Document ID: EPA-HQ-OAR-2003-0051-0785
Agency: epa
Document Type: Supporting & Related Material
Title: 
Posted Date: 2023-08-16T04:00Z

MEMORANDUM 

DATE:	May 1, 2023
	
FROM:	Donna Lee Jones, U.S. Environmental Protection Agency; Gabrielle Raymond, RTI International
	U.S. Environmental Protection Agency, Research Triangle Park

TO:		Coke Ovens Residual Risk and Technology Review (RTR) Project File

--------------------------------------------------------------------------------
SUBJECT:	Maximum Achievable Control Technology Standard Calculations, Cost Impacts, and Beyond-the-Floor Cost Impacts for Coke Ovens Facilities under 40 CFR Part 63, Subpart CCCCC
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                                   CONTENTS
1.0	INTRODUCTION AND BACKGROUND	3
2.0	HAP EMISSIONS MEASURED AT COKE FACILITIES	4
3.0	MACT FLOOR	7
3.1	Quantity of Below the Detection Limit (BDL) Data	8
3.2	HAP MACT Limit	9
4.0	MACT LIMIT IMPACTS	11
4.1	Units Meeting MACT Limits	11
4.2	Costs to Meet MACT Limits	18
5.0	BEYOND THE FLOOR ANALYSIS	18
5.1	Background	18
5.2	HAP Control Devices by MACT Process Type at Coke Facilities	18
5.3	Total BTF Annual Costs, Emissions Reductions, and Cost Effectiveness for APCD per Process Type at Coke Facilities	19
5.4	BTF Limits for HNR HRSG Bypass/Waste Heat Stacks (Existing & New Sources)	19
6.0	REFERENCES	24
APPENDIX A:	1
APPENDIX B:	1
MACT FLOOR DEVELOPMENT	1
B.1 Introduction	1
B.2 Process Units	1
B.3 MACT Floor Statistical Analyses - Upper Prediction Limit	1
Normally-Distributed Dataset	3
Lognormally-Distributed Dataset (Bhaumik and Gibbons, 2004)	4
Skewed/Unknown-Distributed Dataset (Non-Normal/Non-Lognormal) (Gayen, 1949)	4
B.4 Representative Detection Limit	5
B.5 MACT Floor Emissions Limit Development Methodology	5
Step 1.	5
Step 2.	6
Step 3.	9
Step 4.	10
Step 5.	11
Step 6.	14
Step 7.	21
B.6 Results of the MACT Floor Analyses	21
B.7 References for Appendix B	23
APPENDIX C:	1
BEYOND-THE-FLOOR COST DETAILS FOR COKE PQBS FACILITIES	1
C.1 Development of Input Parameters for BTF Analyses	1
C.2 Pushing BTF Analysis	1
Input Parameters for BTF Controls for Pushing	1
Development of Unit Costs for Ductwork for BTF Controls for Pushing	4
Development of Unit Costs for ACI for BTF Controls for Pushing	4
Development of Unit Costs for WAS for BTF Controls for Pushing	5
BTF Costs per Facility for Pushing	10
BTF Emission Reductions for Pushing	11
BTF Cost Effectiveness for Pushing	14
C.3 ByP Battery Combustion Stack BTF Analysis	14
Input Parameters for BTF Controls for ByP Battery Combustion Stacks	15
Development of Unit Costs for Ductwork for BTF Controls for ByP Battery Combustion Stacks	18
Development of Unit Costs for ACI for BTF Controls for ByP Battery Combustion Stacks	18
Development of Unit Costs for WAS for BTF Controls for ByP Battery Combustion Stacks	19
BTF Costs per Facility for ByP Battery Combustion Stacks	22
BTF Emission Reductions for ByP Battery Combustion Stacks	23
BTF Cost Effectiveness for ByP Battery Combustion Stacks	25
C.4 HNR HRSG Main Stack BTF Analysis	25
Input Parameters for BTF Controls for HNR HRSG Main Stacks	25
Development of Unit Costs for Ductwork for BTF Controls for HNR HRSG Main Stacks	26
Development of Unit Costs for ACI for BTF controls for HNR HRSG Main Stacks	27
Development of Unit Costs for WAS for BTF Controls for HNR HRSG Main Stacks	28
BTF Costs per Facility for HNR HRSG Main Stacks	29
BTF Emission Reductions for HNR HRSG Main Stacks	31
BTF Cost Effectiveness for HNR HRSG Main Stacks	32
C.5 HNR HRSG Bypass/Waste Heat Stack BTF Analysis	33
Input Parameters for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks	33
Development of Unit Costs for Ductwork for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks	34
Development of Unit Costs for ACI for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks	38
Development of Unit Costs for WAS for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks	42
Development of Unit Costs for RTO for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks	44
BTF Costs per Facility for HNR HRSG Bypass/Waste Heat Stacks	44
BTF Emission Reductions for HNR HRSG Bypass/Waste Heat Stacks	46
BTF Cost Effectiveness for HNR HRSG Bypass/Waste Heat Stacks	47
C.6 References for Appendix C	49
APPENDIX D:	1
BTF ANALYSIS FOR HNR HRSG BYPASS/WASTE HEAT STACKS	1
D.1 Input Parameters for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks	1
D.2 Development of Unit Costs for Ductwork for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks	2
D.3 Development of Unit Costs for BTF Controls for ACI and BH for HNR HRSG Bypass/Waste Heat Stacks	6
D.4 BTF Costs for HNR HRSG Bypass/Waste Heat Stacks	12
D.5 BTF Emission Reductions for HNR HRSG Bypass/Waste Heat Stacks	12
D.6 BTF Cost Effectiveness for HNR HRSG Bypass/Waste Heat Stacks	14
D.7 References for Appendix D	16

1.0	INTRODUCTION AND BACKGROUND

      This memorandum discusses hazardous air pollutant (HAP) emissions and maximum achievable control technology (MACT) calculations for unregulated and under-regulated emission sources at coke oven facilities, as part of the Residual Risk and Technology Review (RTR) of the National Emission Standards for Hazardous Air Pollutants (NESHAP) for Coke Ovens: Pushing, Quenching, and Battery Stacks (PQBS) (40 CFR, part 63, subpart CCCCC), required under the Clean Air Act (CAA), sections 112(d)(2)&(3) and (d)(6). In addition, this memorandum evaluates beyond-the-floor (BTF) control techniques and the costs of the BTF air pollution control devices (APCD). See Appendix A for a list of applicable acronyms.
      
      In the coke production process, coal is heated in ovens in the absence of air to temperatures approaching 2,000°F (1,100[o]C), which drives off most of the volatile organic constituents of the coal, as gases and vapor, to form coke, which consists almost entirely of carbon. Coal is charged into the top or end of the oven, depending on the process, and the finished coke is pushed out using doors on both ends of the ovens. The hot coke product is cooled in quench towers that use water spray to cool hot coke in rail cars that drive into the bottoms of quench towers. The coke product is used either in blast furnaces in the integrated iron and steel industry (II&S) or at iron and steel foundries that produce iron molds for shaping molten metal. Coke oven temperatures are slightly higher to produce blast furnace coke than foundry coke. Coking lasts for 15 to 18 hours to produce blast furnace coke and 25 to 30 hours to produce foundry coke. 
      
      The coke ovens are arranged in a series of adjacent ovens called batteries, where one battery may have up to 100 ovens and multiple batteries may be used by one facility. For the 14 coke facilities in the Coke Oven Risk Modeling Database, the number of batteries per facility ranged from 1 to 10, and the total number of ovens at the facility ranged from 56 to 708, with median values of 3 batteries per facility and 126 ovens total at the facility. Ovens at by-product (ByP) facilities are tall and narrow (approximately 20 ft/6 m by 1.3 ft/0.4 m; whereas, at heat and nonrecovery recovery (HNR) facilities, the ovens are short and wide (approximately 7.8 ft/2.4 m by 12 ft/3.6 m). ByP ovens are operated at positive pressure, whereas HNR ovens operate under negative pressure. The organic gases and vapors that evolve from the ovens are removed through an exhaust system: for ByP plants, gases are sent to a chemical recovery plant that recovers chemicals and other by-products for sale and also cleans the coke oven gas (and is regulated under 40 CFR part 61, subpart L NESHAP); for nonrecovery plants (i.e., no chemical recovery) with heat recovery, the oven gases are sent to a heat recovery steam generator that produces power for sale and also to units that perform gas cleaning; for nonrecovery plants without heat recovery, oven exhaust gases are released to the air through waste heat stacks. 
       
2.0	HAP EMISSIONS MEASURED AT COKE FACILITIES

      Table 1 shows the facilities and process of the coke oven PQBS category units tested for the 2016 and 2022 coke oven CAA section 114 requests and the HAP measured that were used to develop MACT limits. The Erie Coke facility, which produced foundry coke, received the 2016 coke oven CAA section 114 request and, as required, conducted testing August through October 2016 on several coke category units: ByP pushing and ByP combustion stack. In 2020, the EPA was notified that the Erie Coke facility was shut down in late 2019. As such, the emissions for Erie Coke units and emissions were not included in the coke oven PQBS MACT floor calculations. In 2020, Cleveland-Cliffs Inc. acquired the AK Steel: Follansbee, WV (Mountain State Carbon) and Middletown, OH cokemaking facilities and the ArcelorMittal USA LLC: Burns Harbor, IN; Monessen, PA; and Warren, OH cokemaking facilities. 

The existing work practice standards for quench towers are the most appropriate standards at this time, as truly repeatable testing is near impossible on these highly variable sources. There are also safety considerations with testing these quench tower sources. As such, no MACT limits were developed for quench towers. 
                        Table 1. Coke Oven PQBS Tested Units
                                   Facility
                               Unit Description
                                 Facility Type
                         HAP Data Used for MACT Limits
                            Pushing Control Devices
CC-Middletown-OH
Moveable shed/hood&baghouse
Byproduct
                               Hg, AG, HCN, PAH
CC-Burnsharbor-IN
Coke Battery #2 moveable shed/hood&baghouse
Byproduct
                               Hg, AG, HCN, PAH
CC-Monessen-PA
Moveable shed/hood&baghouse
Byproduct
                               Hg, AG, HCN, PAH
SC-GraniteCity-IL
Flat Push Hot Car Mobile scrubber car&multiclone
HNR
                                      Hg
SC-Middletown-OH
Flat Push Hot Car Mobile scrubber car&multiclone
HNR
                               Hg, AG, HCN, PAH
                          Battery (Combustion) Stacks
CC-Middletown-OH
Combustion Stack
Byproduct
                                Hg, PM, AG, HCN
CC-Burnsharbor-IN
Coke Battery No. 2 Underfire Stack
Byproduct
                                Hg, PM, AG, HCN
CC-Monessen-PA
Battery Combustion Stack #2
Byproduct
                                Hg, PM, AG, HCN
USS-Clairton-PA
Battery B Combustion Stack (S012)
Byproduct
                                Hg, PM, AG, HCN
                             HNR HRSG Main Stacks
SC-Middletown-OH
P901- Coke Oven (Battery A-C) - Main Stack
HNR
                                Hg, PM, AG, PAH
CE-EastChicago-IN / 
SC-EastChicago-IN
HRSG Main Stack
HNR
                                Hg, PM, AG, PAH
                       HNR HRSG Bypass/waste heat stacks
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
HNR
                             Hg, PM, AG, PAH, Form
SC-FranklinFurnace-OH
Bypass Vent Stack 6
HNR
                               Hg, PM, AG, Form
Note: Acronyms are as follows: acid gases (AG) that include hydrogen chloride (HCl) and hydrogen fluoride (HF); hydrogen cyanide (HCN); mercury (Hg); particulate matter (PM); polycyclic aromatic hydrocarbons (PAH); speciated volatile HAP (VOHAP); formaldehyde (form). 
      
      Table 2 indicates the HAP at eight coke oven facilities measured during source tests at the various operating units submitted for the CAA section 114 information request (hereafter referred to as the "coke oven test data") and which were used to calculate MACT floor. The coke oven test data used in the MACT limit calculations and subsequent BTF analyses were "not adjusted for nondetected" values. For stack run data where values were at or below detection, for MACT limits the method detection limit (MDL) is used for the run/fraction mass, as per EPA protocol for developing emissions estimates that potentially could be used to develop emission standards. This protocol is opposed to the EPA's protocol for risk assessment data, which includes converting stack run data to half of the MDL, where values were at or below detection, in developing test run values for performing risk assessments. The HAP emissions and other operating and test information for each unit can be found in the responses to the coke oven CAA section 114 requests included in the docket for the rule as well as in the memorandum titled Coke Ovens Risk and Technology Review: Data Summary ( EPA, 2023A) located in the docket for this rule (Docket ID No. EPA-HQ-OAR-2002-0085).
.

Table 2. Valid Data Available for Unregulated and Under-regulated HAP Emissions by Process for PQBS Processes
HAP/
HAP Groups[1]
Pushing
(ByP & HNR)
ByP Battery Stack
HNR HRSG
Main Stacks
HNR HRSG Bypass/waste heat stacks
AG
√
√
√
√
Dioxin/furansTEQ[2]
BDL
BDL
BDL 
BDL
Formaldehyde
BDL
BDL 
√[6]
√
PM/HAP Metals (non-Hg)[3]
NA[4]
√
√
√
HCN
√
√
BDL 
BDL[5]
Mercury
√
√
√
√
PAH (total)
√
BDL 
√
√
VOHAP (total)
BDL
BDL 
BDL[6]
BDL
1 For list of individual HAP in the HAP groups see Table 3. Note: NA = not applicable. BDL = above 50% of the data was below the detection limit. See Table 4.
[2] The 17 specific dioxin/furan congener mass values from testing were converted to 2,3,7,8-TCDD toxic equivalency (TEQ) values using the 2005 World Health Organization (WHO) toxicity equivalence factors (TEF). (EPA, 2010) The 17 congener TEQ values then were summed to calculate a total TEQ value for each stack test run.
[3] The HAP metals are as follows (non-Hg): antimony, arsenic, beryllium, cadmium, chromium, cobalt, lead, manganese, nickel, and selenium. 
[4] A PM MACT standard for pushing, as a surrogate for HAP metals, is included in the current coke oven PQBS rule (§63.7290); therefore, MACT limits were not needed for HAP metals (non-Hg) from pushing.
[5] Data acquired through SC-GraniteCity-IL testing was considered invalid. Data quired through SC-FranklinFurnace-OH testing was BDL for all three runs. For more details, see the memorandum titled Coke Ovens Risk and Technology Review: Data Summary ( EPA, 2023A). 
[6] Testing was not required during the 2016 Coke CAA section 114 request for this HAP because volatiles were not expected from the source due to the high temperatures. During the 2022 Coke CAA section 114 request, one source tested for Formaldehyde and benzene, toluene, ethylbenzene, and xylenes (BTEX). 

                 Table 3. Individual HAP Within the HAP Groups
HAP Group
Individual HAP
AG
hydrogen fluoride, 
hydrogen chloride 
Total PAH
acenaphthene, acenaphthylene, anthracene, benz[a]anthracene, benzo[a]pyrene, benzo[b]fluoranthene, benzo[g,h,i,]perylene, benzo[k]fluoranthene, chrysene, dibenzo[a,h]anthracene, fluoranthene, fluorene, indeno[1,2,3-c,d]pyrene, naphthalene, phenanthrene, perylene, pyrene
Total D/F TEQ
2,3,7,8-tetrachlorodibenzo-p-dioxin TEQ, 
1,2,3,7,8-pentachlorodibenzo-p-dioxin TEQ, 
1,2,3,4,7,8-hexachlorodibenzo-p-dioxin TEQ, 
1,2,3,6,7,8-hexachlorodibenzo-p-dioxin TEQ, 
1,2,3,7,8,9-hexachlorodibenzo-p-dioxin TEQ, 
1,2,3,4,6,7,8-heptachlorodibenzo-p-dioxin TEQ, 
octachlorodibenzo-p-dioxin TEQ, 
2,3,7,8-tetrachlorodibenzofuran TEQ, 
1,2,3,7,8-pentachlorodibenzofuran TEQ, 
2,3,4,7,8-pentachlorodibenzofuran TEQ, 
1,2,3,4,7,8-hexachlorodibenzofuran TEQ, 
1,2,3,6,7,8-hexachlorodibenzofuran TEQ, 
2,3,4,6,7,8-hexachlorodibenzofuran TEQ, 
1,2,3,7,8,9-hexachlorodibenzofuran TEQ, 
1,2,3,4,6,7,8-heptachlorodibenzofuran TEQ, 
1,2,3,4,7,8,9-heptachlorodibenzofuran TEQ, 
Octachlorodibenzofuran TEQ
Total VOHAP
acrylonitrile, benzene, bromoform, methyl bromide, carbon disulfide, carbon tetrachloride, chlorobenzene, ethyl chloride, chloroform, methyl chloride, ethylene dichloride, vinylidene chloride, propylene dichloride, ethyl benzene, methyl iodide, methylene chloride, styrene, 1,1,2,2-tetrachloroethane, tetrachloroethylene, toluene, methyl chloroform, 1,1,2-trichloroethane, trichloroethylene, vinyl chloride, xylenes (mixed isomers)

3.0	MACT FLOOR

      In the Coke Oven Emissions Database, for stack run data where values were at or below detection, the method detection limit (MDL) or similar value was used for the run/fraction mass, as per EPA protocol for developing emissions estimates that potentially could be used to develop emission standards. This type of data is classified as data that is "not adjusted for nondetected" values and was used for the calculation of MACT limits and estimates of air pollution control device cost effectiveness in the Maximum Achievable Control Technology Standard Calculations, Cost Impacts, and Beyond-the-Floor Cost Impacts for Coke Ovens Facilities under 40 CFR Part 63, Subpart CCCCC memorandum. Note that for test runs classified as detection level limited (DLL) or above detection limit (ADL) there were no adjustments made to the test run values. For more information on the data sets used see the Coke Ovens Risk and Technology Review: Data Summary memorandum ( EPA, 2023A). 
      
