## Attachment 1:

Cost Estimate Provided by Eramet Marietta

### Estimated Costs For Potential Fugitive Particulate Control Modifications

at Eramet Marietta Inc. (as of 11/22/2013)

The costs estimates below represent the curren t estimates of the costs to implement and

operate additional fugitive partic ulate controls at the Eramet Marietta Inc. facility. These

estimates are necessarily general due to the fact that control strategies are conceptual and no

detailed design work has been conducted. Altho ugh a 30% contingency has been incorporated in

the estimates due to the status of the design, no contingency to account for anticipated start-up

and shakedown costs has been included and EM I therefore believes the actual costs of

implementing the described contro ls are likely to be higher.

Furnace 1 :

 Tapping Hood – Modify hood to increase capture efficiency, vented to existing tapping

baghouse.

 Casting Hood – Install capture system (hood) for casting operations, vented to existing

tapping baghouse.

 Roof Ventilation – Partition roof canopy (above crane rails) to contain fugitive emissions,

vented through roof monitors to existing furnace baghouse via ducts.

1) Furnace 1: Tapping Fan Upgrade

a. Equipment/materials costs

i. Ductwork, ID Fan, Dampers, Actuators, Electric al $ 228,000

ii. Instrumentation 11,000

iii. Taxes 12,000

iv. Freight 13,000

b. Installation cost (inc. labor) 26,000

c. Engineering & design costs 53,000

Subtotal $ 343,000

2) Furnace 1: Casting Hood

a. Equipment/materials costs

i. Hood, Ductwork, Dampers, Actuators, Electrical $ 432,000

ii. Instrumentation 22,000

iii. Taxes 26,000

iv. Freight 22,000

b. Installation cost (inc. labor) 130,000

### ‐ 2

‐ 

### c. Engineering & design costs 100,000

Subtotal $ 732,000

3) Furnace 1: Roof Ventilation

a. Equipment/materials costs

i. Ductwork, Hood, Dampers, Structural Steel, Electrical $ 1,093,000

ii. Instrumentation 109,000

iii. Taxes 66,000

iv. Freight 55,000

b. Installation cost (inc. labor) 1,335,000

c. Engineering & design costs 423,000

Subtotal $ 3,081,000

Furnace 1 Total Equipment, Installation, Engineering $ 4,156,000 1



### Furnace 1 Retrofit Costs (Downtime) CBI 2



### Furnace 1 Annualized Capital Cost Recovery 3 

### $ 392,297

Furnace 1 Annual O&M Costs $ 461,211

Furnace 1 Annualized Costs (Capital plus O&M) $ 853,508

1 

### Estimate does not include an a dditional contingency that would be appropriate to account for

expected start-up and shakedown co sts associated with integration of new abatement equipment.

2 

### Downtime costs based on estimated lost sa les, which involves confidential business

information (CBI). These costs are provided under separate cover and should be treated as CBI.

3 

### Calculated in 2012 dollars for 20-year useful li fe at 7% interest ra te in accordance with

methodology provided in “Engineering Review of Proposed Ferroalloy NESHAP Requirements

for Eramet Marietta Inc.” (ENVIRON Interna tional Corp. 2012), included as Appendix B to

EMI’s January 31, 2012 comments on proposed NESH AP. The estimated annualized capital

cost presented does not include any portion of estimated retrofit costs attributable to furnace

downtime.

### ‐ 3

‐ 

### Furnace 12 :

 Tapping Hood – Modify hood to increase capture e fficiency, vented to existing scrubber.

 Roof Ventilation – Partition roof canopy (above crane rails) to contain fugitive emissions,

vented through roof monitors to existing scrubber via ducts.

 Upgrades to existing scrubber OR insta llation of secondary dust collector

1) Furnace 12: Roof Ventilation/Tap System Capture

a. Equipment/materials costs

i. Ductwork, Hood, Dampers, Structural Steel, Electrical $ 1,385,000

ii. Scrubber Upgrades OR Dust Collector 7,318,000

iii. Instrumentation 261,000

iv. Taxes 522,000

v. Freight 435,000

b. Installation cost 4,956,000

c. Engineering & design costs 2,183,000

Furnace 12 Total Equipment, Installation, Engineering $ 17,060,000 4



### Furnace 12 Retrofit Costs (Downtime) CBI 5



### Furnace 12 Annualized Capital Cost Recovery 6 

### $ 1,474,377

Furnace 12 Annual O&M Costs $ 2,178,599

Furnace 12 Annualized Costs (Capital plus O&M) $ 3,652,975

4 

### Estimate does not include an a dditional contingency that would be appropriate to account for

expected start-up and shakedown co sts associated with integration of new abatement equipment.

