p.1 

OAR Box 1313 

Prepped by LaTeia Shed 

Document Number: 

92) ll-B-66 

Docket Number: 

A-88-02 

Printed 6/12/2008 9:03:31 AM Sheet 92 of 99 
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MRI® MIDWEST-T-tESWTRef-l INSTITUTE 

IT-ft-W o Suite 350 

401 Harrison Oaks Boulevard 

Cary, North Carolina 27513 

Telephone (919) 467-5215 

FAX (919) 467-8060 

Date: July 6, 1989 

Subject: Summary of Retrofit Capital and Annualized Cost Data for the 

Engineering Control Devices for the Hard and Decorative 

Chromium Electroplating and Chromic Acid Anodizing Model Plants 

Chromium Electroplating NESHAP 

EPA Contract No. 68-02-3817; ESD Project 85/02a 

MRI Project 7717-K 

From: Robin Barker ' 

Mary Jo Caldwell 

To: Andrew M. Smith / 

ESD/ISB/SSS (MD-13) ~ f 

U. S. Environmental Protection Agency --•-..' Y'5 ' / 

Research Triangle Park, N.C. 27711 --—.J 

I. Introduction 

This memorandum presents the capital and annualized cost estimates 

for retrofitting chevron-blade mist eliminators (single and double), 

packed-bed scrubbers (single and double), and mesh-pad mist eliminators on 

each of the model plants for hard and decorative chromium electroplating 

and chromic acid anodizing. The retrofit costs for each model plant 

include costs for ductwork modifications and for the removal and disposal 

of existing air pollution control equipment. Actual retrofit costs will 

vary from plant to plant and will depend on the particular facility's 

layout and present control level. Based on site visit information on the 

plant layout and location of the existing control devices, the retrofit 

cost estimates presented in this memorandum are representative of 

expenditures that existing facilities would incur. Not included in the 

retrofit cost scenario is consideration for structural modifications 

because of possible space constraints that an existing facility might 

encounter, such as removal of a wall or equipment to make room for the 

control device. 

II. Model Plant: Retrofit Capital Cost Estimates 

Three control device vendors were contacted to obtain estimates on 

the additional cost to retrofit new controls at an existing facility 

(including the removal of an existing control device) over the installed 

capital cost for control at a new facility. " Two control device vendors 

estimated that the cost to retrofit new controls at an existing facility 

would increase the total capital costs from 5 to 15 and 5 to 20 percent, 

respectively. ~ A third control device vendor estimated the increase in 

the total capital cost for new controls could be as much as 50 percent for 

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smaller, less expensive control systems, but thai-, the increase would be 

less for larger, more expensive control systems. Based on these vendor 

estimates, an increase of 20 percent of the installed capital costs for 

new facilities was selected for calculating retrofit costs for the model 

plants. Transportation and disposal costs for existing control devices, 

which were not included in the vendor estimates, were assumed to be 

5 percent of the installed capital costs of control at new facilities. 

This assumption was based on transportation and disposal costs for 

hexavalent chromium solid wastes and estimates of the amount of waste to 

be disposed. Bulk transportation and disposal co;>ts were obtained from 

Chemical Waste Management in Anaheim, California. The amount of waste to 

be disposed was based on the type and size of various control devices. 

Thus, the total increase in cost to retrofit new controls at existing 

facilities is 25 percent of the installed capital cost of control for new 

facilities (i.e., estimated retrofit capital costs are 125 percent of the 

installed capital cost for new facilities). 

The total installed capital costs for chevron-blade mist 

eliminators, packed-bed scrubbers, and mesh-pad mist eliminators at new 

facilities were compiled from vendor estimates for each type of control 

device. These costs are presented and documented in the memoranda 

entitled "Summary of Chevron-Blade Mist Eliminator and Packed-Bed Scrubber 

Cost Data for Hard and Decorative Chromium Electroplating and Chromic Acid 

Anodizing Model Plants" and "Summary of Mesh-Pad Mist Eliminator Cost Data 

for Hard and Decorative Chromium Electroplating and Chromic Acid Anodizing 

Model Plants." » Table 1 presents the estimated retrofit capital cost of 

these control devices for each model plant. 