      The MACT analyses use the upper predictive limit (UPL) approach to identify the average emission limitation achieved by the best performing sources. The EPA uses this approach because it incorporates the average performance of the best performing sources as well as the variability of the performance during testing conditions. The UPL represents the value which one can expect the mean of a specified number of future observations (e.g., 3-run average) to fall below for the specified level of confidence (99 percent), based upon the results from the same population. In other words, the UPL estimates what the upper bound of future values will be based upon present or past background data. The UPL approach encompasses all the data point-to-data point variability in the collected data, as derived from the dataset to which it is applied. An average HAP emission value is calculated for each unit, and then the individual facility average emission values are ranked from lowest to highest value. The best performing sources per process type and HAP are identified from the rankings consistent with the criteria in CAA section 112(d)(3) for determining MACT standards for existing sources. These sources are referred to as the "MACT floor pool." The existing and new source MACT floor pool datasets were evaluated statistically to determine the distributions for both existing and new sources, by process type and by HAP. After determining the type of data distribution for the dataset, the UPL was calculated using the corresponding equation for the distribution for that dataset and groupings of emission points.
      
The results of the UPL calculations were compared to the 3xRDL values of the performance test method(s), as per EPA guidance ( EPA, 2011; Parker, 2018), to ensure that data measurement variability is addressed. In the comparison of the 3xRDL value to the calculated UPL, if the calculated UPL value is less than the 3xRDL value, the 3xRDL value is used as the basis for the standard because the 3xRDL value provides the lowest emission rate that can be measured using the performance test method while maintaining a relative method precision on the order of 10 to 20 percent of the measured value. If the UPL value is equal to or greater than the 3xRDL value, then the UPL value is used as the basis for the standard.

A MACT floor dataset based on fewer than 7 data points is considered to be a limited dataset. For the PQBS source category the pushing: Hg, AG, HCN, and PAH; ByP battery combustion stack: Hg, PM, AG, and HCN; HRSG main stack: Hg, PM, AG, PAH; and Bypass/waste heat stack Hg, PM, AG, PAH, and Formaldehyde datasets were limited. For limited datasets, each individual dataset can be further evaluated in order to ensure that the uncertainty associated with a limited dataset does not cause the calculated emission limit to be so high that it does not reflect the average performance of the units upon which the limit is based after accounting for variability in the emissions of those units. For limited datasets with less than seven data points, the steps outlined in the memorandum Approach for Applying the Upper Prediction Limit to Limited Dataset memorandum (EPA, 2023b) were followed. Each limited dataset is evaluated to determine whether it is appropriate to make any modifications to the approach to calculate MACT floors. The final selected data distribution ensures that the distribution best represents each dataset; ensures that the correct equation for the distribution was applied to the data; and compares individual components of each limited dataset to determine if the standards based on limited datasets reasonably represent the performance of the units included in the dataset. Based on the evaluation of limits based on limited data sets, no changes to the standard floor calculation procedure were determined to be warranted for the coke ovens limited datasets. For more details, see the memorandum Approach for Applying the Upper Prediction Limit to Limited Datasets located in the docket for this rule (EPA, 2023b). 

3.1	Quantity of Below the Detection Limit (BDL) Data

      Every stack test run is assigned a "run flag". Run flags are determined by the facility/analytical laboratory for each run. They compare each analytical fraction mass to the method detection limit (MDL) or other detection limit values (e.g., reporting limit) as available. The run flag can be designated as above detection limit (ADL) or below detection limit (BDL). For EPA Method 29, mercury runs have five analytical fractions and the other HAP metals have two analytical fractions. The run flag is BDL if all of the fraction masses are below the MDL, detection level limited (DLL) if one or more of fraction masses are below the MDL, and ADL if all of the fraction masses are above the MDL.

      The run flags were examined for each process type and pollutant to determine the percentage of data that had a BDL flag ( EPA, 2014). For those datasets that had 50 or less percent BDL data, MACT standards were developed. Table 4 shows the percent BDL for each process type and pollutant.
      
      
      
             Table 4. Summary of BDL Values in Coke Oven PQBS Test Data 
                       as Percent of MACT Floor Pool Test Data
                                    Process
                                      HAP

                                      Hg
                                      PM
                                     AG[1]
                                      HCN
                                    PAH[1]
                                  D/F TEQ[1]
                                   VOHAP[1]
                                     Form
Pushing 
(ByP & HNR)
                                      40%
                                     NA[2]
                                      13%
                                      0%
                                      50%
                                      92%
                                      92%
                                      58%
ByP Battery (Combustion) Stack
                                      25%
                                      0%
                                      13%
                                      50%
                                      67%
                                      67%
                                      58%
                                     100%
HNR HRSG Main Stacks
                                      0%
                                      10%
                                      50%
                                     100%
                                      5%
                                     100%
                                    100%[3]
                                    29%[3]
HNR HRSG Bypass/ Waste Heat Stacks
                                      0%
                                      0%
                                      0%
                                    100%[4]
                                      24%
                                     100%
                                      60%
                                      20%
[1] For these group HAP, the percent BDL for each individual HAP was calculated and the average of individual BDL shown as the overall group BDL value.
[2] Pushing already has PM limits.
[3] HRSG main stack testing was not required during the 2016 Coke CAA section 114 request for this HAP because volatiles were not expected from the source due to the high temperatures. During the 2022 Coke CAA section 114 request, one source tested for Formaldehyde and BTEX. 
[4] HCN data at SunCoke GraniteCity bypass/waste heat were suspect and were not used; SunCoke Franklin Furnace data were BDL for all three runs.
      
3.2	HAP MACT Limit

      For the coke oven PQBS RTR, MACT limits were developed from coke oven test data for Hg, PM, total AG, HCN, total PAH, and formaldehyde for pushing, ByP battery combustion, HNR HRSG main stacks, and HNR HRSG waste bypass/waste heat stacks, as applicable. Although, HNR process units of HRSG main stacks and HNR HRSG waste bypass/waste heat stacks were not in the original PQBS coke oven MACT, these units are part of the HNR coke-making process and, therefore, are addressed in the coke oven PQBS RTR.
      
      An upper predictive limit (UPL) was developed to determine a HAP MACT limit for existing sources and new sources. To ensure that measurement variability is adequately addressed in the MACT standard, a procedure described in Westlin and Merrill (2011) was used to address the variability in the MACT floors for coke facilities. In the Westlin and Merrill (2011) procedure, a list of representative detection levels (RDL) obtained from available HAP-specific method detection levels are used to account for the effect of measurement imprecision associated with the stack test data. The RDL values are multiplied by three to further account for measurement imprecision to produce "3xRDL" values. As described in Appendix B, the HAP specific 3xRDL value for existing sources, was compared to the calculated UPL value for each HAP UPL calculated per process type. According to the Westlin and Merrill (2011) procedure, the larger of the values, 3xRDL value vs. calculated UPL value, should be used for the MACT limit, to ensure that measurement variability is adequately addressed. See Appendix B for details of how UPLs were calculated, determination of 3xRDL value, and the MACT limits were determined for existing and new sources per HAP per process type. Table 5 shows the existing source and new source MACT limits for the coke oven PQBS source category.
         Table 5. Existing and New Source MACT limits for the Coke Industry
Process
                          Existing and/ or New Source
                                     UOM 
                              HAP/HAP Group[1,2]

                                       
                                       
                                      Hg
                                     PM[3]
                                      AG
                                      HCN
                                      PAH
                                    D/F TEQ
                                     VOHAP
                                 Formal-dehyde
Pushing 
(ByP & HNR)
                                   Existing
                                  lb/ton coke
                                    8.9E-07
                                     [UPL]
                                      [5]
                                    0.0052
                                     [UPL]
                                    0.0011
                                   [UPL[8]]
                                    3.4E-04
                                   [UPL[8]]
                                      [4]
                                      [4]
                                      [4]

                                      New
                                       
                                    3.4E-07
                                    [3xRDL]
                                       
                                    5.1E-04
                                     [UPL]
                                    3.8E-05
                                   [UPL[8]]
                                    1.4E-05
                                   [UPL[8]]
                                       
                                       
                                       
ByP Battery (Combustion) Stack
                                   Existing
                                  lb/ton coke
                                  (or gr/dscf
                                    for PM)
                                    5.8E-05
                                     [UPL]
                                     0.10
                                     [UPL]
                                     0.083
                                     [UPL]
                                    0.0039
                                   [UPL[8]]
                                      [4]
                                      [4]
                                      [4]
                                      [4]

                                      New
                                       
                                    7.1E-06
                                     [UPL]
                                     0.014
                                     [UPL]
                                     0.013
                                     [UPL]
                                    7.4E-04
                                   [UPL[8]]
                                       
                                       
                                       
                                       
HNR HRSG Main Stacks
                                   Existing
                                    gr/dscf
                                 2.4E-06 [UPL]
                                    0.0065
                                     [UPL]
                                     0.038
                                     [UPL]
                                      [4]
                                    4.7E-07
                                   [UPL[8]]
                                      [4]
                                     [4,6]
                                      [6]

                                      New
                                       
                                    1.5E-06
                                     [UPL]
                                 7.5E-04 [UPL]
                                 0.0029 [UPL]
                                      [4]
                               3.7E-07 [UPL[8]]
                                      [4]
                                     [4,6]
                                      [6]
HNR HRSG Bypass/ Waste Heat Stacks
                                   Existing
                                    gr/dscf
                                       
                                       
                                     0.013
                                     [UPL]
                                    [4, 7]
                                    2.4E-06
                                   [UPL[8]]
                                      [4]
                                      [4]
                                    0.0011
                                     [UPL]

                                      New
                                       
                                       
                                       
                                     0.070
                                     [UPL]
                                       
                                       
                                       
                                       
                                    1.9E-05
                                     [UPL]
HR HRSG Bypass/ Waste Heat Stack
                                   Existing
                                    gr/dscf
                                   1.7E-05 
                                     [UPL]
                                     0.034
                                     [UPL]
                                       
                                       
                                       
                                       
                                       
                                       

                                      New
                                       
                                    7.8E-06
                                     [UPL]
                                    0.025 
                                     [UPL]
                                       
                                       
                                       
                                       
                                       
                                       
NR HRSG Bypass/ Waste Heat Stack
                                   Existing
                                    gr/dscf
                               1.7E-06 [UPL[9]]
                                   6.6E-04 
                                  [3xRDL[9]]
                                       
                                       
                                       
                                       
                                       
                                       

                                      New
                                       
                                   7.8E-07 
                                   [UPL[9]]
                                   6.6E-04 
                                  [3xRDL[9]]
                                       
                                       
                                       
                                       
                                       
                                       
1 For list of individual HAP in the HAP groups see Table 3.
2 MACT limit basis indicated in square brackets beneath value, where UPL = upper prediction limit. 3xRDL is three times representative detection limit. See Appendix B for more information regarding calculation of UPLs and 3xRDLs.
[3] PM, as a surrogate for non-Hg metal HAP.
[4] Dataset with greater than 50 percent BDL. 
[5] Pushing already has PM limits in 40 CFR part 63, subpart CCCCC.
[6] HRSG main stack testing was not required during the 2016 Coke CAA section 114 request for this HAP because volatiles were not expected from the source due to the high temperatures. During the 2022 Coke CAA section 114 request, one source tested for formaldehyde and BTEX. Due to the low emission quantities with many, if not all, values BDL, the EPA is not setting numerical emission limits for formaldehyde and BTEX. See the "Data Memorandum" for details of the test results. (EPA, 2023a)
[7] HCN data at SC-GraniteCity-IL bypass/waste heat stack were suspect and were not used.
[8] No 3xRDL value available at this time. 
[9] BTF limits, discussed in Section 5.4.
                                          
4.0	MACT LIMIT IMPACTS
      
4.1	Units Meeting MACT Limits 
      
   The MACT limits from Table 5 were compared to the emissions from the coke facility units to determine which units meet the MACT limits. For the units that had coke oven CAA section 114 requests test data or were similar to a unit that was tested, their test data were used to compare to the MACT limits. For the units that did not have coke oven test data, their emissions were estimated to compare to the MACT limits. The following paragraphs describe the estimating methodology for each process type and the results of the comparisons. 
   
      Using the MACT floor pollutant data sets (called the "MACT floor pool") for pushing and ByP battery combustion stacks, the average emissions and average annual coke production (TPY) were calculated. These values were used to estimate emissions for units that were not in the MACT floor pool using each unit's annual production (TPY) in the following equation: 

Estimated EmissionsUnit i=Avg EmissionsMACT Floor Pool1xAnnual ProductionUnit iAvg Annual ProductionMACT Floor Pool

      For HNR HRSG main stack and HNR HRSG bypass/waste heat stack sources, the emissions for sources not tested were assumed equal to test data from SC-Middletown-OH and CE-EastChicago-IN HRSG main stack and test data from the SC-GraniteCity-IL and SC-FranklinFurnace-OH bypass/waste heat stack, respectively. The SunCoke representatives stated that emissions from these sources were not related to coke production (Batten, 2020). 

      The estimated emissions for each unit at each facility were compared to the MACT limits to determine if each unit could meet the MACT limit. Table 6 shows the pushing emissions for each unit compared to the MACT limits. This comparison shows that all pushing units at all facilities meet the MACT limits for Hg, AG, HCN, and PAH. Table 7 shows the ByP battery combustion stack emissions for each unit compared to the MACT limits. This comparison shows that all ByP battery combustion stack units meet the MACT limits for Hg, PM, AG, and HCN. Table 8 shows the HNR HRSG main stack emissions for each unit compared to the MACT limits. This comparison shows that all HNR HRSG main stack units meet the MACT limits for Hg, PM, AG, and PAH. Table 9 shows the HNR HRSG bypass/waste heat stack emissions for each unit compared to the MACT limits. This comparison shows that all HNR HRSG bypass/waste heat stack units meet the MACT limits for Hg, PM, AG, PAH, and formaldehyde. 