5 

### Downtime costs based on estimated lost sa les, which involves confidential business

information (CBI). These costs are provided under separate cover and should be treated as CBI.

6 

### Calculated in 2012 dollars for 20-year useful li fe at 7% interest ra te in accordance with

methodology provided in “Engineering Review of Proposed Ferroalloy NESHAP Requirements

for Eramet Marietta Inc.” (ENVIRON Interna tional Corp. 2012), included as Appendix B to

EMI’s January 31, 2012 comments on proposed NESH AP. The estimated annualized capital

cost presented does not include any portion of estimated retrofit costs attributable to furnace

downtime.

### ‐ 4

‐ 

### MOR :

 Casting Hood – Modify hood to increase captu re efficiency, vented to existing MOR

baghouse.

 Roof Ventilation – Partition roof canopy (above crane rails) to contain fugitive emissions,

vented through roof monitors to existing MOR baghouse via ducts.

1) MOR: Roof Ventilation/Casting Hood

a. Equipment/materials costs

i. Roof Modification/Repair $ 650,000

ii. Ductwork, Hood, Dampers, Structural Steel, Electrical 801,000

iii. Instrumentation 145,000

iv. Taxes 87,000

v. Freight 73,000

b. Installation cost (inc. labor) 1,613,000

c. Engineering & design costs 562,000

MOR Total Equipment, Inst allation, Engineering $ 3,931,000 7



### MOR Retrofit Costs (Downtime) CBI 8



### MOR Annualized Capital Cost Recovery 9 

### $ 371,059

MOR Annual O&M Costs $ 329,586

MOR Annualized Costs (Capita l plus O&M) $ 700,644

7 

### Estimate does not include an a dditional contingency that would be appropriate to account for

expected start-up and shakedown co sts associated with integration of new abatement equipment.

8 

### Downtime costs based on estimated lost sa les, which involves confidential business

information (CBI). These costs are provided under separate cover and should be treated as CBI.

9 

### Calculated in 2012 dollars for 20-year useful li fe at 7% interest ra te in accordance with

methodology provided in “Engineering Review of Proposed Ferroalloy NESHAP Requirements

for Eramet Marietta Inc.” (ENVIRON Interna tional Corp. 2012), included as Appendix B to

EMI’s January 31, 2012 comments on proposed NESH AP. The estimated annualized capital

cost presented does not include any portion of estimated retrofit costs attributable to furnace

downtime.

## Attachment 2:

Cost Estimate Provided by Felman Production

# Answers for EPA

1. Tapping upgrades:

A. Changing to a drill and plug gun to more efficiently open and close the tap hole

1. No. 2 Furnace tapping drill and plugging gun:

a. Equipment: $460,000 (ordered 11/2010)

b. Original Structure: $ 56,000

c. Original Engineering: $ 5,000

d. Engineering: $1 0,000.

e. Installation: $3 0,000.

f. First drill and gun expected arrival mid

- April 2012

g. Second drill and gun expected delivery mid

- May 2012

h. Total: $561,000

2. No. 5 furnace tapping drill a nd plugging gun:

a. Original Equipment: $ 202 ,000 ( purchased in 2007/2008).

b. Original Structure: $ 21,000

c. Original Engineering: $ 2,000

d. Equipment Modifications in 2011

- 2012 : $17,000

e. Engineering for modifications in 2012: $5,000

f. Manpower for conversion in 2011

- 2012: $3,000

g. Engineering to convert to hydraulics: $2,000

h. Equipment to convert to hydraulics: $ 50 ,000

i. Manpower to convert to hydraulics: $ 20 ,000

j. Total: $ 322,000

3. No. 7 furnace tapping drill and plugging gun:

a. Original Equipment: $202,000 (purchased in 2007/2008).

b. Original Structure: $ 21,000

c. Original Engineering: $ 2,000

d. Equipment Modifications in 2011

- 2012: $17,000

e. Engineering for modifications in 2012: $5,000

f. Manpower for conversion in 2011

- 2012: $3,000

g. Engineering to convert to hydraulics: $ 2 ,000

h. Equipment to convert to hydraulics: $50,000

i. Manpower to convert to hydraulics: $20,000

j. Total: $322,000



### B. Increasing the size of the tapping hood : This is included in 2B below.



### C. Increasing tapping hood ventilation (new baghou se fan/fan housing)

1. No. 2 Furnace Baghouse : Planned for 2013 Capital

- Change to 2014 /2015 due to market conditions

a. New baghouse fan/fan housing , inlet damper, outlet damper, transitions (2 Required) : $ 900 ,000.

b. Installation labor: $200 ,000.

c. Baghouse engineering study: $9,000.

d. Fan design engineering: included in cost of equipment.

e. Expansion Joint /ductwork replacement: $220,000.

f. Total: $1,329,000.