III. Model Plant Retrofit Annualized Cost Estimates 

Total annualized retrofit costs of chevron-blade mist eliminators, 

packed-bed scrubbers, and mesh-pad mist eliminators for each hard and 

decorative chromium plating and chromic acid anodizing model plant are 

presented in Table 2. The annualized retrofit costs are the same as the 

annualized costs of a new control device except for the capital recovery 

costs and indirect costs because these costs are both a function of the 

installed capital cost. Capital recovery costs for a retrofit situation 

are higher because the installed capital costs for retrofit control 

devices are 25 percent higher than those for new control devices. 

Indirect costs include overhead, taxes, insurance, and administration. 

Taxes, insurance, and administration are based on 4 percent of the capital 

costs; thus, these costs also are higher for retrofit than for new 

facilities. Table 3 presents the net annualized retrofit costs 

(annualized cost minus the chromic acid recovery credit) for the model 

plants. 

Z5 
k 

TABLE 1. RETROFIT CAPITAL COSTS FOR MODEL PLANTSa 

(November 1988 Dollars) 

Process/control device 

Hard chromium plating 

Chevron-blade mist eliminator (single set of 

Chevron-blade mist eliminator (double set of 

Single packed-bed horizontal flow scrubber 

Double packed-bed horizontal flow scrubber 

Mesh-pad mist eliminator 

Decorative chromium plating 

Chevron-blade mist eliminator (single set of 

Chevron-blade mist eliminator (double set of 

Single packed-bed horizontal flow scrubber 

Double packed-bed horizontal flow scrubber 

Mesh-pad mist eliminator 

Chromic acid anodizing 

Chevron-blade mist eliminator (single set of 

Chevron-blade mist eliminator (double set of 

Single packed-bed horizontal flow scrubber 

Double packed-bed horizontal flow scrubber 

Mesh-pad mist eliminator 

aAll costs rounded to nearest $100. Retrofit < 

including the cost of removal, transportation 

necessary retrofit modifications. 

blades) 

blades) 

blades) 

blades) 

blades) 

blades) 

:osts are the 

, and disposal 

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Model plant . 

Small 

28,100 

29,800 

45,900 

50,000 

28,900 

28,100 

29,800 

45,900 

50,000 

28,900 

28,100 

29,800 

45,900 

50,000 

28,900 

installed capital 

of 

Note: Retrofit cost estimates were calculated using the basic 

and, therefore, may not equal the installed model plant cap 

1.25. 

any existing 

Medium 

56,900 

62,400 

92,800 

108,300 

82,500 

56,300 

59,500 

91,800 

100,000 

49,000 

size 

Large 

113,800 

124,800 

185,500 

216,500 

156,300 

93,500 

99,300 

155,900 w 

173,400 

109,100 

60,800 

63,000 

98,400 

112,300 

114,900 

costs of the system, 

control dev 

control device costs per 

ital cost for new facilities 

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IV. References 

1. Telecon. R. Barker, MRI, with P. Welch, Duall Industries. April 28, 

1989. Retrofit costs as a percentage of new facility costs. 

2. Telecon. M. J. Caldwell, MRI, with Zitko, L., ChromeTech, Inc. 

May 1, 1989. Retrofit costs as a percentage of new facility costs. 

3. Telecon. M. J. Caldwell, MRI, with Hankinson, K., KCH Services. 

May 1, 1989. Retrofit costs as a percentage of new facility costs. 

4. Telecon. Caldwell, M. J., MRI, with Glbvenor S., Chemical Waste 

Management, Anaheim, California. April 13, 1989. Information on 

disposal and transportation costs for hexavalent chromium solid waste. 

5. Memorandum from R. Barker, MRI, to A. Smith, U. S. Environmental 

Protection Agency. Summary of Chevron-Blade Mist Eliminator and 

Packed-Bed Scrubber Cost Data for Hard and Decorative Chromium 

Electroplating and Chromic Acid Anodizing Model Plants. June 22, 

1989. 

6. Memorandum from R. Barker, MRI, to A. Smith, U. S. Environmental 

Protection Agency. Summary of the Mesh-Pad Mist Eliminator Cost Data 

for Hard and Decorative Chromium Electroplating and Chromic Acid 

Anodizing Model Plants. July 6, 1989. 

b