  Table 6. Pushing Hg, AG, HCN, and PAH Emissions Compared to the MACT Limits
                                   Facility
                                Emission Source
                    Unit Meets MACT Limit for Indicated HAP
                                 Hg MACT Limit
                              8.9E-07 lb/ton coke
                                 AG MACT Limit
                              0.0052 lb/ton coke
                                HCN MACT Limit
                              0.0011 lb/ton coke
                                PAH MACT Limit
                              3.4E-04 lb/ton coke
                                       
                                       
                                       
                                Hg lb/ton coke
                                AG lb/ton coke
                                HCN lb/ton coke
                                PAH lb/ton coke
ABC-Tarrant-AL
coke pushing operations for batteries 1 baghouse 1
                               Hg, AG, HCN. PAH
                                    6.9E-08
                                    0.00051
                                    0.00015
                                    1.4E-05
ABC-Tarrant-AL
coke pushing operations for batteries 1 baghouse 2
                               Hg, AG, HCN. PAH
                                    6.9E-08
                                    0.00051
                                    0.00015
                                    1.4E-05
ABC-Tarrant-AL
coke pushing operations for batteries 5 and 6 baghouse
                               Hg, AG, HCN. PAH
                                    5.4E-08
                                    0.00040
                                    0.00012
                                    1.1E-05
BLU-Birmingham-AL
pushing emissions for coke batteries # 3, 4 & 5
                               Hg, AG, HCN. PAH
                                    1.3E-07
                                    0.00094
                                    0.00028
                                    2.6E-05
CC-Follansbee-WV
batteries #1, #2, and #3 pushing baghouse
                               Hg, AG, HCN. PAH
                                    4.0E-08
                                    0.00029
                                    0.00009
                                    8.2E-06
CC-Follansbee-WV
battery #8 pushing venturi scrubber
                               Hg, AG, HCN. PAH
                                    1.7E-07
                                    0.00122
                                    0.00036
                                    3.4E-05
CC-Middletown-OH
wilputte coke oven battery - pec baghouse[1]
                               Hg, AG, HCN. PAH
                                    2.5E-08
                                    0.00029
                                    0.00011
                                    6.7E-06
CC-BurnsHarbor-IN
eu512-06 pushing #1[2]
                               Hg, AG, HCN. PAH
                                    1.7E-07
                                    0.00239
                                    0.00084
                                    3.6E-05
CC-BurnsHarbor-IN
eu512-14 pushing #2[1]
                               Hg, AG, HCN. PAH
                                    1.7E-07
                                    0.00239
                                    0.00084
                                    3.6E-05
CC-Monessen-PA
pushing baghouse[1]
                               Hg, AG, HCN. PAH
                                    4.8E-07
                                    0.00117
                                    0.00074
                                    1.1E-04
CC-Warren-OH
no. 4 coke oven battery - pushing - chemico system
                               Hg, AG, HCN. PAH
                                    1.3E-07
                                    0.00096
                                    0.00028
                                    2.7E-05
EES-RiverRouge-MI
pushing emission control system
                               Hg, AG, HCN. PAH
                                    3.6E-07
                                    0.00264
                                    0.00078
                                    7.4E-05
USS-Clairton-PA
pec baghouse 1-3
                               Hg, AG, HCN. PAH
                                    2.4E-07
                                    0.00175
                                    0.00051
                                    4.9E-05
USS-Clairton-PA
pec baghouse 13-15
                               Hg, AG, HCN. PAH
                                    2.5E-07
                                    0.00182
                                    0.00053
                                    5.1E-05
USS-Clairton-PA
pec baghouse 19-20
                               Hg, AG, HCN. PAH
                                    3.1E-07
                                    0.00228
                                    0.00067
                                    6.4E-05
USS-Clairton-PA
pec baghouse b
                               Hg, AG, HCN. PAH
                                    2.6E-07
                                    0.00193
                                    0.00057
                                    5.4E-05
USS-Clairton-PA
pec baghouse c
                               Hg, AG, HCN. PAH
                                    3.2E-07
                                    0.00236
                                    0.00070
                                    6.6E-05
SC-EastChicago-IN
pushing machine for batteries a, b, c and d
                               Hg, AG, HCN. PAH
                                    4.8E-07
                                    0.00349
                                    0.00103
                                    9.8E-05
SC-FranklinFurnace-OH
pushing multiclone stack ab
                               Hg, AG, HCN. PAH
                                    1.3E-07
                                    0.00092
                                    0.00027
                                    2.6E-05
SC-FranklinFurnace-OH
pushing multiclone stack cd
                               Hg, AG, HCN. PAH
                                    1.3E-07
                                    0.00092
                                    0.00027
                                    2.6E-05
SC-GraniteCity-IL
flat push hot car with multiclone abc
                               Hg, AG, HCN. PAH
                                    2.0E-07
                                    0.00115
                                    0.00034
                                    3.2E-05
SC-Middletown-OH
flat push hot car with multiclone abc[1]
                               Hg, AG, HCN. PAH
                                    4.5E-08
                                    0.00166
                                    0.00002
                                    4.1E-06
SC-Vansant-VA
cokeside shed settling chamber pushing along battery 2d
                               Hg, AG, HCN. PAH
                                    3.3E-08
                                    0.00024
                                    0.00007
                                    6.8E-06
SC-Vansant-VA
cokeside shed settling chamber pushing along battery 2e
                               Hg, AG, HCN. PAH
                                    5.0E-08
                                    0.00036
                                    0.00011
                                    1.0E-05
SC-Vansant-VA
cokeside shed settling chamber pushing along battery 3b
                               Hg, AG, HCN. PAH
                                    4.8E-08
                                    0.00035
                                    0.00010
                                    9.8E-06
SC-Vansant-VA
cokeside shed settling chamber pushing along battery 3c
                               Hg, AG, HCN. PAH
                                    6.6E-08
                                    0.00048
                                    0.00014
                                    1.4E-05
SC-Vansant-VA
cokeside shed settling chamber pushing along battery 3f
                               Hg, AG, HCN. PAH
                                    3.1E-08
                                    0.00023
                                    0.00007
                                    6.4E-06
SC-Vansant-VA
cokeside shed settling chamber pushing along battery 3g
                               Hg, AG, HCN. PAH
                                    3.3E-08
                                    0.00024
                                    0.00007
                                    6.8E-06
1 Tested unit.
[2] Similar unit to tested unit. 
Table 7. ByP Battery Combustion Stack Hg, PM, AG, and HCN Emissions Compared to the MACT Limits
                                   Facility
                                Emission Source
                    Unit Meets MACT Limit for Indicated HAP
                                 Hg MACT Limit
                              5.8E-05 lb/ton coke
                                 PM MACT Limit
                                 0.10 gr/dscf
                                 AG MACT Limit
                               0.083 lb/ton coke
                                HCN MACT Limit
                              0.0039 lb/ton coke
                                       
                                       
                                       
                                Hg lb/ton coke
                                  PM gr/dscf
                                AG lb/ton coke
                                HCN lb/ton coke
ABC-Tarrant-AL
underfiring stack #1, battery #1
                                Hg, PM, AG, HCN
                                    1.1E-05
                                     0.020
                                     0.023
                                    0.0014
ABC-Tarrant-AL
underfiring stack #4, batteries #5 and #6
                                Hg, PM, AG, HCN
                                    4.2E-06
                                    0.0080
                                    0.0090
                                    0.00054
BLU-Birmingham-AL
underfiring stack of batteries no. 3 & 4
                                Hg, PM, AG, HCN
                                    5.7E-06
                                     0.011
                                     0.012
                                    0.00074
BLU-Birmingham-AL
underfiring stack of coke battery no. 5
                                Hg, PM, AG, HCN
                                    4.1E-06
                                    0.0079
                                    0.0089
                                    0.00053
CC-Follansbee-WV
battery #1 combustion
                                Hg, PM, AG, HCN
                                    1.0E-06
                                    0.0020
                                    0.0022
                                    0.00013
CC-Follansbee-WV
battery #2 combustion
                                Hg, PM, AG, HCN
                                    1.0E-06
                                    0.0020
                                    0.0022
                                    0.00013
CC-Follansbee-WV
battery #3 combustion
                                Hg, PM, AG, HCN
                                    1.0E-06
                                    0.0020
                                    0.0022
                                    0.00013
CC-Follansbee-WV
battery #8 combustion
                                Hg, PM, AG, HCN
                                    1.3E-05
                                     0.024
                                     0.028
                                    0.0016
CC-Middletown-OH
wilputte battery - combustion stack[1]
                                Hg, PM, AG, HCN
                                    4.2E-06
                                     0.029
                                     0.061
                                    0.0030
CC-BurnsHarbor-IN
eu512-08 battery #1 underfire[2]
                                Hg, PM, AG, HCN
                                    3.2E-05
                                     0.050
                                     0.016
                                    0.0024
CC-BurnsHarbor-IN
eu512-16 battery #2 underfire[1]
                                Hg, PM, AG, HCN
                                    3.2E-05
                                     0.050
                                     0.016
                                    0.0024
CC-Monessen-PA
battery 1b combustion stack[2]
                                Hg, PM, AG, HCN
                                    3.9E-06
                                    0.0067
                                     0.010
                                    0.00052
CC-Monessen-PA
battery 2 combustion stack[1]
                                Hg, PM, AG, HCN
                                    3.9E-06
                                    0.0067
                                     0.010
                                    0.00052
CC-Warren-OH
no. 4 battery - oven underfiring
                                Hg, PM, AG, HCN
                                    1.0E-05
                                     0.019
                                     0.022
                                    0.0013
EES-RiverRouge-MI
battery heating stack
                                Hg, PM, AG, HCN
                                    2.8E-05
                                     0.053
                                     0.060
                                    0.0036
USS-Clairton-PA
coke oven battery 1 underfiring[2]
                                Hg, PM, AG, HCN
                                    7.1E-06
                                    0.0047
                                     0.015
                                    0.00017
USS-Clairton-PA
coke oven battery 2 underfiring[2]
                                Hg, PM, AG, HCN
                                    7.1E-06
                                    0.0047
                                     0.015
                                    0.00017
USS-Clairton-PA
coke oven battery 3 underfiring[2]
                                Hg, PM, AG, HCN
                                    7.1E-06
                                    0.0047
                                     0.015
                                    0.00017
USS-Clairton-PA
coke oven battery 13 underfiring[2]
                                Hg, PM, AG, HCN
                                    7.1E-06
                                    0.0047
                                     0.015
                                    0.00017
USS-Clairton-PA
coke oven battery 14 underfiring[2]
                                Hg, PM, AG, HCN
                                    7.1E-06
                                    0.0047
                                     0.015
                                    0.00017
USS-Clairton-PA
coke oven battery 15 underfiring[2]
                                Hg, PM, AG, HCN
                                    7.1E-06
                                    0.0047
                                     0.015
                                    0.00017
USS-Clairton-PA
coke oven battery 19 underfiring[2]
                                Hg, PM, AG, HCN
                                    7.1E-06
                                    0.0047
                                     0.015
                                    0.00017
USS-Clairton-PA
coke oven battery 20 underfiring[2]
                                Hg, PM, AG, HCN
                                    7.1E-06
                                    0.0047
                                     0.015
                                    0.00017
USS-Clairton-PA
coke oven b battery underfiring[1]
                                Hg, PM, AG, HCN
                                    7.1E-06
                                    0.0047
                                     0.015
                                    0.00017
USS-Clairton-PA
coke oven c battery underfiring[2]
                                Hg, PM, AG, HCN
                                    7.1E-06
                                    0.0047
                                     0.015
                                    0.00017
[1] Tested unit.
2 Similar unit to tested unit.
                                       
                                       
Table 8. HNR HRSG Main Stack Hg, PM, AG, and Total PAH Emissions Compared to the MACT Limits
                                   Facility
                                Emission Source
                    Unit Meets MACT Limit for Indicated HAP
                                 Hg MACT Limit
                                2.4E-06 gr/dscf
                                 PM MACT Limit
                                0.0065 gr/dscf
                                 AG MACT Limit
                                 0.038 gr/dscf
                             Total PAH MACT Limit
                                4.7E-07 gr/dscf
                                       
                                       
                                       
                                  Hg gr/dscf
                                  PM gr/dscf
                                  AG gr/dscf
                               Total PAH gr/dscf
CE-EastChicago-IN / 
SC-EastChicago-IN
HRSG main stack
                                Hg, PM, AG, PAH
                                    1.7E-06
                                    0.00036
                                    0.0082
                                    2.8E-07
SC-FranklinFurnace-OH
p901- coke ovens (battery a&b) - main stack ab
                                Hg, PM, AG, PAH
                                    1.5E-06
                                    0.0010
                                    0.0064
                                    3.1E-07
SC-FranklinFurnace-OH
p902- coke ovens (battery c&d) - main stack cd
                                Hg, PM, AG, PAH
                                    1.5E-06
                                    0.0010
                                    0.0064
                                    3.1E-07
SC-GraniteCity-IL
0005 -coke ovens (battery a&b&c) - main stack
                                Hg, PM, AG, PAH
                                    1.5E-06
                                    0.0010
                                    0.0064
                                    3.1E-07
SC-Middletown-OH
p901- coke oven (battery a-c) - main stack
                                Hg, PM, AG, PAH
                                    9.0E-07
                                    0.0027
                                    0.0022
                                    3.8E-07
Note: Tested units are SC-Middletown-OH Main Stack and CE-EastChicago-IN Main Stack. All other units have operating hours that are the same as the tested units.

Table 9. HNR HRSG Bypass/Waste Heat Stack Hg, PM, AG, Total PAH, and Formaldehyde 
                     Emissions Compared to the MACT Limits
                                   Facility
                               Emission Sources
                    Unit Meets MACT Limit for Indicated HAP
                         Hg MACT Limit 1.7E-05 gr/dscf
                                 PM MACT Limit
                                 0.034 gr/dscf
                                AG MACT Limit 
                                 0.13 gr/dscf
                             Total PAH MACT Limit
                                2.4E-06 gr/dscf
                            Formaldehyde MACT Limit
                               0.0011-05 gr/dscf
                                       
                                       
                                       
                                  Hg gr/dscf
                                  PM gr/dscf
                                  AG gr/dscf
                               Total PAH gr/dscf
                             Formaldehyde gr/dscf
SC-EastChicago-IN
venting stack 1-16
                         Hg, PM, AG, PAH, Formaldehyde
                                    6.1E-06
                                     0.017
                                     0.072
                                    6.5E-07
                                    4.3E-05
SC-FranklinFurnace-OH
bypass vent 1-5 and 7-10
                         Hg, PM, AG, PAH, Formaldehyde
                                    7.0E-06
                                     0.020
                                     0.086
                                    6.5E-07
                                    1.0E-04
SC-FranklinFurnace-OH
bypass vent 6
                         Hg, PM, AG, PAH, Formaldehyde
                                    7.0E-06
                                     0.020
                                     0.086
                                    6.5E-07
                                    1.0E-04
SC-GraniteCity-IL
bypass vent 1-4 and 6
                         Hg, PM, AG, PAH, Formaldehyde
                                    5.2E-06
                                     0.013
                                     0.058
                                    6.5E-07
                                    4.7E-06
SC-GraniteCity-IL
bypass vent 5
                         Hg, PM, AG, PAH, Formaldehyde
                                    5.2E-06
                                     0.013
                                     0.058
                                    6.5E-07
                                    4.7E-06
SC-Middletown-OH
bypass vent 1-5
                         Hg, PM, AG, PAH, Formaldehyde
                                    6.1E-06
                                     0.017
                                     0.072
                                    6.5E-07
                                    4.3E-05
SC-Vansant-VA
venting stack 1-16
                         Hg, PM, AG, PAH, Formaldehyde
                                    6.1E-06
                                     0.017
                                     0.072
                                    6.5E-07
                                    4.3E-05
Note: Tested units are SC-FranklinFurnace-OH Bypass Vent 6 and SC-GraniteCity-IL Bypass Vent 5. All other sources are assumed to have the same concentrations in the coke oven exhaust as the average of the tested source because all sources use the same HNR process.
                                         
   
4.2	Costs to Meet MACT Limits
   
   Because all sources were shown to meet the MACT limits, as discussed in Section 4.1, there are no APCD costs associated with compliance with the MACT limits. There are compliance costs for testing of the emission points with MACT limits, which has been proposed for every 5 years. For details of the proposed compliance costs, see the memorandum Coke Ovens Risk and Technology Review: Compliance Costs located in the docket for this rule (EPA, 2023c).
      
5.0	BEYOND THE FLOOR ANALYSIS

The following sections summarize the results of the BTF analysis for HAP emissions from the PQBS source category beyond what can be achieved by the MACT limits described above. The primary sources of emissions data and cost parameters for the BTF analysis were the responses to the coke oven CAA section 114 requests and other references cited below. Copies of the coke oven CAA section 114 requests and responses are included in docket for this rule (Docket ID No. EPA-HQ-OAR-2002-0085). 
      
5.1	Background

To evaluate opportunities for emission reductions beyond those that would result from the new MACT limits, control techniques were identified and evaluated that can achieve an emissions level more stringent than the MACT limit. Identification of BTF control techniques and costs of BTF controls are described below.

5.2	HAP Control Devices by MACT Process Type at Coke Facilities

      Table 10 shows the APCD identified as BTF control for each HAP and process type and the expected control efficiencies of these APCD per HAP. 
      
Table 10. BTF APCD and Control Efficiencies for Coke Oven MACT Limits by HAP and Process Type
                                 Process Type
                          HAP with MACT Limit[1][,2]
                                  BTF APCD[3]
                          Control Efficiency per HAP 
ByP & HNR Pushing
                                      Hg
                                      ACI
                                      95%

                                      PAH
                                       
                                      80%

                                      AG
                                      WAS
                                     99.9%

                                      HCN
                                       
                                      95%
ByP Battery Combustion Stack
                                      Hg
                                      ACI
                                      95%

                                      PM
                                      WAS
                                      95%

                                      AG
                                       
                                     99.9%

                                      HCN
                                       
                                      95%
HNR HRSG Main Stack
                                      Hg
                                      ACI
                                      95%

                                      PAH
                                       
                                      80%

                                      PM
                                      WAS
                                      95%

                                      AG
                                       
                                     99.9%
HNR HRSG Bypass/Waste Heat Stack
                                      Hg
                                      ACI
                                      95%

                                      PM
                                      WAS
                                      95%

                                      AG
                                       
                                     99.9%

                                      PAH
                                      RTO
                                      98%

                                 Formaldehyde
                                       
                                      98%
HNR HRSG Bypass/Waste Heat Stack
                                      Hg
                                      ACI
                                      90%

                                      PM
                                      BH
                                     99.9%
[1] AG = acid gases, hydrogen chloride and hydrogen fluoride. HAP = hazardous air pollutants. HCN = hydrogen cyanide. Hg = mercury. PAH = polycyclic hydrocarbon. PM = particulate matter.
[2] PM, as a surrogate for non-Hg metal HAP.
[3] Wet alkaline scrubber (WAS); activated carbon injection (ACI); regenerative thermal oxidizer (RTO).