2. No. 2 Furnace tapping hood modifications (planned 2013) : Change to 2014 /2015 due to market conditions

a. Re placement of tapping / pouring damper equipment: $ 50 ,000.

b. Ductwork modification materials: $20,000.

c. Installation labor: $60,000.

d. Engineering: $20,000.

e. Total: $150,000.

3. No. 5 Furnace Baghouse (May 2012):

a. New baghouse fan / fan housing, inlet dam per, ou tlet damper, transition: $4 50 ,000.

b. Installation labor: $ 70 ,000.

c. Baghouse engineering study: $9,000

. d. Fan design engineering: included in cost of equipment.

# Answers for EPA

e. Expansion Joint /ductwork replacement: $220,000.

f. Total: $749,000.

4. No. 7 Furnace Baghouse (3 rd Quarter 2012)

- Due to market conditions Furnace is currently Shutdown. There is

no specific start up plans at this time.

a. New baghouse fan / fan housing, inlet dam per, outlet damper, transition: $450,000.

b. Installation labor: $70,000.

c. Baghouse engineering study: $9,000

. d. Fan design engineering: included in cost of equipment.

e. Expansion Joint /ductwork replacement: $220,000.

f. Total: $749,000.



### D. Adding a tapping platform enclosure.

1. No. 2 Furnace:

a. Material s to enclose both tap holes: $3 0,000.

b. Labor for enclosing both tap holes: $20,000.

c. Engineering: $5,000

. d. Total : $5 5,000

.

2. No. 5 Furnace:

a. Materials to extend platform and enclose tap hole: $40,000.

b. Labor for extending platform and enclosing tap hole: $20,000.

c. Engineering: $10,000.

d. Total: $70,000.

3.

. No. 7 Furnace:

a. Materials to extend platform and enclose tap hole: $40,000.

b. Labor for extending platform and enclosing tap hole: $20,000.

c. Engineering: $10,000.

d. Total: $70,000.

E. Extending No. 7 Tilter Fume capture system to No. 9 Rake

- out

.

1. Engineering: $5,000.

2. Materials: $30,000.

3. Labor: $25,000.

4. Total: $60,000.



### 2. Casting Upgrades

.

A. Add a ladle tilter and hydraulic system (retrofit vs. purchase new equipment )

- The cost of designing, purchasing, and

installation of a new system is estimated to be $1,000,000 per tilter. Retrofit cost is included in 2B below.

B. Building enclosure around ladle tilter, including movable lid.

1. No. 2 Tilter : Completed 07/2011

a. Engineering: $10,000.

b. Materials: $170,000.

c. Labor: $165,000.

d. Total: $ 345,000.

2. No. 5 Tilter: Initial modification cost 11/2010

. a. Engineering: $5,000.

b. Materials: $100,000.

c. Labor: $80 ,000.

d. Total: $185,000

. 3. No. 5 Tilter: Final modifications . ( 6/30/2012)

a. Engineering: $5,000.

b. Materials: $100,000.

c. Labor: $100,000.

d. Total: $205,000.

4. No. 7 Tilter: Initial modification cost 11/2010.

a. Engineering: $5,000.

# Answers for EPA

b. Materials: $100,000.

c. Labor: $ 80 ,000.

d. Total: $185,000

3. No. 7 Tilter: Final modifications. (4/30/2012)

a. Engineering: $5,000.

b. Materials: $100,000.

c. Labor: $100,000.

d. Total: $205,000.

4. No.2 Tilter: Exhaust Duct replacement (Oct ober 2013 )

a. Total cost: $86,000

C. Adding covers to slag runners: This is included in 2B above. The hood extensions should capture the fumes. Will re

evaluate after modifications.

D. Addition of fans to direct fume from casting nests toward the hood

- This will be address if necessary after tilter

modifications.



### 3. Furnace fugitive upgrade:

A. Adding mesh curtains on furnace charging floor.

- Not practical, curtain life less than 6 0 days.

1. Materials: $50,000 per furnace.

2. Labor: $2,000 per furnace.

3. Total: $52,000 per furnace= $156,000

. B. Add doors to furnaces

1. Materials: $50,000 per furnace.

2. Labor: $20,000 per furnace.

3. Total: $70,000 per furnace.



### 4. Crushing plant upgrade.

A. No. 1 Crusher: (Completion 4/2012)

- Due to design errors this system failed.

