ($/ft2): [4]

 Mechanical shaker: 0 0 0 0

 Reverse-air $0.53 $0.69 $0.76 $0.99

 Pulse-jet $0.95 $1.08 $1.24 $1.29

DESIGN PARAMETERS

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

 Mechanical shaker: 2.7

 Reverse-air: 2.7

 Pulse-jet: 8.7

-- Net cloth area required (ft2):

 Mechanical shaker: 379157

 Reverse-air: 379157

 Pulse-jet: 117682

-- Gross cloth area required (ft2):

 Mechanical shaker: 394323

Reverse-air: 394323

 Pulse-jet: 117682

-- Area per bag/cage (ft2): 13

-- Number of bags/cages (pulse-jet only): 8772

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

 Mechanical shaker: 2.97

Reverse-air: 2.97

 Pulse-jet: 2.65
Main Stack - Standard Bags

Main stack Dec. 20, 2010

TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

COST BASE DATE: Third Quarter 1986 [2]

CAPITAL COSTS

Equipment Costs ($):

Item: Cost ($):

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

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

Baghouse 0 2,794,245 909,003 663,057

Bags 0 292,785 134,157 134,157

Insulation 0 316,588 247,660 110,990

Stainless 0 0 0 0

Cages 0 0 102,001 102,001

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

Total: 0 3,403,619 1,392,821 1,010,204

PEC($)-base: 0 4,016,270 1,643,528 1,192,041

 ' ' -esc.: 0 8,327,916 3,407,930 2,471,749

TCI ($): 0 18,071,577 7,395,207 5,363,696

 ($/acfm): 0 18 7 5

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

ANNUAL COST INPUTS:

Operating factor (hr/yr): 7920

Operating labor rate ($/hr): $15.82

Maintenance labor rate ($/hr): $17.40

Operating labor factor (hr/sh): 2.00

Maintenance labor factor (hr/sh): 1.00

Electricity price ($/kWhr): 0.062

Compressed air ($/1000 scf): 0.16

Dust disposal ($/ton): 20

Annual interest rate (fraction): 0.07

Control system life (years): 20

Capital recovery factor: 0.0944

Bag life (years): 5

Capital recovery factor (bags): 0.2439

Taxes, insurance, admin. factor: 4%

 ANNUAL COSTS ($/yr):

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

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

Oper. labor 0 31,324 31,324 31,324

Supv. labor 0 4,699 4,699 4,699

Maint. labor 0 17,228 17,228 17,228

Maint. matl. 0 17,228 17,228 17,228

Electricity 0 360,179 239,906 239,906

Compr. air 0 0 155,671 155,671

Bag repl. 0 92,012 42,783 42,783

Dust dispos. 0 1,299 1,299 1,299

Overhead 0 42,287 42,287 42,287

Tax,ins.,adm 0 722,863 295,808 214,548

Cap. recov. 0 1,670,218 681,497 489,737

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

Total Annual 0 2,959,336 1,529,730 1,256,709
Main Stack - Standard Bags

Main stack Dec. 20, 2010

TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

COST BASE DATE: Third Quarter 1986 [2]

ANNUAL COST WEIGHTING FACTORS:

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

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

Oper. labor 0.000 0.011 0.020 0.025

Supv. labor 0.000 0.002 0.003 0.004

Maint. labor 0.000 0.006 0.011 0.014

Maint. matl. 0.000 0.006 0.011 0.014

Overhead 0.000 0.014 0.028 0.034

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

S/T labor: 0.000 0.038 0.074 0.090

Compr. air 0.000 0.000 0.102 0.124

Bag repl. 0.000 0.031 0.028 0.034

Dust dispos. 0.000 0.000 0.001 0.001

Electricity 0.000 0.122 0.157 0.191

Tax,ins.,adm 0.000 0.244 0.193 0.171

Cap. recov. 0.000 0.564 0.446 0.390

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

S/T capital: 0.000 0.809 0.639 0.560

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

Total: 0.000 1.000 1.000 1.000

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

RELATIONSHIP BETWEEN GROSS AND NET CLOTH AREA

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

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

1 2.000

4001 1.500

12001 1.250

24001 1.170

36001 1.125

48001 1.110

60001 1.100

72001 1.090

84001 1.080

96001 1.070

108001 1.060

132001 1.050

180001 1.040

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

in Chapter 5 of the 'OAQPS Control Cost Manual'(4th edition).