5.3	Total BTF Annual Costs, Emissions Reductions, and Cost Effectiveness for APCD per Process Type at Coke Facilities

   The total BTF annual costs were calculated by summing the individual unit costs per APCD at each process type per facility. The development of the BTF unit costs per APCD per process type are located in Appendix C. The baseline emissions were estimated using similar calculation methodology that was used to calculate the HAP emissions for the modeling file, as described in Coke Ovens Risk and Technology Review: Data Summary ( EPA, 2023A). In most cases, the baseline emissions are controlled emissions but, in some cases, the emissions are not. The development of the baseline emissions and calculation of emission reductions using BTF APCD control devices are described further in Appendix C. The unit emissions reductions were summed to calculate the BTF total emissions reductions for each APCD at each process type per facility. The cost effectiveness values for BTF APCD were calculated for the coke oven MACT sources by dividing the annualized costs by the emission reductions. Tables 11 through 15 show the total BTF annual costs, emissions reductions, and cost effectiveness per pollutant and APCD for each process at coke facilities. Note, the values presented were calculated from unrounded emissions. Compliance costs for testing are discussed in the memorandum Coke Ovens Risk and Technology Review: Compliance Costs located in the docket for this rule (EPA, 2023c).

5.4	BTF Limits for HNR HRSG Bypass/Waste Heat Stacks (Existing & New Sources) 

      The EPA is proposing BTF limits for the nonrecovery (NR) HRSG bypass/waste heat stacks, see Table 16 below and Appendix D for more details. The limits are calculated using the following equation:

           BTF UPL Limit = MACT UPL Limit x (1-Control Efficiency).

Table 11. Pushing BTF Total Annual Costs, Emissions Reductions, and Cost Effectiveness per APCD
                                   Facility
                            Total Annual Costs ($)
                           HAP Emissions Reductions
                           due to BTF Controls (TPY)
                          Cost Effectiveness ($/Ton)
                                       
                                 Ductwork ($K)
                           ACI for Hg & PAH ($K)
                           WAS for AG & HCN ($M)
                                   Hg w/ ACI
                                  PAH w/ ACI
                                   AG w/ WAS
                                  HCN w/ WAS
                                   Hg w/ ACI
                                     ($B)
                                  PAH w/ ACI 
                                     ($M)
                                AG w/ WAS ($M)
                                HCN w/ WAS ($M)
                                   Total HAP
                             w/ Ductwork +ACI+ WAS
                                     ($M)
ABC-Tarrant-AL
                                      $35
                                     $508
                                     $7.6
                                    2.5E-05
                                     0.14
                                    3.8E-01
                                    2.2E-01
                                      $20
                                     $3.7
                                      $20
                                      $34
                                      $11
BLU-Birmingham-AL
                                      $12
                                     $169
                                     $2.6
                                    1.7E-05
                                     0.091
                                    2.5E-01
                                    1.5E-01
                                      $10
                                     $1.9
                                      $10
                                      $17
                                     $5.6
CC-Follansbee-WV
                                      $23
                                     $339
                                     $5.1
                                    5.9E-05
                                     0.011
                                    3.6E-01
                                    1.4E-01
                                     $5.7
                                      $30
                                      $14
                                      $37
                                      $11
CC-Middletown-OH
                                      $12
                                     $169
                                     $2.6
                                    4.2E-05
                                    0.0080
                                    5.7E-02
                                    2.2E-02
                                     $4.0
                                      $21
                                      $45
                                     $118
                                      $32
CC-BurnsHarbor-IN
                                      $23
                                     $339
                                     $5.3
                                    2.0E-04
                                     0.038
                                    2.3E+00
                                    7.6E-01
                                     $1.7
                                     $8.9
                                     $2.3
                                     $7.0
                                     $1.9
CC-Monessen-PA
                                      $12
                                     $169
                                     $2.6
                                    3.6E-05
                                    0.0067
                                    2.0E-01
                                    1.2E-01
                                     $4.8
                                      $25
                                      $13
                                      $22
                                     $8.6
CC-Warren-OH
                                      $12
                                     $169
                                     $2.6
                                    3.8E-05
                                    0.0072
                                    2.3E-01
                                    8.9E-02
                                     $4.5
                                      $24
                                      $11
                                      $29
                                     $8.4
EES-RiverRouge-MI
                                      $12
                                     $169
                                     $2.6
                                    1.0E-04
                                     0.020
                                    6.3E-01
                                    2.4E-01
                                     $1.6
                                     $8.6
                                     $4.2
                                      $11
                                     $3.2
USS-Clairton-PA
                                      $59
                                     $846
                                     $13.1
                                    4.0E-04
                                     0.076
                                    2.4E+00
                                    9.3E-01
                                     $2.1
                                      $11
                                     $5.4
                                      $14
                                     $4.1
SC-EastChicago-IN
                                     $9.4
                                      $67
                                     $1.4
                                    7.6E-05
                                    0.0022
                                    1.1E+00
                                    1.5E-02
                                     $876M
                                      $31
                                     $1.3
                                      $91
                                     $1.3
SC-FranklinFurnace-OH
                                      $19
                                     $133
                                     $2.5
                                    4.0E-05
                                    0.0011
                                    5.7E-01
                                    7.8E-03
                                     $3.4
                                     $119
                                     $4.4
                                     $318
                                     $4.6
SC-GraniteCity-IL
                                     $9.4
                                      $67
                                     $1.3
                                    2.5E-05
                                    0.00070
                                    3.6E-01
                                    4.9E-03
                                     $2.7
                                      $95
                                     $3.5
                                     $257
                                     $3.7
SC-Middletown-OH
                                     $9.4
                                      $67
                                     $1.2
                                    2.1E-05
                                    0.00059
                                    3.0E-01
                                    4.1E-03
                                     $3.2
                                     $114
                                     $4.2
                                     $305
                                     $4.4
SC-Vansant-VA
                                      $57
                                     $401
                                     $7.2
                                    3.1E-05
                                    0.00088
                                    4.4E-01
                                    6.1E-03
                                      $13
                                     $454
                                      $16
                                     $1.2B
                                      $17
Industry Total
                                     $303
                                     $3.6M
                                      $62
                                    0.0011
                                     0.40
                                      10
                                      2.7
                                     $3.2
                                     $9.1
                                     $6.0
                                      $21
                                     $4.9
Note: B=Billion, M=Million, K=Thousand. 
      
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
Table 12. ByP Battery Combustion Stack BTF Total Annual Costs, Emissions Reductions, and Cost Effectiveness per APCD[1,2]
                                   Facility
                            Total Annual Costs ($)
                           HAP Emissions Reductions 
                           due to BTF Controls (TPY)
                          Cost Effectiveness ($/Ton)
                                       
                                 Ductwork ($K)
                                  ACI for  Hg
                                     ($K)
                 WAS for Non-Hg Metal HAP, AG, & HCN ($M)
                                   Hg w/ ACI
                            Non-Hg Metal HAP w/ WAS
                                   AG w/ WAS
                                  HCN w/ WAS
                                  Hg w/ ACI 
                                     ($M)
                         Non-Hg Metal HAP w/ WAS ($M)
                                  AG w/ WAS 
                                     ($K)
                                HCN w/ WAS ($M)
                       Total HAP w/ Ductwork + ACI + WAS
                                     ($K)
ABC-Tarrant-AL
                                      $24
                                     $334
                                     $4.0
                                    0.0012
                                     0.11
                                      2.2
                                     0.94
                                     $268
                                      $37
                                     $1.8M
                                     $4.1
                                     $1.3M
BLU-Birmingham-AL
                                      $24
                                     $334
                                     $4.0
                                    0.00083
                                     0.073
                                      1.5
                                     0.62
                                     $405
                                      $55
                                     $2.7M
                                     $6.1
                                     $2.0M
CC-Follansbee-WV
                                      $48
                                     $669
                                     $8.1
                                    0.0032
                                     0.11
                                      7.2
                                     0.41
                                     $211
                                      $71
                                     $1.1M
                                      $19
                                     $1.1M
CC-Middletown-OH
                                      $12
                                     $167
                                     $2.1
                                    0.00080
                                     0.075
                                      12
                                     0.58
                                     $210
                                      $28
                                     $169
                                     $3.4
                                     $174
CC-BurnsHarbor-IN
                                      $24
                                     $334
                                     $4.4
                                     0.029
                                      1.1
                                      15
                                      2.2
                                      $12
                                     $4.1
                                     $283
                                     $1.9
                                     $253
CC-Monessen-PA
                                      $24
                                     $334
                                     $4.0
                                    0.00062
                                     0.012
                                      1.7
                                     0.083
                                     $542
                                     $325
                                     $2.3M
                                      $46
                                     $2.4M
CC-Warren-OH
                                      $12
                                     $167
                                     $2.1
                                    0.0020
                                     0.073
                                      4.6
                                     0.26
                                      $83
                                      $28
                                     $446
                                     $7.5
                                     $452
EES-RiverRouge-MI
                                      $12
                                     $167
                                     $2.1
                                    0.0055
                                     0.20
                                      13
                                     0.72
                                      $30
                                      $11
                                     $170
                                     $2.8
                                     $172
USS-Clairton-PA
                                     $120
                                     $1.7M
                                      $20
                                     0.013
                                     0.11
                                      29
                                     0.31
                                     $131
                                     $190
                                     $716
                                      $63
                                     $768
Industry Total
                                     $299
                                     $4.2M
                                      $51
                                     0.056
                                      1.8
                                      86
                                      6.1
                                      $75
                                      $28
                                     $594
                                     $8.0
                                     $592
[1] PM MACT limit, as a surrogate for non-Hg metal HAP. 
[2] M=Million, K=Thousand. 

Table 13. HNR HRSG Main Stack BTF Total Annual Costs, Emissions Reductions, and Cost Effectiveness per APCD[1,2]
                                   Facility
                            Total Annual Costs ($)
              HAP Emissions Reductions due to BTF Controls (TPY)
                          Cost Effectiveness ($/Ton)

                                 Ductwork ($K)
                           ACI for Hg & PAH ($K)
                    WAS for Non-Hg Metal HAP & AG ($M)
                                   Hg w/ ACI
                                  PAH w/ ACI
                            Non-Hg Metal HAP w/ WAS
                                   AG w/ WAS
                                  Hg w/ ACI 
                                     ($M)
                                  PAH w/ ACI 
                                     ($M)
                         Non-Hg Metal HAP w/ WAS ($M)
                                  AG w/ WAS 
                                     ($K)
                                   Total HAP
                         w/ Ductwork + ACI + WAS ($K)
SC-EastChicago-IN 
                                      $20
                                     $486
                                     $6.1
                                     0.047
                                    0.0063
                                     0.046
                                      236
                                      $10
                                      $77
                                     $132
                                      $26
                                      $28
SC-FranklinFurnace-OH
                                      $40
                                     $973
                                      $12
                                     0.054
                                    0.0090
                                     0.16
                                      255
                                      $18
                                     $108
                                      $76
                                      $47
                                      $51
SC-GraniteCity-IL
                                      $20
                                     $486
                                     $6.0
                                     0.027
                                    0.0045
                                     0.079
                                      128
                                      $18
                                     $108
                                      $76
                                      $47
                                      $51
SC-Middletown-OH
                                      $20
                                     $486
                                     $6.0
                                    0.0074
                                    0.0027
                                     0.11
                                      19
                                      $66
                                     $179
                                      $54
                                     $314
                                     $338
Industry Total
                                     $100
                                     $2.4M
                                      $30
                                     0.14
                                     0.023
                                     0.40
                                      638
                                      $18
                                     $108
                                      $76
                                      $47
                                      $51
[1] PM MACT limit, as a surrogate for non-Hg metal HAP. 
[2] M=Million, K=Thousand. 

Table 14. HNR HRSG Bypass/Waste Heat Stack BTF Total Annual Costs and Emissions Reductions per APCD[1,2]
                                   Facility
                            Total Annual Costs ($)
              HAP Emissions Reductions due to BTF Controls (TPY)

                                 Ductwork ($K)
                                ACI for Hg ($M)
                      WAS for Non-Hg Metal HAP & AG 
                                     ($M)
                      RTO for PAH & Formaldehyde ($M)
                                   Hg w/ ACI
                            Non-Hg Metal HAP w/ WAS
                                   AG w/ WAS
                                  PAH w/ RTO
                              Formaldehyde w/ RTO
SC-EastChicago-IN
                                     $182
                                     $2.9
                                      $12
                                      $23
                                     0.022
                                      1.1
                                      278
                                    0.0026
                                     0.021
SC-FranklinFurnace-OH
                                      $61
                                     $1.8
                                     $9.4
                                      $16
                                    0.0025
                                     0.11
                                      34
                                    0.00027
                                     0.042
SC-GraniteCity-IL
                                      $40
                                     $1.1
                                     $5.2
                                     $9.3
                                    0.0021
                                     0.12
                                      24
                                    0.00027
                                    0.0018
SC-Middletown-OH
                                      $33
                                     $902K
                                     $4.7
                                     $8.1
                                    0.0019
                                     0.096
                                      24
                                    0.00022
                                     0.018
SC-Vansant-VA
                                     $426
                                     $1.6
                                     $7.7
                                      $13
                                     0.076
                                      3.8
                                      955
                                    0.0089
                                     0.72
Industry Total
                                     $741
                                     $8.3
                                      $39
                                      $69
                                     0.104
                                      5.3
                                     1,314
                                     0.012
                                     0.99
[1] PM MACT limit, as a surrogate for non-Hg metal HAP. 
[2] M=Million, K=Thousand. 

Table 15. HNR HRSG Bypass/Waste Heat Stack Total BTF Cost Effectiveness per APCD[1,2]
                                   Facility
                          Cost Effectiveness ($/Ton)
                                       
                                  Hg w/ ACI 
                                     ($M)
                           Non-Hg Metal HAP w/ WAS 
                                     ($M)
                                AG w/ WAS ($K)
                              PAH ($/Ton) w/ RTO 
                                     ($B)
                         Formaldehyde ($/Ton) w/ RTO 
                                     ($M)
                            Total HAP 
w/ Ductwork+
                               ACI+WAS+RTO ($K)
SC-EastChicago-IN
                                     $132
                                      $11
                                      $45
                                     $8.9
                                     $110
                                     $138
SC-FranklinFurnace-OH
                                     $712
                                      $82
                                     $277
                                      $59
                                     $384
                                     $810
SC-GraniteCity-IL
                                     $518
                                      $44
                                     $216
                                      $35
                                     $5.2B
                                     $644
SC-Middletown-OH
                                     $477
                                      $49
                                     $197
                                      $37
                                     $452
                                     $575
SC-Vansant-VA
                                      $21
                                     $2.0
                                     $8.1
                                     $1.4
                                      $18
                                      $23
Industry Total
                                      $80
                                     $7.5
                                      $30
                                     $5.7
                                      $70
                                      $89
[1] PM MACT limit, as a surrogate for non-Hg metal HAP.
[2] B=Billion, M=Million, K=Thousand.
      