1. Engineering: $78,000.

2. Material: $200,000.

3. Labor: $200,000.

4. Total: $478,000

B. No. 1 Crusher: Completion 2014.

1. Engineering and Materials: $381,078

2. Labor: $100,800

3. Total: $481,878

C . No. 2 Crusher: (Completion 2013) Due to market conditions furnaces currently Shutdown. There is no specific start up

plans at this time.

1. Engineering: $78,000.

2. Material: $200,000.

3. Labor: $200,000.

4. Total: $478,000.

* Capital dollar amount based on actual paid invoices and best estimates from Engineering, contractors , vendors and suppliers.

## Attachment 3 :

Additional Detailed Cost Estimates for FelmanTOTAL ANNUAL COST SPREADSHEET PROGRAM--STRAIGHT DUCTWORK for Rooftop Ventilation[1]

DUCTS: COST BASE DATE: CEPCI 1993 [2] 359.2

COST ESCALATION: CEPCI 2012 [3] 584.6

INPUT PARAMETERS

Ductwork:

-- Inlet stream flowrate (acfm): 120,000

-- Duct velocity (ft/min): [4] 3,800

-- Duct length (ft): [5] 1000 Estimated based on building dimensions and likely FF location

-- Material of construction: [6] Sheet-galv CS

-- Insulation thickness (in.): (text input) [7] 0

-- Duct design: [8] Circular-longitudinal

-- Cost equation parameters: [9]

a: 2.03

b: 0.784

-- Cost equation form: [10] 1

-- Control system installation factor: [11] 1.5

(if no system, enter '0')

-- Fan-motor combined efficiency (fraction): 0.6

DESIGN PARAMETERS

-- Duct diameter (in.): 

### 76

-- Pressure drop (in. w.c.): [12] 2

CAPITAL COSTS

Ductwork Cost ($)--base: $60,542

Ductwork Cost ($)--escalated: $98,532

Purchased Equipment Cost ($): $106,414

Retrofit Adjustment (100%) $212,829

Total Capital Investment ($): [13] $319,243

ANNUAL COST INPUTS

Operating factor (hours/year): 8760

Electricity price ($/kWhr): 0.0682

Annual interest rate (fractional): 0.07

Ductwork economic life (years): 20

Capital recovery factor (system): 0.094392926

Taxes, insurance, admin. factor: 0.04

Labor, $/hr [15] 17.42

ANNUAL COSTS

Item Cost ($/yr) Wt.Fact.

Electricity $23,910 0.345911107

Taxes, insurance, administrative $12,770 0.184742293

Capital recovery $30,134 0.435959138

Labor [14] $1,442 0.020867164

Overhead [15] $865 0.012520299

Total Annual Cost $69,122 1

Notes:

[1] Data used to develop this program were taken from 'OAQPS Control Cost Manual', 5th edition, Chapter 10. Prices are for CIRCULAR straight ductwork, only.

[2] Chemical Engineering Plant Cost Index CEPCI for base year. Base costs reflect this date.

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

[4] See 'Manual,' pp. 10-30 to 10-33.

[5] Duct length is a site-specific parameter that can vary from < 10 to > 1000 ft.

[6] Choices available are: carbon steel sheet (galv. CS sh.), stainless steel sheet (304 SS sh.), coated carbon steel plate (coat. CS pl.), 304 stainless steel plate (304 SS pl.), polyvinyl chloride (PVC), and fiber-reinforced plastic (FRP)

[7] Choices are: 0, 1, and 3.

[8] Choices are: circular spiral (circ.-spiral) and circular longitudinal (circ.-long.)

[9] Equation type and parameters depend on duct material of construction. Parameters reflect 2nd quarter 1993 costs. See 'Manual,' pp. 10-44 to 10-49.

[10] Choices are: power function (1) and exponential (2).

[11] Installation factor depends on control device ductwork is supporting. This factor, when multiplied by Purchased Equipment Cost, yields Total Capital Investment (TCI). If ductwork is installed alone, factor is 1.25 to 1.50. (Default = 1.50.) See 'Manual'.

[12] Pressure drop applies ONLY to circular, spiral-wound galvanized duct with 10 joints per 100 feet. For pressure drop data for other duct types, see 'Manual,' Chapter 10.