[2] Base equipment costs reflect this date.

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

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

purchased equipment cost, and total capital investment have been

escalated to this date via VAPCCI and control equipment vendor data.

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

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

(See 'Manual,' Chapter 5, Table 5.7.)
Main Stack - Membrane Bags

Main stack

TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

COST BASE DATE: Third Quarter 1986 [2]

2008 575.4

 INPUT PARAMETERS:

-- Inlet stream flowrate (acfm): 1023723

-- Inlet stream temperature (oF): 170

-- Dust type: Blast furnace dust

-- Inlet dust loading (gr/ft3): 0.0018699

Dust mass median diameter (microns): 3.68

-- Filtration time (min): 10

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

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

 A: 2.5

 B: 1

 C: 1.2

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

 Material: 10

Application: 0.8

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

-- Fraction of bags cleaned (shaker & rev-air): 0

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

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

-- Bag material: Fiberglass w/PTFE 

Membranes (cost 

modifier at right)

3.75

-- Fabric effective residual drag (in. H2O/fpm): 1

-- Bag prices ($/ft2): [4]

 Mechanical shaker: 0 0 0 0

 Reverse-air $1.99 $2.59 $2.85 $3.71

 Pulse-jet $3.56 $4.05 $4.65 $4.84

DESIGN PARAMETERS

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

 Mechanical shaker: 2.7

 Reverse-air: 2.7

 Pulse-jet: 8.7

-- Net cloth area required (ft2):

 Mechanical shaker: 379157

 Reverse-air: 379157

 Pulse-jet: 117682

-- Gross cloth area required (ft2):

 Mechanical shaker: 394323

Reverse-air: 394323

 Pulse-jet: 117682

-- Area per bag/cage (ft2): 13

-- Number of bags/cages (pulse-jet only): 8772

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

 Mechanical shaker: 2.97

Reverse-air: 2.97

 Pulse-jet: 2.65
Main Stack - Membrane Bags

Main stack

TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

COST BASE DATE: Third Quarter 1986 [2]

CAPITAL COSTS

Equipment Costs ($):

Item: Cost ($):

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

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

Baghouse 0 2,794,245 909,003 663,057

Bags 0 1,097,943 503,089 503,089

Insulation 0 316,588 247,660 110,990

Stainless 0 0 0 0

Cages 0 0 102,001 102,001

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

Total: 0 4,208,777 1,761,753 1,379,136

PEC($)-base: 0 4,966,356 2,078,868 1,627,380

 ' ' -esc.: 0 10,297,963 4,310,626 3,374,446

TCI ($): 0 22,346,579 9,354,058 7,322,548

 ($/acfm): 0 22 9 7

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

ANNUAL COST INPUTS:

Operating factor (hr/yr): 7920

Operating labor rate ($/hr): $15.82

Maintenance labor rate ($/hr): $17.40

Operating labor factor (hr/sh): 2.00

Maintenance labor factor (hr/sh): 1.00

Electricity price ($/kWhr): 0.062

Compressed air ($/1000 scf): 0.16

Dust disposal ($/ton): 20

Annual interest rate (fraction): 0.07

Control system life (years): 20

Capital recovery factor: 0.0944

Bag life (years): 5

Capital recovery factor (bags): 0.2439

Taxes, insurance, admin. factor: 4%

 ANNUAL COSTS ($/yr):

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

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

Oper. labor 0 31,324 31,324 31,324

Supv. labor 0 4,699 4,699 4,699

Maint. labor 0 17,228 17,228 17,228

Maint. matl. 0 17,228 17,228 17,228

Electricity 0 360,179 239,906 239,906

Compr. air 0 0 155,671 155,671

Bag repl. 0 304,092 139,961 139,961

Dust dispos. 0 1,299 1,299 1,299

Overhead 0 42,287 42,287 42,287

Tax,ins.,adm 0 893,863 374,162 292,902

Cap. recov. 0 1,991,666 828,788 637,028

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

Total Annual 0 3,663,865 1,852,553 1,579,532
Main Stack - Membrane Bags

Main stack

TOTAL ANNUAL COST SPREADSHEET PROGRAM--FABRIC FILTERS [1]

COST BASE DATE: Third Quarter 1986 [2]

ANNUAL COST WEIGHTING FACTORS:

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

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

Oper. labor 0.000 0.009 0.017 0.020

Supv. labor 0.000 0.001 0.003 0.003

Maint. labor 0.000 0.005 0.009 0.011

Maint. matl. 0.000 0.005 0.009 0.011

Overhead 0.000 0.012 0.023 0.027

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

S/T labor: 0.000 0.031 0.061 0.071

Compr. air 0.000 0.000 0.084 0.099

Bag repl. 0.000 0.083 0.076 0.089

Dust dispos. 0.000 0.000 0.001 0.001

Electricity 0.000 0.098 0.130 0.152

Tax,ins.,adm 0.000 0.244 0.202 0.185

Cap. recov. 0.000 0.544 0.447 0.403

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

S/T capital: 0.000 0.788 0.649 0.589

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

Total: 0.000 1.000 1.000 1.000

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

RELATIONSHIP BETWEEN GROSS AND NET CLOTH AREA

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

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

1 2.000

4001 1.500

12001 1.250

24001 1.170

36001 1.125

48001 1.110

60001 1.100

72001 1.090

84001 1.080

96001 1.070

108001 1.060

132001 1.050

180001 1.040

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

in Chapter 5 of the 'OAQPS Control Cost Manual'(4th edition).

[2] Base equipment costs reflect this date.

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

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

purchased equipment cost, and total capital investment have been

escalated to this date via VAPCCI and control equipment vendor data.

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

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

(See 'Manual,' Chapter 5, Table 5.7.)
TCI TAC TCI TAC TCI

Main Stack 7,395,207 1,529,730 9,354,058 1,852,553 1,958,851

Standard Bags Membrane Bags Incremental Cost

Main Stack - Membrane Bag Costs for PJ Modular and Impacts
TAC

Baseline Pb 

Emissions 

(tpy)

Emission 

Reduction @ 

50% RE 

(tpy)

CE 

($/ton)

322,823 13.31 6.7 48,508

Incremental Cost Impacts

or PJ Modular and Impacts
Doe Run, Herculaneum - Summary of Stack Test Results 

Main Stack Test Date May-99 Apr-01 Apr-02 Jan-03 Dec-04 Dec-06 June, 2008 Average

Inlet stream flowrate (acfm): 1038328 1088486 1088923 943784 1028143 962603 1015794 1023723

inlet stream flowrate ((DSCFM) 794047 855576 838309 824628 826128 809737 793078 820215

Inlet stream temperature (oF): 181.3 186 199 127 164 153 177 170

Inlet dust loading (gr/ft3): per DSCF 2.94E-03 6.44E-04 3.21E-03 2.43E-03 1.00E-03 5.45E-04 2.32E-03 1.87E-03

production rate during test (tonnes/hr) 25.35 8.05 18.018 15.88 16.82

production rate during test (ton/hr) 80.98 8.875 19.861 17.5 31.80

lead emission rate (t/yr) 87.9 20.7 100.88 75.60 31.1 16.64 69.40 57.46

lead emssion rate (lb/hr) 20.07 4.72 23.032 17.26 7.1 3.8 15.845 13.12

lead emission rate (lb/ton) 0.25 0.17 2.60 0.87 0.41 0.86

w/o 2.59 0.42

Baghouse 7/9 stack Test Date June,2 008

Inlet stream flowrate (acfm): 519614

inlet stream flowrate ((DSCFM) 475165

Inlet stream temperature (oF): 107

Inlet dust loading (gr/ft3): per DSCF 0.0000720

production rate during test (tonnes/hr)

production rate during test (ton/hr)

lead emission rate (t/yr) 1.29

lead emssion rate (lb/hr) 0.2956

Baghouse 8 stack Test Date June,2 008

Inlet stream flowrate (acfm): 76274

inlet stream flowrate ((DSCFM) 70562

Inlet stream temperature (oF): 104

Inlet dust loading (gr/ft3): per DSCF 4.90E-05

production rate during test (tonnes/hr)

production rate during test (ton/hr)

lead emission rate (t/yr) 0.13

lead emssion rate (lb/hr) 0.0297

Total emissions for all 3 stacks (average scenarios) (TPY) 58.89

Total emissions for all 3 stacks (maximum scenarios) (TPY) 102.30

Total average emissions for 7,8,9 (TPY) 1.42

These values were not included in the stack test data and were calcualted from the stack test lb/hr value using 8760 hours per year.