Table 16. BTF Limits for NR HRSG Bypass/Waste Heat Stacks (Existing & New Sources)
                                      HAP
                          Existing and/or New Source
                                MACT UPL Limit
                              BTF Control Device 
                            (% Control Efficiency)
                      Cost Effectiveness from BTF control
                                BTF UPL Limits
                                  BTF Limits
Non-Hg HAP Metals (PM)
                                   Existing
                                                               0.034 PM gr/dscf
                                  BH (99.9%)
                             $645K/ton HAP Metals
                                                             3.4E-05 PM gr/dscf
                                                     6.6E-04 PM gr/dscf [3xRDL]

                                      New
                                                               0.025 PM gr/dscf
                                       
                                       
                                                             2.5E-05 PM gr/dscf
                                                     6.6E-04 PM gr/dscf [3xRDL]
Mercury
                                   Existing
                                                                1.7E-05 gr/dscf
                                 ACI+BH (90%)
                                    $11K/lb
                                                                1.7E-06 gr/dscf
                                                          1.7E-06 gr/dscf [UPL]

                                      New
                                                                7.8E-06 gr/dscf
                                       
                                       
                                                                7.8E-07 gr/dscf
                                                          7.8E-07 gr/dscf [UPL]

      
      
6.0	REFERENCES

Batten, 2020. Personal communication (email). K. Batten, SunCoke, with D. L. Jones, U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards, Research Triangle Park, North Carolina. Docket ID No. EPA-HQ-OAR-2002-0085. October 7, 2020.
EPA, 2010. Recommended Toxicity Equivalence Factors (TEFs) for Human Health Risk Assessments of 2,3,7,8-Tetrachlorodibenzo-p-dioxin and Dioxin-Like Compounds. Publication No. EPA/100/R - 10/005. U.S. Environmental Protection Agency, Washington, DC. December 2010.
EPA, 2011. Data and Procedure for Handling Below Detection Level Data in Analyzing Various Pollutant Emissions Databases for MACT and RTR Emissions Limits. P. Westlin and R. Merrill. Environmental Protection Agency, Office of Air Quality Planning and Standards, Research Triangle Park, North Carolina. 2011.
EPA, 2014. Determination of "non-detect" from EPA Method 29 (multi-metals) and EPA Method 23 (dioxin/furan) test data when evaluating the setting of MACT floors versus establishing work practice standards. Memorandum from S. Johnson, U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards, Research Triangle Park, North Carolina. June 5, 2014.
EPA, 2018. Development of Representative Detection Levels of Certain Organic HAP Expressed as Pounds per Million British Thermal Units of Fuel Input for RTR Risk Modeling Dataset for Coal- and Oil-fired EGUs. Memorandum from B. Parker, EPA/OAQPS/SPPD, to Docket ID No: EPA-HQ-OAR-2018-0794. U.S. Environmental Protection Agency, Research Triangle Park, NC. July 2018.
EPA, 2021. Use of the Upper Prediction Limit for Calculating MACT Floors. Memorandum from D. L Jones, EPA/OAQPS/SPPD, Research Triangle Park, North Carolina, to Docket No. EPA-HQ-OAR-2002-0083. September 2, 2021. 
EPA, 2023a. Coke Ovens Risk and Technology Review: Data Summary. Jones, D. L., U.S. Environmental Protection Agency, Research Triangle Park, NC, and G. Raymond, RTI International, Research Triangle Park, NC. May 1, 2023. Docket ID No. EPA-HQ-OAR-2002-0085.
EPA, 2023b. Approach for Applying the Upper Prediction Limit to Limited Datasets. Memorandum from D.L. Jones, EPA/OAQPS/SPPD, to Docket No. EPA-HQ-OAR-2002-0083. May 1, 2023.
EPA, 2023c. Coke Ovens Risk and Technology Review: Compliance Costs. D. L. Jones, U.S. Environmental Protection Agency and G.E. Raymond, RTI International. U.S. Environmental Protection Agency, Research Triangle Park, North Carolina. May 1, 2023. Docket ID Nos. EPA-HQ-OAR-2002-0085 and EPA-HQ-OAR-2003-0051.

 

                                  APPENDIX A:
                          Acronyms and Abbreviations 
                                       
acfm
actual cubic feet per minute
ACI
activated carbon injection
ADL
above detection limit
AG
acid gases
AKS
AK Steel (now Cleveland Cliffs, Inc.)
AM
Arcelor Mittal (now Cleveland Cliffs, Inc.)
APCD
air pollution control device 
BH
baghouse
BDL
below detection limit
BTF
beyond-the-floor
ByP
by-product coke production process
˚C
degrees Celsius 
CAA
Clean Air Act
df
degrees of freedom
D/F
dioxin/furans
DLL
detection level limited
dscf
dry standard cubic feet
dscfm
dry standard cubic feet per minute
dscm
dry standard cubic meters
EP
emission process 
EPA
U.S. Environmental Protection Agency
˚F
degrees Fahrenheit 
ft
feet
fps
feet per second
gr/dscf
grains per dry standard cubic foot
HAP
hazardous air pollutant
HCl
hydrogen chloride
HCN
hydrogen cyanide
HF
hydrogen fluoride
HNR
heat and/or nonrecovery
Hg
mercury
HRSG
heat recovery steam generator
hr/yr
hours per year
i
each individual unit
II&S
integrated iron and steel manufacturing source category
K
kurtosis statistic
kWhr
kilo watt hour
lb/hr
pounds per hour
lb/ton
pounds per ton
MACT
maximum achievable control technology
MDL
method detection limit
mg/dscm
milligrams per dry standard cubic meter
n 
number of data points in MACT floor pool
NA
not applicable
NESHAP
National Emission Standards for Hazardous Air Pollutants
ng/dscm
nanograms per dry standard cubic meter
%
percent
PAHs
polycyclic aromatic hydrocarbons
PCM
pushing/charging machine
P&EF
processes and emissions flow table
PM
particulate matter
PM filterable
filterable particulate matter
PQBS
pushing, quenching, and battery stacks
RTO
regenerative thermal oxidizer
RDL
representative detection levels
RTR
residual risk and technology review
S
skewness statistic
SC
SunCoke, Inc.
SEK
standard error of the kurtosis statistic 
SES
standard error of the skewness statistic 
SO2
sulfur dioxide
TEF
toxicity equivalence factors
TEQ
toxic equivalency
tpy
tons per year
ug/dscm
micrograms per dry standard cubic meter
um
micrometer
UOM
units of measurement
UPL
upper predictive limit
USS
U.S. Steel Corporation
VOHAP
speciated volatile HAP
WAS
wet alkaline scrubber
WHO
World Health Organization
                                       
                                       
                                       
                                       
                                 APPENDIX B: 
                            MACT FLOOR DEVELOPMENT

B.1 Introduction 

      This appendix presents the methodology and the results of developing numerical MACT floor standards for coke oven existing and new sources. Calculations are provided in the accompanying Microsoft Excel(R) file. This MACT floor standard analysis used emissions and operating data collected in the coke oven CAA section 114 requests described in Section 2.0. For more details about the coke dataset, see the memorandum Summary of Coke Ovens Risk and Technology Review: Data Summary ( EPA, 2023a).

B.2 Process Units

The HAP emissions sources at coke facilities for which MACT floors were developed include pushing, battery combustion stacks, HRSG main stacks, and HRSG bypass/waste heat stacks. To develop existing and new source limits for each applicable HAP, information on individual unit stack test run by run data (concentration or lb/ton coke) from the coke oven CAA section 114 requests was used. 

B.3 MACT Floor Statistical Analyses - Upper Prediction Limit

The MACT standard analysis for Coke PQBS uses an upper prediction limit (UPL) approach to identify the average emission limitation achieved by the best performing sources. The UPL approach is used in MACT standard analyses because it incorporates the average performance of the best performing sources and the variability of the performance during testing conditions. (EPA, 2021) The UPL represents the value which one can expect the mean of a specified number of future observations (e.g., 3-run average) to fall below for the specified level of confidence, based upon the results of an independent sample from the same population. The level of confidence represents the level of protection afforded to facilities whose emissions are in line with the best performers. For example, a 99 percent level of confidence means that a facility whose emissions are in line with the best performers has one chance in 100 of exceeding the MACT standard emission limit. A prediction interval for a single future observation (or an average of several test observations) is an interval that will, with a specified degree of confidence, contain the next (or the average of some other pre-specified number of) randomly selected observation(s) from a population. In other words, the UPL estimates what the upper bound of future values will be, based upon present or past background samples taken. The UPL approach encompasses all the data point-to-data point variability. The predictions derive from the dataset to which it is applied, and, thus, can be applied to any type of data.
There are different equations for calculating a UPL based on the distribution of the dataset. Data can be normally distributed, lognormally distributed, or neither and thus have a skewed distribution. The statistical tests of skewness and kurtosis was implemented to determine the distribution of the best performing sources' data. (EPA, 2021)

The skewness statistic (S) characterizes the degree of asymmetry of a given data distribution. Normally distributed data have an S value of zero. An S value that is greater than zero indicates that the data are asymmetrically distributed with a right tail extending towards positive values; similarly, an S value that is less than zero indicates that the data are asymmetrically distributed with a left tail extending towards negative values. The value of S can be approximated using the following equation (which is implemented in Microsoft Excel(R) using the "SKEW" function):
	
where:
n = sample size
 =	 mean of MACT floor pool
xi =	 individual source mean
                                   stdev = 	
As part of determining whether a data distribution can be considered normal, the S value must be compared to the standard error of the skewness statistic (SES). The SES value can be approximated using the following equation:
	
According to the skewness hypothesis test, if the absolute value of S is less than two times the absolute value of SES, the skewness of the data can be considered normal.
The kurtosis statistic (K) characterizes the degree of peakedness or flatness of a given data distribution in comparison to a normal distribution. Normally distributed data have a K value of zero. A K value that is greater than zero indicates a relatively peaked distribution. A K value that is less than zero indicates a relatively flat distribution. The estimate of K can be calculated one of two ways. For datasets with more than three run values, kurtosis can be estimated using the following equation (which is implemented in Microsoft Excel(R) using the "KURT" function):
	
This equation cannot be used for datasets with three run values (n=3) because there will be a zero in the denominator of the first and second term. Instead, for datasets with three run values, kurtosis is estimated using the following equation:
	
As part of determining whether a data distribution can be considered normal, the K value must be compared to the standard error of the kurtosis statistic (SEK). The SEK value can be approximated using the following equation:
	 for datasets with more than three runs (n>3)
	 for datasets with three runs (n=3)
According to the kurtosis hypothesis test, if the absolute value of K is less than two times the absolute value of SEK, the kurtosis of the data can be considered normal.

For this MACT standard analysis, if the results from both the skewness and kurtosis hypothesis tests indicated the dataset was normally distributed, the dataset was treated as normally distributed in subsequent UPL calculations. If either of these tests indicated the dataset was not normally distributed, the dataset was log-transformed, and the log-transformed dataset was evaluated for kurtosis and skewness. If both tests of the log-transformed data indicated the log-transformed dataset was normally distributed, the dataset was treated as lognormally distributed in subsequent UPL calculations. If either of these tests indicated that the raw data was normally distributed AND the log-transformed dataset was normally distributed the skewness/SES values from raw data were compared to the skewness/SES values from log-transformed data. The smaller skewness/SES value was selected as an indication of a larger likelihood of the data to come from the corresponding distribution. If either of these tests indicated the log-transformed dataset was not normally distributed, the dataset was treated as skewed distribution in subsequent UPL calculations.
      
      After completing the determination of the type of data distribution for each dataset, the UPL was calculated using the corresponding equation for the distribution for that dataset.

Normally-Distributed Dataset
	
where:
UPL =	 upper prediction limit
 =	 mean of the data calculated as 
n =	 number of test runs = 
m = 	number of future test runs in the compliance average
N =	 number of sources
s2 =	 pooled variance calculated as 
tdf,0.99 = quantile of t-distribution at the 99 percent level of confidence with degrees of freedom (df); this value can be calculated with the Student's t-test statistical method, using the "TINV" function in Microsoft Excel(R) software
df =	 degrees of freedom calculated as 
Lognormally-Distributed Dataset (Bhaumik and Gibbons, 2004)
	
where:
 = 	 = the average of the log transformed data from the data
 =	 = variance estimate of the log transformed data
Z0.99 =	the 99th-percentile of the log-normal distribution estimated using the trapezoidal rule approach from the following equation:

Skewed/Unknown-Distributed Dataset (Non-Normal/Non-Lognormal) (Gayen, 1949)
	
where:
UPL = 	upper prediction limit
 = 	mean of the data calculated as 
n = 	number of test runs = 
m = 	number of future test runs in the compliance average
N = 	number of sources
s2 = 	pooled variance calculated as 
tdf,p = 	recalculated quantile of t-distribution based on specified level of confidence (i.e., 99 percent)
df = 	degrees of freedom calculated as 

B.4 Representative Detection Limit

The imprecision of test method measurements is another component of data variability. At very low emissions levels, as encountered in some of the data in the coke dataset, the inherent imprecision in the pollutant measurement method has a large influence on the reliability of the data underlying a MACT standard emission limit. Of particular concern are those data that are reported near or below a test method's pollutant detection capability. Because of matrix effects, laboratory techniques, sample volume, and other factors, method detection limits normally vary from test to test. In the data gathering from the coke industry in the 2016 coke oven CAA section 114 requests, the coke facilities were requested to note data that were measured below the method detection limit and to report those values as equal to the test-specific method detection limit.

Variability of data due to measurement imprecision is inherently and reasonably addressed in calculating a MACT standard emission limit when most of the data are significantly above the method detection limit. For datasets with a large number of test results below the method detection limit (reported as method detection limit values), other techniques need to be used to account for data variability. Indeed, under such a shift, the data distribution becomes truncated on the lower end, leading to an artificial overabundance of values occurring at the method detection limit. There is a concern that a MACT standard emission limit based on a truncated data base (i.e., calculated using values at or near the method detection limit) may not account adequately for data measurement variability, because the measurement error associated with those values provides a large degree of uncertainty. The expected measurement imprecision for an emissions value occurring at or near the detection limit is about 40 to 50 percent. Relative pollutant measurement imprecision decreases to a consistent 10 to 15 percent for values measured at a level about three times the method detection limit (ASME, 2001).
      
      The approach taken to account for measurement variability includes defining a detection limit that is representative of the data used in establishing a MACT standard emission limitation and also minimizes the influence of an outlier test-specific method detection limit value. A list of representative detection levels (RDL) has been developed from available HAP-specific method detection levels ( EPA, 2011) (Parker, 2018). These RDL values are then multiplied by three to decrease measurement imprecision to around 10 to 15 percent (as noted in the previous paragraph), resulting in values referred to as "3xRDL" values. The appropriate 3xRDL value then is compared to the calculated UPL value for each HAP and individual emission unit or process group. The larger of the 3xRDL value and the calculated UPL value is used for the MACT standard emission limit to ensure that measurement variability is adequately addressed.
      
      For more information regarding the general use of the UPL and why it is appropriate for calculating MACT floors, see the memorandum Use of the Upper Prediction Limit for Calculating MACT Floors (EPA, 2021).

B.5 MACT Floor Emissions Limit Development Methodology
	
      The following are the seven discrete steps used in development of MACT floors for the coke industry.
 
Step 1.

The first step is calculation of an average emission value for each individual emission unit, by HAP and by each unit of measure in the available test data. For any run fractions marked as less than the method detection limit (or other reporting limit), the fraction was considered below the detection limit (BDL). For the EPA Method 29 multi-metals test, each metal laboratory analysis typically has two separate fractions: front-half (filter) and back-half (impinger catch); Hg can have three additional back-half fractions. For this analysis, the method detection limit (MDL) for each fraction was used as the mass to calculate a run value, e.g., pound per ton (lb/ton).
 
Step 2.

      Once an average HAP emission value was calculated for each unit, all of the individual average emission values were ranked from lowest to highest value. See Tables B-1  -  B-17 for the ranking of sources per pollutant emissions.
      
     Table B-1. Pushing  -  Hg Emissions Ranking from Coke Oven Test Data
                                   Facility
                                 Emission Unit
                               Hg (lb/ton coke)
                                     Rank
                              Used in MACT Floor?
AKS-Middletown-OH
Pushing Baghouse
                                   2.50E-08
                                       1
                                      Yes
SC-Middletown-OH
Middletown Flat Push Hot Car
                                   4.48E-08
                                       2
                                      Yes
CC-Burnsharbor-IN
#2 Coke Battery Pushing Baghouse Stack
                                   1.66E-07
                                       3
                                      Yes
SC-GraniteCity-IL
Gateway Flat Push Hot Car
                                   2.00E-07
                                       4
                                      Yes
CC-Monessen-PA
Pushing Baghouse Stack
                                   4.77E-07
                                       5
                                      Yes
      
     Table B-2. Pushing  -  AG Emissions Ranking from Coke Oven Test Data
                                   Facility
                                 Emission Unit
                                      AG 
                                 (lb/ton coke)
                                     Rank
                              Used in MACT Floor?
AKS-Middletown-OH
Pushing Baghouse
                                    0.00029
                                       1
                                      Yes
CC-Monessen-PA
Pushing Baghouse Stack
                                    0.0012
                                       2
                                      Yes
SC-Middletown-OH
Middletown Flat Push Hot Car
                                    0.0017
                                       3
                                      Yes
CC-Burnsharbor-IN
#2 Coke Battery Pushing Baghouse Stack
                                    0.0024
                                       4
                                      Yes

     Table B-3. Pushing  -  HCN Emissions Ranking from Coke Oven Test Data
                                   Facility
                                 Emission Unit
                                     HCN 
                                 (lb/ton coke)
                                     Rank
                              Used in MACT Floor?
SC-Middletown-OH
Middletown Flat Push Hot Car
                                   0.000024
                                       1
                                      Yes
AKS-Middletown-OH
Pushing Baghouse
                                    0.00011
                                       2
                                      Yes
CC-Monessen-PA
Pushing Baghouse Stack
                                    0.00074
                                       3
                                      Yes
CC-Burnsharbor-IN
#2 Coke Battery Pushing Baghouse Stack
                                    0.00084
                                       4
                                      Yes