[13] Product of installation factor and Purchased Equipment Cost. Costs are presented both in terms of 2nd quarter '93 and above escalation date. Latter costs are based on Producer Price Index PCU 3444#1 ('Air-conditioning ducts and stove pipe')

[14] Labor of 17.42/hr ; 6 hr/month ; 15% supervision factor, from Bureau of Labor Statistics National Compensation survey, 2009, for Metal Furnace & Kiln Operators

[15] 60% of Labor costs Electricity price for Industrial sector in 2011 - taken from

Average Retail Price of Electricity to Ultimate Customers by

End-Use Sectors 2001 through 2011

http://www.eia.gov/electricity/data.cfm#sales"PhaseII"AdditionalFabricFilterforFelmanReplacesFurnace7FFasrooflineventilationFFforscenariowithallthreeoperationalfurnacesFerroalloysFurnaceFugitiveEmissionsFelmanRoofVentControlDeviceNewRoofVentFFAnnualOperatingHours,hr/yr(H) 8760ExhaustGasFlowRate,acfm(Qa) 120,000Necessaryfor12ACH,ascitedinChu&GassmanDesignNarrative,7/9/12providedbyFelman.OperatingLaborRate,$/hr(LR) $29.96 Laborof29.96/hr;fromBureauofLaborStatisticsNationalCompensationsurvey,2012,forFirst‐LineSupervisorsofProductionandOperatingWorkersatIronandSteelMillsandFerroalloyManufacturingCapitalRecoveryFactor(CRF) 0.094392926 CRFcalculatedassuming20‐yearequipmentlifeand7%interestRetrofitFactor 1.2BHTotalCapitalInvestmant,$(TCI) $8,271,684Calculatedusingalgorithm1530*RetrofitFactor*(acfm^0.81)for6.0cloth‐to‐airratioEngineering&ConstructionManagement $827,168 10%oftotalTCIw/baghouse,5%ofTCIw/obaghouseLaborAdjustment(shift,perdiem,etc.) $413,584 5%oftotalTCIContractorProfitandFees $413,584 5%oftotalTCICapital,Engineering,andConstructionCost,$(CECC)$9,926,0215522265Owner'scosts,inc"HomeOffice"costs(OC) $496,301 5%ofCECCAFUDCforPJFF:6%fora2yrengrandconstcycle. $625,339 6%of(CECC+OC)TotalProjectCost,$(TPC)$11,047,661CECC+OC+AFUDCDirectAnnualCost,$/yr(DAC)OperatingLabor $8,202 Calculatedusing(0.25hr/8‐hrshift)x3shifts/dayx365days/yrxLRAdministration&SupervisoryLabor $660 Calculatedusing3%ofthesumoftheOperatingLaborand40%oftheMaintainanceMaintenance&Materials $34,465 FixedO&MadditionalmaintenancematerialandlaborcostsIndirectAnnualCost,$/yr(IAC)Overhead $25,996 OAQPSControlCostManual‐calculatedusing0.6x(Labor+Maintenance)PropertyTax,Insurance,&Admin $275,723 OAQPSControlCostManual‐calculatedusing0.04xTCICapitalRecovery $780,788 CalculatedusingCRFxTCITotalAnnualCost $1,125,834 SumofDAC+IAC1Sargent&Lundy,IPMModel‐UpdatestoCostandPerformanceforAPCTechnologies,ParticulateControlCostDevelopmentMethodologyFinal,March2013

## Attachment 4 :

Revised Building Ventilation Cost Estimates for Felman

## Revised Felman Building Ventilation Costs

Based on costs provided by Felman in comments on EPA's November 2011 Proposal.

"Building Ventilation Costs January 30, 2012", EPA

‐ HQ

‐ OAR

‐ 2010

‐ 0895

‐ 0073

Baghouse $6,200,000

Ductwork $10,478,442

Total Capital Investment (TCI) 1 $28,228,603

Amortized Capital Cost (20 yr, 7% Int.) $2,664,580

Annual Costs $2,377,965

Total Annualized Costs $5,042,545

CRF (20 years, 7% interest) 0.094392926

Ductwork Purchased Equipment Cost (PEC) Capital Labor

Metal corrugated panels $8,848 $10,080

20'x20' coiling door $11,800 $3,940

10'x10' coiling door $5,325 $1,770

15'x10' coiling door $5,900 $1,966

17'x22' coiling door $11,800 $3,940

Misc Matl & Labor $6,537 $6,537

Ductwork (Corten steel) $775,000 $8,525,000

HV units $1,000,000 $100,000

Total $1,825,210 $8,653,233 Purchased Equipment Cost (PEC)

1 Felman's estimate applied overhead and contingency adjustments to ductwork

costs twice. As per Felman's estimates, TCI = 2.17*PEC for the baghouse, and

TCI=1.41*PEC for ductwork.