     Table B-4. Pushing  -  PAH Emissions Ranking from Coke Oven Test Data
                                   Facility
                                 Emission Unit
                               PAH (lb/ton coke)
                                     Rank
                              Used in MACT Floor?
SC-Middletown-OH
Middletown Flat Push Hot Car
                                   4.11E-06
                                       1
                                      Yes
AKS-Middletown-OH
Pushing Baghouse
                                   6.75E-06
                                       2
                                      Yes
CC-Burnsharbor-IN
#2 Coke Battery Pushing Baghouse Stack
                                   3.57E-05
                                       3
                                      Yes
CC-Monessen-PA
Pushing Baghouse Stack
                                   1.08E-04
                                       4
                                      Yes
Table B-5. ByP Battery Combustion  -  Hg Emissions Ranking from Coke Oven Test Data
                                   Facility
                                 Emission Unit
                               Hg (lb/ton coke)
                                     Rank
                              Used in MACT Floor?
CC-Monessen-PA
Battery Combustion Stack #2
                                   3.86E-06
                                       1
                                      Yes
AKS-Middletown-OH
Combustion Stack
                                   4.18E-06
                                       2
                                      Yes
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                   7.13E-06
                                       3
                                      Yes
CC-Burnsharbor-IN
Coke Battery No. 2 Underfire Stack
                                   3.23E-05
                                       4
                                      Yes
                                       
Table B-6. ByP Battery Combustion  -  PM Emissions Ranking from Coke Oven Test Data
                                   Facility
                                 Emission Unit
                                 PM (gr/dscf)
                                     Rank
                              Used in MACT Floor?
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                    0.0047
                                       1
                                      Yes
CC-Monessen-PA
Battery Combustion Stack #2
                                    0.0067
                                       2
                                      Yes
AKS-Middletown-OH
Combustion Stack
                                     0.029
                                       3
                                      Yes
CC-BurnsHarbor-IN
Coke Battery No. 2 Underfire Stack
                                     0.050
                                       4
                                      Yes

Table B-7. ByP Battery Combustion  -  AG Emissions Ranking from Coke Oven Test Data
                                   Facility
                                 Emission Unit
                                      AG 
                                 (lb/ton coke)
                                     Rank
                              Used in MACT Floor?
CC-Monessen-PA
Battery Combustion Stack #2
                                     0.010
                                       1
                                      Yes
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                     0.015
                                       2
                                      Yes
CC-BurnsHarbor-IN
Coke Battery No. 2 Underfire Stack
                                     0.016
                                       3
                                      Yes
AKS-Middletown-OH
Combustion Stack
                                     0.061
                                       4
                                      Yes

Table B-8. ByP Battery Combustion  -  HCN Emissions Ranking from Coke Oven Test Data
                                   Facility
                                 Emission Unit
                                     HCN 
                                 (lb/ton coke)
                                     Rank
                              Used in MACT Floor?
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                    0.00017
                                       1
                                      Yes
CC-Monessen-PA
Battery Combustion Stack #2
                                    0.00052
                                       2
                                      Yes
CC-Burnsharbor-IN
Coke Battery No. 2 Underfire Stack
                                    0.0024
                                       3
                                      Yes
AKS-Middletown-OH
Combustion Stack
                                    0.0030
                                       4
                                      Yes
                                       
Table B-9. HNR HRSG Main Stack  -  Hg Emissions Ranking from Coke Oven Test Data
                                   Facility
                                 Emission Unit
                                 Hg (gr/dscf)
                                     Rank
                              Used in MACT Floor?
SC-Middletown-OH
P901- Battery A-C - Main Stack
                                    9.0E-07
                                       1
                                      Yes
CE-EastChicago-IN / 
SC-EastChicago-IN
HRSG Main Stack
                                    1.7E-06
                                       2
                                      Yes

Table B-10. HNR HRSG Main Stack  -  PM Emissions Ranking from Coke Oven Test Data
                                   Facility
                                 Emission Unit
                                 PM (gr/dscf)
                                     Rank
                              Used in MACT Floor?
CE-EastChicago-IN / 
SC-EastChicago-IN
HRSG Main Stack
                                    0.00036
                                       1
                                      Yes
SC-Middletown-OH
P901- Battery A-C - Main Stack
                                    0.0027
                                       2
                                      Yes

Table B-11. HNR HRSG Main Stack  -  AG Emissions Ranking from Coke Oven Test Data
                                   Facility
                                 Emission Unit
                                 AG (gr/dscf)
                                     Rank
                              Used in MACT Floor?
SC-Middletown-OH
P901- Battery A-C - Main Stack
                                    0.0022
                                       1
                                      Yes
CE-EastChicago-IN / 
SC-EastChicago-IN
HRSG Main Stack
                                    0.0082
                                       2
                                      Yes
                                       
Table B-12. HNR HRSG Main Stack  -  PAH Emissions Ranking from Coke Oven Test Data
                                   Facility
                                 Emission Unit
                                 PAH (gr/dscf)
                                     Rank
                              Used in MACT Floor?
CE-EastChicago-IN / 
SC-EastChicago-IN
HRSG Main Stack
                                    2.8E-07
                                       1
                                      Yes
SC-Middletown-OH
P901- Battery A-C - Main Stack
                                    3.8E-07
                                       2
                                      Yes

    Table B-13. HNR HRSG Bypass/ Waste Heat Stack  -  Hg Emissions Ranking 
                           from Coke Oven Test Data
                                   Facility
                                 Emission Unit
                                 Hg (gr/dscf)
                                     Rank
                              Used in MACT Floor?
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                    5.2E-06
                                       1
                                      Yes
SC-FranklinFurnace-OH
Bypass Vent Stack 6
                                    7.0E-06
                                       2
                                      Yes

    Table B-14. HNR HRSG Bypass/ Waste Heat Stack  -  PM Emissions Ranking 
                           from Coke Oven Test Data
                                   Facility
                                 Emission Unit
                                 PM (gr/dscf)
                                     Rank
                              Used in MACT Floor?
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                     0.013
                                       1
                                      Yes
SC-FranklinFurnace-OH
Bypass Vent Stack 6
                                     0.020
                                       2
                                      Yes

    Table B-15. HNR HRSG Bypass/ Waste Heat Stack  -  AG Emissions Ranking 
                           from Coke Oven Test Data
                                   Facility
                                 Emission Unit
                                 AG (gr/dscf)
                                     Rank
                              Used in MACT Floor?
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                     0.058
                                       1
                                      Yes
SC-FranklinFurnace-OH
Bypass Vent Stack 6
                                     0.086
                                       2
                                      Yes

   Table B-16. HNR HRSG Bypass/ Waste Heat Stack  -  PAH Emissions Ranking 
                           from Coke Oven Test Data
                                   Facility
                                 Emission Unit
                                 PAH (gr/dscf)
                                     Rank
                              Used in MACT Floor?
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                    6.5E-07
                                       1
                                      Yes

Table B-17. HNR HRSG Bypass/ Waste Heat Stack  -  Formaldehyde Emissions Ranking 
                           from Coke Oven Test Data
                                   Facility
                                 Emission Unit
                            Formaldehyde (gr/dscf)
                                     Rank
                              Used in MACT Floor?
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                    4.7E-06
                                       1
                                      Yes
SC-FranklinFurnace-OH
Bypass Vent Stack 6
                                    1.0E-04
                                       2
                                      Yes

Step 3.

The best performing sources per process type and HAP were identified from the rankings shown in Tables B-1 through B-17, consistent with the criteria in CAA section 112(d)(3) for determining MACT standards for existing sources. These sources are referred to as the "MACT floor pool." For the existing source and new source MACT standards, the number of individual sources in the MACT floor pool was determined, as shown in Table B-18.

Table B-18. Number of Sources in Existing and New Source MACT Floor Pool 
per Process Type and HAP
                                 Process Type
                                      HAP
                               Number of Sources
                                   with Data
                          Existing and/or New Source
                                No. Sources in
                                MACT Floor Pool
                    No. Data Points in MACT Floor Pool (n)
Pushing
                                      Hg
                                       5
                                   Existing
                                       5
                                      15

                                       
                                       
                                      New
                                       1
                                       3

                                 AG & PAH
                                       4
                                   Existing
                                       4
                                      12

                                       
                                       
                                      New
                                       1
                                       3

                                      HCN
                                       4
                                   Existing
                                       4
                                      13

                                       
                                       
                                      New
                                       1
                                       3
ByP Battery Combustion
                             Hg, PM, AG, & HCN
                                       4
                                   Existing
                                       4
                                      12

                                       
                                       
                                      New
                                       1
                                       3
HNR HRSG Main Stack
                                 PM & PAH
                                       2
                                   Existing
                                       2
                                      10

                                       
                                       
                                      New
                                       1
                                       7

                                  HG & AG
                                       2
                                   Existing
                                       2
                                      10

                                       
                                       
                                      New
                                       2
                                       3
HNR HRSG Bypass/waste heat stack
                               Hg, PM, & AG
                                       2
                                   Existing
                                       2
                                       6

                                       
                                       
                                      New
                                       1
                                       3

                                 Formaldehyde
                                       2
                                   Existing
                                       2
                                       5

                                       
                                       
                                      New
                                       1
                                       3

                                      PAH
                                       1
                              Existing & New
                                       1
                                       3
    
    
Step 4.

The existing and new source MACT floor pool datasets were evaluated for kurtosis and skewness to determine the distribution, as described in Section B.3, above. Table B-19 shows the data distribution per existing and new source MACT floor pool, per process type, per HAP. 
 
Table B-19. Existing and New Source MACT Floor Pool Data Distribution 
per Process Type and HAP
Process Type
HAP
Existing and/or New Source
Data Distribution
Pushing
Hg
Existing
Lognormal

New
Normal

AG
Existing
Lognormal

New
Normal

HCN
Existing
Normal

New
Normal

PAH
Existing
Lognormal

New
Normal
ByP Battery Combustion
Hg
Existing
Lognormal

New
Normal

PM
Existing
Lognormal

New
Normal

AG
Existing
Lognormal

New
Lognormal

HCN
Existing
Normal

New
Normal
HNR HRSG Main Stack
Hg
Existing
Normal

New
Lognormal

PM
Existing
Lognormal

New
Normal

AG
Existing
Lognormal

New
Normal

PAH
Existing
Lognormal

New
Lognormal
HNR HRSG Bypass/waste heat stack
Hg
Existing
Skewed

New
Normal

PM
Existing
Lognormal

New
Lognormal

AG
Existing
Lognormal

New
Normal

PAH
Existing & New
Lognormal

Formaldehyde
Existing
Lognormal

New
Lognormal

Step 5.

After determining the type of data distribution for the dataset, the UPL was calculated using the corresponding equation for the distribution for that dataset and groupings of emission points, as described in Section B.3, above. Table B-20 shows the UPL values for existing sources and new sources.
                Table B-20. Existing and New Source UPL Values
Process Type
HAP
Existing and/or New Source
No. Data Points in MACT Floor Pool (n)
Average of Top Sources
Variance of Top Sources
UPL
UPL
UOM
UPL Template
Pushing

Hg
Existing
15
                                    1.8E-07
                                    3.4E-14
                                    8.9E-07
lb/ton coke
Lognormal

New
3
                                    2.5E-08
                                    3.4E-18
                                    3.6E-08
lb/ton coke
Normal

AG
Existing
12
                                    0.0014
                                    9.2E-07
                                    0.0051
lb/ton coke
Lognormal

New
3
                                    2.9E-04
                                    1.5E-09
                                    5.1E-04
lb/ton coke
Normal

HCN
Existing
13
                                    4.1E-04
                                    1.4E-07
                                    0.0011
lb/ton coke
Normal

New
4
                                    2.4E-05
                                    5.8E-12
                                    3.8E-05
lb/ton coke
Normal

PAH
Existing
12
                                    3.9E-05
                                    2.0E-09
                                    3.4E-04
lb/ton coke
Lognormal

New
3
                                    4.1E-06
                                    2.9E-12
                                    1.4E-05
lb/ton coke
Normal
ByP Battery Combustion

Hg
Existing
12
                                    1.2E-05
                                    1.8E-10
                                    5.7E-05
lb/ton coke
Lognormal

New
3
                                    3.9E-06
                                    3.2E-13
                                    7.1E-06
lb/ton coke
Normal

PM
Existing
12
                                     0.023
                                    7.3E-04
                                     0.10
gr/dscf
Lognormal

New
3
                                    0.0047
                                    2.4E-06
                                     0.014
gr/dscf
Normal

AG
Existing
12
                                     0.026
                                    5.1E-04
                                     0.083
lb/ton coke
Lognormal

New
3
                                     0.010
                                    3.9E-07
                                     0.012
lb/ton coke
Lognormal

HCN
Existing
12
                                    0.0015
                                    1.7E-06
                                    0.0038
lb/ton coke
Normal

New
3
                                    1.7E-04
                                    9.8E-09
                                    7.3E-04
lb/ton coke
Normal
HNR HRSG Main Stack

Hg
Existing
10
                                    1.5E-06
                                    2.1E-13
                                    2.3E-06
gr/dscf
Normal

New
3
                                    9.0E-07
                                    4.3E-14
                                    1.5E-06
gr/dscf
Lognormal

PM
Existing
10
                                    0.0010
                                    1.3E-06
                                    0.0064
gr/dscf
Lognormal

New
7
                                    3.6E-04
                                    3.1E-08
                                    7.4E-04
gr/dscf
Normal

AG
Existing
10
                                    0.0064
                                    5.0E-05
                                     0.038
gr/dscf
Lognormal

New
3
                                    0.0022
                                    1.1E-08
                                    0.0028
gr/dscf
Normal

PAH
Existing
10
                                    3.1E-07
                                    5.9E-15
                                    4.6E-07
gr/dscf
Lognormal

New
7
                                    2.8E-07
                                    1.3E-15
                                    3.6E-07
gr/dscf
Lognormal
HNR HRSG Bypass/waste heat stack
Hg
Existing
6
                                    6.1E-06
                                    6.0E-12
                                    1.7E-05
gr/dscf
Skewed

New
3
                                    5.2E-06
                                    1.9E-13
                                    7.7E-06
gr/dscf
Normal

PM
Existing
6
                                     0.017
                                    4.5E-05
                                     0.033
gr/dscf
Lognormal

New
3
                                     0.013
                                    1.8-05
                                     0.025
gr/dscf
Lognormal

AG
Existing
6
                                     0.072
                                    4.5E-04
                                     0.12
gr/dscf
Lognormal

New
3
                                     0.058
                                    4.0E-06
                                     0.070
gr/dscf
Normal

PAH
Existing & New
3
                                    6.5E-07
                                    2.3E-13
                                    2.3E-06
gr/dscf
Lognormal

Formaldehyde
Existing
5
                                    4.3E-05
                                    3.1E-09
                                    0.0011
gr/dscf
Lognormal

New
3
                                    4.7E-06
                                    1.3E-11
                                    1.9E-05
gr/dscf
Lognormal
Note: Distribution and corresponding UPL template used: Normal, Lognormal, or Skewed.

Step 6.

The results of the UPL calculations were compared to the 3xRDL values of the relevant performance test method(s) as per EPA guidance ( EPA, 2011; Parker, 2018). As described in Section B.4, this step ensures that data measurement variability is addressed. The 3xRDL values in the EPA's Westlin and Merrill (2011) and Parker (2018) guidance documents were presented in units of concentration (e.g., ug/dscm). In order to compare the calculated UPL that are not in units of concentration to the 3xRDL, the 3xRDL value was converted to the units of the emission limits using a ratio of the emission data in the units of interest (e.g., lb/ton coke) to the emission data in units of concentration. 

In the comparison of the converted 3xRDL value to the calculated UPL in the same units of measure, if the calculated UPL value was less than the 3xRDL value, the 3xRDL value was used as the basis for the standard because the 3xRDL value provides the lowest emission rate that can be measured using the performance test method while maintaining a relative method precision on the order of 10 to 20 percent of the measured value. If the UPL value was equal to or greater than the 3xRDL value, then the UPL value was used as the basis for the standard.
       
       The following calculations were used to convert the 3xRDL concentration values to the values of the UPL (e.g., lb/ton coke). For UPLs calculated in units of concentration (e.g., gr/dscf), it is not necessary to convert the 3xRDL value to other units because the 3xRDL values are already in units of concentration (ug/dscm). 
       
       For each existing source MACT floor pool per process type and HAP, the concentration (ug/dscm) and lb/ton coke values were compiled and the sample volume (dscm) noted for all runs. The ratio of lb/ton coke to ug/dscm concentration emissions for each run was calculated. 
       
       The average of all the run-by-run emission ratios were then calculated per process type and HAP. Table B-21 shows the average ratio per process type and HAP. 
       
 Table B-21. Average of Run-by-Run Hg Emission Ratios per Process Type and HAP
Process Type
HAP
Average Ratio
Average Ratio UOM[3]
Pushing
Hg
                                    6.1E-07
lb/ton coke  /  ug/dscm

AG
                                    6.9E-07
lb/ton coke  /  ug/dscm

HCN
N/A[1]

PAH
N/A[1]

ByP Battery Combustion
Hg
                                   7.54E-06
lb/ton coke  /  ug/dscm

PM
N/A[2]

AG
3.3E-06
lb/ton coke  /  ug/dscm

HCN
N/A[1]

HNR HRSG Main Stack
Hg
N/A[2]

PM
N/A[2]

AG
N/A[2]

PAH
N/A[1,2]

HNR HRSG Bypass/waste heat stack
Hg
N/A[2]

PM
N/A[2]

AG
N/A[2]

PAH
N/A[1,2]

Formaldehyde
N/A[2]

1 There are no RDL values currently for HCN and PAH.
[2] For UPLs calculated in units of concentration (e.g., gr/dscf), it is not necessary to convert the 3xRDL value to other units because the 3xRDL values are already in units of concentration (ug/dscm); therefore, the ratio of units is 1.0.
 [3] ug/dscm = micrograms per dry standard cubic meters
 
       The typical sample volume for each MACT floor pool was identified per process type and HAP. Table B-22 shows the typical sample volume for each MACT floor pool per process type and HAP.
                                       
Table B-22. Typical Sample Volume for each MACT Floor Pool per Process Type and HAP
Process Type
HAP
Typical Sample Volume (dscm)[1,2]
Pushing
Hg
3

AG
1

HCN
N/A

PAH

ByP Battery Combustion
Hg
3

PM

AG
1

HCN
N/A
HNR HRSG Main Stack
Hg
2

PM

AG
1

PAH
N/A
HNR HRSG Bypass/waste heat stack
Hg
2

PM

AG
1

PAH
N/A

Formaldehyde
N/A
         1 There are no RDL values currently for HCN and PAH.
          [2] Formaldehyde does not have a sample volume specific RDL (Parker, 2018).
 
       The appropriate 3xRDL concentration value for the typical sample volume was identified in the EPA guidance documents ( EPA, 2011; Parker, 2018). Table B-23 shows the appropriate 3xRDL concentration values for each process type per HAP for the typical sample volume.

Table B-23. 3xRDL Values[1] 
                                 Process Type
                                      HAP
                 3xRDL Concentrations[1,2,3] by Typical Volume
                                 UOM of 3xRDL
Pushing
                                      Hg
                                    5.6E-01
                                   ug/dscm

                                      AG
                                    3.6E+02
                                   ug/dscm

                                      HCN
                                      N/A
                                       

                                      PAH
                                      N/A
                                       
ByP Battery Combustion
                                      Hg
                                    5.6E-01
                                   μg/dscm

                                      PM
                                    1.0E+03
                                   μg/dscm

                                      AG
                                    3.6E+02
                                   μg/dscm

                                      HCN
                                      N/A
                                       
HNR HRSG Main Stack
                                      Hg
                                    8.4E-01
                                   μg/dscm

                                      PM
                                    1.5E+03
                                   μg/dscm

                                      AG
                                    3.6E+02
                                   μg/dscm

                                      PAH
                                      N/A
                                       
HNR HRSG Bypass/waste heat stack
                                      Hg
                                    8.4E-01
                                   μg/dscm

                                      PM
                                    1.5E+03
                                   μg/dscm

                                      AG
                                    3.6E+02
                                   μg/dscm

                                      PAH
                                      N/A
                                       

                                 Formaldehyde
                                   1.43E+03
                                    ng/dscm
1 There are no RDL values currently for HCN and PAH.
[2] Formaldehyde does not have a sample volume specific RDL (Parker, 2018).
[3] From Westlin and Merrill (2011) and Parker (2018).

       The appropriate 3xRDL concentration value for the typical sample volume was multiplied by the average ratio in Table B-21 above to convert the 3xRDL value into the units of measure used in the UPL calculation (e.g., lb/ton coke). Table B-24 shows the converted 3xRDL values per process type per HAP. 
                      Table B-24. Converted 3xRDL Values
                                 Process Type
                                      HAP
                                 Average Ratio
                               Average Ratio UOM
                        3xRDL at Typical Sample Volume
                                   3xRDL UOM
                             Converted 3xRDL Value
                           Converted 3xRDL Value UOM
Pushing
                                      Hg
                                    6.1E-07
                           lb/ton coke  /  ug/dscm
                                    5.6E-01
                                   ug/dscm
                                    3.4E-07
                                  lb/ton coke

                                      AG
                                    6.9E-07
                           lb/ton coke  /  ug/dscm
                                    3.6E+02
                                   ug/dscm
                                    2.5E-04
                                  lb/ton coke

                                      HCN
                                    N/A[1]
                                       
                                      N/A
                                       
                                      N/A
                                       

                                      PAH
                                    N/A[1]
                                       
                                      N/A
                                       
                                      N/A
                                       
ByP Battery Combustion
                                      Hg
                                   7.54E-06
                           lb/ton coke  /  ug/dscm
                                    5.6E-01
                                   ug/dscm
                                    4.2E-06
                                  lb/ton coke

                                      PM
                                    N/A[2]
                                       
                                    1.0E+03
                                   μg/dscm
                                    4.4E-04
                                    gr/dscf

                                      AG
                                    3.3E-06
                           lb/ton coke  /  ug/dscm
                                    3.6E+02
                                   μg/dscm
                                    1.2E-03
                                  lb/ton coke

                                      HCN
                                    N/A[1]
                                       
                                      N/A
                                       
                                      N/A
                                       
HNR HRSG Main Stack
                                      Hg
                                    N/A[2]
                                       
                                    8.4E-01
                                   μg/dscm
                                    3.7E-07
                                    gr/dscf

                                      PM
                                    N/A[2]
                                       
                                    1.5E+03
                                   μg/dscm
                                    6.6E-04
                                    gr/dscf

                                      AG
                                    N/A[2]
                                       
                                    3.6E+02
                                   μg/dscm
                                    1.6E-04
                                    gr/dscf

                                      PAH
                                   N/A[1,2]
                                       
                                      N/A
                                       
                                      N/A
                                       
HNR HRSG Bypass/waste heat stack
                                      Hg
                                    N/A[2]
                                       
                                    8.4E-01
                                   μg/dscm
                                    3.7E-07
                                    gr/dscf

                                      PM
                                    N/A[2]
                                       
                                    1.5E+03
                                   μg/dscm
                                    6.6E-04
                                    gr/dscf

                                      AG
                                    N/A[2]
                                       
                                    3.6E+02
                                   μg/dscm
                                    1.6E-04
                                    gr/dscf

                                      PAH
                                   N/A[1,2]
                                       
                                      N/A
                                       
                                      N/A
                                       

                                 Formaldehyde
                                  N/A[2][,3]
                                       
                                   1.43E+03
                                    ng/dscm
                                    6.2E-07
                                    gr/dscf
1 There are no RDL values currently for HCN and PAH.
[2] For UPLs calculated in units of concentration (e.g., gr/dscf), it is not necessary to convert the 3xRDL value to other units because the 3xRDL values are already in units of concentration (ug/dscm); therefore, the ratio of units is 1.0.
[3] Formaldehyde does not have a sample volume-specific RDL (Parker, 2018).
       The MACT standard value was selected by comparing the 3xRDL value to the calculated existing and new source UPLs according to the following procedures:
 If the 3xRDL value was less than or equal to the calculated UPL value, the UPL value was used as the MACT standard.
 If the 3xRDL value was greater than the calculated UPL value, the 3xRDL value was used as the MACT standard.
       
       Table B-25 shows the results of the comparison of the UPL and 3xRDL values to determine the MACT limits for existing and new coke sources per process type and HAP.
                                       
     Table B-25. Determining MACT Limits for Existing and New Coke Sources
                                 Process Type
                                      HAP
                          Existing and/or New Source
                             Converted 3xRDL Value
                                      UPL
                            Rounded MACT/BTF  Limit
                                MACT/ BTF Limit
                                   Based On
                                Units of Limit
Pushing
                                      Hg
                                   Existing
                                    3.4E-07
                                    8.9E-07
                                    8.9E-07
                                      UPL
                                  lb/ton coke

                                       
                                      New
                                    3.4E-07
                                    3.6E-08
                                    3.4E-07
                                     3xRDL
                                  lb/ton coke

                                      AG
                                   Existing
                                    2.5E-04
                                    0.0051
                                    0.0052
                                      UPL
                                  lb/ton coke

                                       
                                      New
                                    2.5E-04
                                    5.1E-04
                                    5.1E-04
                                      UPL
                                  lb/ton coke

                                      HCN
                                   Existing
                                      N/A
                                    0.0011
                                    0.0011
                                      UPL
                                  lb/ton coke

                                       
                                      New
                                      N/A
                                    3.8E-05
                                    3.8E-05
                                      UPL
                                  lb/ton coke

                                      PAH
                                   Existing
                                      N/A
                                    3.4E-04
                                    3.4E-04
                                      UPL
                                  lb/ton coke

                                       
                                      New
                                      N/A
                                    1.4E-05
                                    1.4E-05
                                      UPL
                                  lb/ton coke
ByP Battery Combustion
                                      Hg
                                   Existing
                                    4.2E-06
                                    5.7E-05
                                    5.8E-05
                                      UPL
                                  lb/ton coke

                                       
                                      New
                                    4.2E-06
                                    7.1E-06
                                    7.1E-06
                                      UPL
                                  lb/ton coke

                                      PM
                                   Existing
                                    4.4E-04
                                     0.10
                                     0.10
                                      UPL
                                    gr/dscf

                                       
                                      New
                                    4.4E-04
                                     0.014
                                     0.014
                                      UPL
                                    gr/dscf

                                      AG
                                   Existing
                                    1.2E-03
                                     0.083
                                     0.083
                                      UPL
                                  lb/ton coke

                                       
                                      New
                                    1.2E-03
                                     0.012
                                     0.013
                                      UPL
                                  lb/ton coke

                                      HCN
                                   Existing
                                      N/A
                                    0.0038
                                    0.0039
                                      UPL
                                  lb/ton coke

                                       
                                      New
                                      N/A
                                    7.3E-04
                                    7.4E-04
                                      UPL
                                  lb/ton coke
HNR HRSG main stack
                                      Hg
                                   Existing
                                    3.7E-07
                                    2.3E-06
                                    2.4E-06
                                      UPL
                                    gr/dscf

                                       
                                      New
                                    3.7E-07
                                    1.5E-06
                                    1.5E-06
                                      UPL
                                    gr/dscf

                                      PM
                                   Existing
                                    6.6E-04
                                    0.0064
                                    0.0065
                                      UPL
                                    gr/dscf

                                       
                                      New
                                    6.6E-04
                                    7.4E-04
                                    7.5E-04
                                      UPL
                                    gr/dscf

                                      AG
                                   Existing
                                    1.6E-04
                                     0.038
                                     0.038
                                      UPL
                                    gr/dscf

                                       
                                      New
                                    1.6E-04
                                    0.0028
                                    0.0029
                                      UPL
                                    gr/dscf

                                      PAH
                                   Existing
                                      N/A
                                    4.6E-07
                                    4.7E-07
                                      UPL
                                    gr/dscf

                                       
                                      New
                                      N/A
                                    3.6E-07
                                    3.7E-07
                                      UPL
                                    gr/dscf
HNR HRSG Bypass/waste heat stack
                                      AG
                                   Existing
                                    1.6E-04
                                     0.12
                                     0.13
                                      UPL
                                    gr/dscf

                                       
                                      New
                                    1.6E-04
                                     0.070
                                     0.070
                                      UPL
                                    gr/dscf

                                      PAH
                              Existing & New
                                      N/A
                                    2.3E-06
                                    2.4E-06
                                      UPL
                                    gr/dscf

                                 Formaldehyde
                                   Existing
                                    6.2E-07
                                    0.0011
                                    0.0011
                                      UPL
                                    gr/dscf

                                       
                                      New
                                    6.2E-07
                                    1.9E-05
                                    1.9E-05
                                      UPL
                                    gr/dscf
HR HRSG Bypass/waste heat stack
                                      Hg
                                   Existing
                                    3.7E-07
                                    1.7E-05
                                    1.7E-05
                                      UPL
                                    gr/dscf

                                       
                                      New
                                    3.7E-07
                                    7.7E-06
                                    7.8E-06
                                      UPL
                                    gr/dscf

                                      PM
                                   Existing
                                    6.6E-04
                                     0.033
                                     0.034
                                      UPL
                                    gr/dscf

                                       
                                      New
                                    6.6E-04
                                     0.025
                                     0.025
                                      UPL
                                    gr/dscf
NR HRSG Bypass/waste heat stack
                                      Hg
                                   Existing
                                    3.7E-07
                                  1.7E-06[a]
                                    1.7E-06
                                      UPL
                                    gr/dscf

                                       
                                      New
                                    3.7E-07
                                  7.8E-07[a]
                                    7.8E-07
                                      UPL
                                    gr/dscf

                                      PM
                                   Existing
                                    6.6E-04
                                  3.4E-05[a]
                                    6.6E-04
                                     3xRDL
                                    gr/dscf

                                       
                                      New
                                    6.6E-04
                                  2.5E-05[a]
                                    6.6E-04
                                     3xRDL
                                    gr/dscf
Note, the same converted 3xRDL value developed for an existing source MACT floor pool is used in the comparison of the new source UPL of the same process type and HAP. 
[a] BTF limits discussed in section 5.4

Step 7.

A MACT floor dataset based on fewer than 7 data points is considered to be a limited dataset (EPA, 2023b). For limited datasets, each individual dataset can be further evaluated in order to ensure that the uncertainty associated with a limited dataset does not cause the calculated emission limit to be so high that it does not reflect the average performance of the units upon which the limit is based after accounting for variability in the emissions of those units. Table B-26 identifies the MACT floor pool datasets based on fewer than 7 datasets. 
                                       
                         Table B-26. Limited Datasets
Process Type
HAP
Existing and/or New Source
No. Data Points in MACT Floor Pool (n)
Pushing
Hg
New
3

AG

HCN

PAH

ByP Battery Combustion
Hg
New
3

PM

AG

HCN

HNR HRSG Main Stack
Hg & AG
New
3
HNR HRSG Bypass/waste heat stack
Hg, PM, AG
Existing
6

Formaldehyde
Existing
5

Hg, PM, AG, Formaldehyde
New
3

PAH
Existing & New
3
      
      
      For limited datasets with less than seven data points, the steps outlined in the memorandum Approach for Applying the Upper Prediction Limit to Limited Datasets (EPA, 2023b) were followed. Each dataset was evaluated to determine whether it was appropriate to make any modifications to the approach to calculate MACT floors. The selected data distribution ensured that the distribution best represented each dataset; ensured that the correct equation for the distribution was applied to the data; and compared individual components of each limited dataset to determine if the standards based on limited datasets reasonably represent the performance of the units included in the dataset. Based on the evaluation of limits based on limited data sets, no changes to the standard floor calculation procedure were determined to be warranted. The resulting MACT limits are shown in Table B-27 below.

B.6 Results of the MACT Floor Analyses 

Table B-27 presents the existing and new source MACT floor emissions limits, respectively that were developed for the coke source category per process type and HAP.

Table B-27. Existing and New Source MACT Floor Emissions Limits
Process Type
HAP
Existing and/or New Source
MACT Emission Limit
MACT Limit Based On
Units of Measurement
Pushing
                                      Hg
                                   Existing
                                    8.9E-07
UPL
lb/ton coke

                                       
                                      New
                                    3.4E-07
3xRDL

                                      AG
                                   Existing
                                    0.0052
UPL

                                       
                                      New
                                    5.1E-04
UPL

                                      HCN
                                   Existing
                                    0.0011
UPL

                                       
                                      New
                                    3.8E-05
UPL

                                      PAH
                                   Existing
                                    3.4E-04
UPL

                                       
                                      New
                                    1.4E-05
UPL

ByP Battery Combustion
                                      Hg
                                   Existing
                                    5.8E-05
UPL
lb/ton coke

                                       
                                      New
                                    7.1E-06
UPL

                                      PM
                                   Existing
                                     0.10
UPL
gr/dscf

                                       
                                      New
                                     0.014
UPL

                                      AG
                                   Existing
                                     0.083
UPL
lb/ton coke

                                       
                                      New
                                     0.013
UPL

                                      HCN
                                   Existing
                                    0.0039
UPL

                                       
                                      New
                                    7.4E-04
UPL

HNR HRSG Main Stack
                                      Hg
                                   Existing
                                    2.4E-06
UPL
gr/dscf

                                       
                                      New
                                    1.5E-06
UPL

                                      PM
                                   Existing
                                    0.0065
UPL

                                       
                                      New
                                    7.5E-04
UPL

                                      AG
                                   Existing
                                     0.038
UPL

                                       
                                      New
                                    0.0029
UPL

                                      PAH
                                   Existing
                                    4.7E-07
UPL

                                       
                                      New
                                    3.7E-07
UPL

HNR HRSG Bypass/waste heat stack
                                      AG
                                   Existing
                                     0.13
UPL
gr/dscf

                                       
                                      New
                                     0.070
UPL

                                      PAH
                              Existing & New
                                    2.4E-06
UPL
gr/dscf

                                 Formaldehyde
                                   Existing
                                    0.0011
UPL
gr/dscf

                                       
                                      New
                                    1.9E-05
UPL

HR HRSG Bypass/waste heat stack
                                      Hg
                                   Existing
                                    1.7E-05
UPL
gr/dscf

                                       
                                      New
                                    7.8E-06
UPL

                                      PM
                                   Existing
                                     0.034
UPL
gr/dscf

                                       
                                      New
                                     0.025
UPL

NR HRSG Bypass/waste heat stack
                                      Hg
                                   Existing
                                    1.7E-06
UPL[1]
gr/dscf

                                       
                                      New
                                    7.8E-07
UPL[1]

                                      PM
                                   Existing
                                    6.6E-04
3xRDL[1]
gr/dscf

                                       
                                      New
                                    6.6E-04
3xRDL[1]

[1] BTF limits discussed in section 5.4

B.7 References for Appendix B
ASME (founded as the American Society of Mechanical Engineers). 2001. Reference Method Accuracy and Precision (ReMAP): Phase 1, Precision of Manual Stack Emission Measurements. Vol. 60. Center for Research and Technology Development, February 2001.
Bhaumik, D.K., and R.D. Gibbons. 2004. "An Upper Prediction Limit for the Arithmetic Mean of a Lognormal Random Variable." Technometrics, 46(2):239-248.
Gayen, A. K. 1949. "The Distribution of Student's t in Random Samples of any Size Drawn from Non-Normal Universes." Biometrika, Vol. 36, No. 3/4 (Dec. 1949), pp. 353-369. Docket Item No. EPA-HQ-OAR-2013-0291-0171.
EPA, 2011. Data and procedure for handling below detection level data in analyzing various pollutant emissions databases for MACT and RTR emissions limits. P. Westlin and R. Merrill. U.S. Environmental Protection Agency, Research Triangle Park, NC. 2011.
EPA, 2018. Development of Representative Detection Levels of Certain Organic HAP Expressed as Pounds per Million British Thermal Units of Fuel Input for RTR Risk Modeling Dataset for Coal- and Oil-fired EGUs. Memorandum from B. Parker, EPA/OAQPS/SPPD, to Docket ID No: EPA-HQ-OAR-2018-0794. U.S. Environmental Protection Agency, Research Triangle Park, NC. July 2018.
EPA, 2021. Use of the Upper Prediction Limit for Calculating MACT Floors. Memorandum from D. L. Jones, EPA/OAQPS/SPPD, to Docket No. EPA-HQ-OAR-2002-0083. U.S. Environmental Protection Agency, Research Triangle Park, NC. September 2, 2021. 
EPA, 2023a. Coke Ovens Risk and Technology Review: Data Summary. D. L. Jones, U.S. Environmental Protection Agency, Research Triangle Park, NC, and G. Raymond, RTI International, Research Triangle Park, NC. May 1, 2023. Docket ID No. EPA-HQ-OAR-2002-0085.
EPA. 2023b. Approach for Applying the Upper Prediction Limit to Limited Datasets. Memorandum from D. L. Jones, EPA/OAQPS/SPPD, to Docket No. EPA-HQ-OAR-2002-0083. U.S. Environmental Protection Agency, Research Triangle Park, NC. May 1, 2023.

 

 

                                 APPENDIX C: 
            BEYOND-THE-FLOOR COST DETAILS FOR COKE PQBS FACILITIES

      This appendix presents the methodology and the results of developing beyond-the-floor costs and emission reductions for coke oven sources. Calculations are provided in the accompanying Microsoft Excel(R) file. The BTF controls are applied to the existing or MACT level of control, as appropriate.

C.1 Development of Input Parameters for BTF Analyses

      For the operating labor rate used in the unit APCD costs, the mean hourly wage ($29.44/hr) was used for occupation code 17-3026 from the Bureau of Labor Statistics, May 2021, for Industrial Engineering Technologists and Technicians (BLS, 2023). 

	For the cost escalation factors used in the unit APCD costs, as applicable, the gross domestic product (GDP) values were used from the U.S. Bureau of Economic Analysis, Table 1.1.9: Implicit Price Deflators for Gross Domestic Product (BEA, 2023). 

	For the interest rate used in the APCD unit capital recover costs, 7.5% was used from the Federal Reserve "Economic Data, Bank Prime Loan Rate Changes: Historical Dates of Changes and Rates" (FRED, 2023). 

C.2 Pushing BTF Analysis
      
      For pushing sources, Hg, AG, HCN, and PAH MACT limits were developed, as described above in Section 3.0 and Appendix B. All facilities and units could meet the MACT floors. The BTF analysis includes the cost of adding activated carbon injection (ACI) and a wet alkaline scrubber (WAS) to each pushing source to reduce Hg, AG, HCN, and PAH emissions further than the MACT limit. Note, pushing units have existing controls (e.g., baghouses and scrubbers).

Input Parameters for BTF Controls for Pushing

	The actual and standard exhaust flowrates (in actual cubic feet per minute (acfm) and dry standard cubic feet per minute (dscfm)), and stack temperatures (°F) were compiled from the coke oven stack testing of Hg, AG, HCN, and PAH at pushing sources. Overall average exhaust flowrates and stack temperature were calculated from the stack tests to use as inputs for calculating BTF controls for pushing sources. The HNR sources did not report air flow in acfm in their test report; as such, the average ratio of acfm/dscfm for ByP sources was applied to the HNR dscfm values to estimate the HNR acfm values. Table C-1 shows the average stack parameters used for the pushing sources. Copies of the coke oven stack test data are included in the coke oven PQBS docket (Docket ID No. EPA-HQ-OAR-2002-0085). 

                                       
            Table C-1. Average Stack Parameters for Pushing Sources
                                   Facility
                                     Unit
                                   Unit Type
                               Pollutant Tested
                              Flow Actual (acfm)
                           Flow Dry Standard (dscfm)
                             Temp Stack Gas (°F)
CC-Middletown-OH
pushing baghouse
                                      ByP
                                      HCl
                                    41,280
                                    37,180
                                      115
CC-Middletown-OH
pushing baghouse
                                      ByP
                                      HCl
                                    43,043
                                    38,842
                                      110
CC-Middletown-OH
pushing baghouse
                                      ByP
                                      HCl
                                    42,726
                                    38,104
                                      118
CC-Middletown-OH
pushing baghouse
                                      ByP
                                      HCN
                                    43,909
                                    39,305
                                      118
CC-Middletown-OH
pushing baghouse
                                      ByP
                                      HCN
                                    41,980
                                    38,367
                                      106
CC-Middletown-OH
pushing baghouse
                                      ByP
                                      HCN
                                    42,466
                                    37,787
                                      121
CC-Middletown-OH
pushing baghouse
                                      ByP
                                      Hg
                                    42,855
                                    38,098
                                      120
CC-Middletown-OH
pushing baghouse
                                      ByP
                                      Hg
                                    43,170
                                    39,021
                                      111
CC-Middletown-OH
pushing baghouse
                                      ByP
                                      Hg
                                    43,240
                                    38,217
                                      124
CC-Middletown-OH
pushing baghouse
                                      ByP
                                      PAH
                                    42,422
                                    39,109
                                      106
CC-Middletown-OH
pushing baghouse
                                      ByP
                                      PAH
                                    41,660
                                    38,094
                                      108
CC-Middletown-OH
pushing baghouse
                                      ByP
                                      PAH
                                    41,492
                                    38,266
                                      103
CC-Burnsharbor-IN
#2 coke battery pushing emission control baghouse stack
                                      ByP
                                 HCl & HCN
                                    211,575
                                    172,941
                                     149.6
CC-Burnsharbor-IN
#2 coke battery pushing emission control baghouse stack
                                      ByP
                                 HCl & HCN
                                    216,429
                                    176,058
                                     151.3
CC-Burnsharbor-IN
#2 coke battery pushing emission control baghouse stack
                                      ByP
                                 HCl & HCN
                                    215,055
                                    178,701
                                     144.3
CC-Burnsharbor-IN
#2 coke battery pushing emission control baghouse stack
                                      ByP
                                      Hg
                                    236,087
                                    192,816
                                     154.9
CC-Burnsharbor-IN
#2 coke battery pushing emission control baghouse stack
                                      ByP
                                      Hg
                                    235,290
                                    190,462
                                     157.9
CC-Burnsharbor-IN
#2 coke battery pushing emission control baghouse stack
                                      ByP
                                      Hg
                                    229,462
                                    187,036
                                     150.5
CC-Burnsharbor-IN
#2 coke battery pushing emission control baghouse stack
                                      ByP
                                      PAH
                                    235,532
                                    193,818
                                     155.5
CC-Burnsharbor-IN
#2 coke battery pushing emission control baghouse stack
                                      ByP
                                      PAH
                                    235,802
                                    192,138
                                     151.9
CC-Burnsharbor-IN
#2 coke battery pushing emission control baghouse stack
                                      ByP
                                      PAH
                                    215,374
                                    175,398
                                     155.8
CC-Monessen-PA
pushing baghouse stack
                                      ByP
                                      HCl
                                    143,756
                                    119,007
                                     150.1
CC-Monessen-PA
pushing baghouse stack
                                      ByP
                                      HCl
                                    139,093
                                    114,795
                                      110
CC-Monessen-PA
pushing baghouse stack
                                      ByP
                                      HCl
                                    143,932
                                    123,108
                                     101.7
CC-Monessen-PA
pushing baghouse stack
                                      ByP
                                      HCN
                                    88,024
                                    74,862
                                     131.9
CC-Monessen-PA
pushing baghouse stack
                                      ByP
                                      HCN
                                    86,463
                                    73,243
                                     131.3
CC-Monessen-PA
pushing baghouse stack
                                      ByP
                                      HCN
                                    89,144
                                    75,517
                                     128.3
CC-Monessen-PA
pushing baghouse stack
                                      ByP
                                      Hg
                                    87,735
                                    76,322
                                     126.8
CC-Monessen-PA
pushing baghouse stack
                                      ByP
                                      Hg
                                    87,939
                                    77,448
                                     119.9
CC-Monessen-PA
pushing baghouse stack
                                      ByP
                                      Hg
                                    87,895
                                    76,667
                                     123.7
CC-Monessen-PA
pushing baghouse stack
                                      ByP
                                      PAH
                                    83,117
                                    73,823
                                     115.6
CC-Monessen-PA
pushing baghouse stack
                                      ByP
                                      PAH
                                    82,330
                                    72,779
                                     121.1
CC-Monessen-PA
pushing baghouse stack
                                      ByP
                                      PAH
                                    79,908
                                    69,516
                                     123.4
EC-Erie-PA
coke side shed baghouse (802)
                                      ByP
                                 HCl & HCN
                                    92,454
                                    83,522
                                     100.6
EC-Erie-PA
coke side shed baghouse (802)
                                      ByP
                                 HCl & HCN
                                    83,697
                                    75,917
                                     99.4
EC-Erie-PA
coke side shed baghouse (802)
                                      ByP
                                 HCl & HCN
                                    84,064
                                    78,219
                                     91.5
EC-Erie-PA
coke side shed baghouse (802)
                                      ByP
                                      Hg
                                    92,459
                                    83,527
                                     100.6
EC-Erie-PA
coke side shed baghouse (802)
                                      ByP
                                      Hg
                                    83,699
                                    75,919
                                     99.4
EC-Erie-PA
coke side shed baghouse (802)
                                      ByP
                                      Hg
                                    84,066
                                    78,293
                                     91.5
EC-Erie-PA
coke side shed baghouse (802)
                                      ByP
                                      PAH
                                    86,938
                                    76,968
                                     100.4
EC-Erie-PA
coke side shed baghouse (802)
                                      ByP
                                      PAH
                                    79,114
                                    72,183
                                     93.3
EC-Erie-PA
coke side shed baghouse (802)
                                      ByP
                                      PAH
                                    79,871
                                    74,057
                                     92.5
SC-Middletown-OH
Middletown flat push hot car
                                      HNR
                                      HCl
                                       
                                    24,424
                                      365
SC-Middletown-OH
Middletown flat push hot car
                                      HNR
                                      HCl
                                       
                                    24,299
                                      336
SC-Middletown-OH
Middletown flat push hot car
                                      HNR
                                      HCl
                                       
                                    25,205
                                      348
SC-Middletown-OH
Middletown flat push hot car
                                      HNR
                                      HCN
                                       
                                    24,546
                                      333
SC-Middletown-OH
Middletown flat push hot car
                                      HNR
                                      HCN
                                       
                                    26,031
                                      349
SC-Middletown-OH
Middletown flat push hot car
                                      HNR
                                      HCN
                                       
                                    24,619
                                      334
SC-Middletown-OH
Middletown flat push hot car
                                      HNR
                                      Hg
                                       
                                    24,812
                                      274
SC-Middletown-OH
Middletown flat push hot car
                                      HNR
                                      Hg
                                       
                                    26,519
                                      306
SC-Middletown-OH
Middletown flat push hot car
                                      HNR
                                      Hg
                                       
                                    27,425
                                      291
SC-Middletown-OH
Middletown flat push hot car
                                      HNR
                                      PAH
                                       
                                    23,255
                                      319
SC-Middletown-OH
Middletown flat push hot car
                                      HNR
                                      PAH
                                       
                                    23,552
                                      317
SC-Middletown-OH
Middletown flat push hot car
                                      HNR
                                      PAH
                                       
                                    22,873
                                      331
SC-GraniteCity-IL
Gateway Flat Push Hot Car
                                      HNR
                                      Hg
                                       
                                    31,509
                                      289
SC-GraniteCity-IL
Gateway Flat Push Hot Car
                                      HNR
                                      Hg
                                       
                                    26,850
                                      320
SC-GraniteCity-IL
Gateway Flat Push Hot Car
                                      HNR
                                      Hg
                                       
                                    27,404
                                      263
ByP Average

                                       
                                       
                                    107,299
                                    91,558
                                      121
HNR Average

                                       
                                       
                                    29,948
                                    25,555
                                      318

Development of Unit Costs for Ductwork for BTF Controls for Pushing 

      The ductwork cost model from the Ferroalloy NESHAP RTR (EPA, 2015) was used to develop unit costs for pushing sources using specific data available for the coke industry. Table C-2 shows the ductwork unit costs for coke pushing sources.

          Table C-2. Ductwork Unit Costs for BTF Controls for Pushing
                                  Parameters
                                   ByP Value
                                   HNR Value
                               Source/Reference
DUCTS: COST BASE DATE: GDP 1993
                                    68.877
                                    68.877
BEA, 2023
COST ESCALATION: GDP 2022 
                                    126.45
                                    126.45
BEA, 2023
-- Inlet stream flowrate (acfm):
                                    107,299
                                    29,948
Coke Oven Test Data
-- Duct velocity (ft/min): 
                                     3,800
                                     3,800
Ferroalloy (EPA, 2015)
-- Duct length (ft): 
                                      150
                                      150
Engineering judgement
-- Material of construction: 
                                 Sheet-galv CS
                                 Sheet-galv CS
Ferroalloy (EPA, 2015)
-- Insulation thickness (in.): (text input) 
                                       0
                                       0
Ferroalloy (EPA, 2015)
-- Duct design: 
                             Circular-longitudinal
                             Circular-longitudinal
Ferroalloy (EPA, 2015)
-- Cost equation parameters: 
                                       
                                       

          a:
                                     2.03
                                     2.03
Ferroalloy (EPA, 2015)
          b:
                                     0.784
                                     0.784
Ferroalloy (EPA, 2015)
-- Cost equation form: 
                                       1
                                       1
Ferroalloy (EPA, 2015)
-- Control system installation factor: 
                                       0
                                       0
Ferroalloy (EPA, 2015)
   (if no system, enter '0')
                                       
                                       

-- Fan-motor combined efficiency (fraction):
                                      0.6
                                      0.6
Ferroalloy (EPA, 2015)
DESIGN PARAMETERS
                                       
                                       

-- Duct diameter (in.):
                                      76
                                      76
Ferroalloy (EPA, 2015)
-- Pressure drop (in. w.c.): 
                                       0
                                       0
Ferroalloy (EPA, 2015)
CAPITAL COSTS
                                       
                                       

Ductwork Cost ($)--base:
                                    $9,081
                                    $9,081
Ferroalloy (EPA, 2015)
Ductwork Cost ($)--escalated:
                                    $16,672
                                    $16,672
Ferroalloy (EPA, 2015)
Purchased Equipment Cost ($):
                                    $18,006
                                    $18,006
Ferroalloy (EPA, 2015)
Retrofit Adjustment (25%)
                                    $22,507
                                    $22,507
Ferroalloy (EPA, 2015)
Total Capital Investment ($): 
                                    $33,761
                                    $33,761
Ferroalloy (EPA, 2015)
ANNUAL COST INPUTS
                                       
                                       

Operating factor (hours/year):
                                     8760
                                     8760
Coke oven test data
Electricity price ($/kWhr):
                                     0.067
                                     0.067
Ferroalloy (EPA, 2015)
Annual interest rate (fractional):
                                     0.075
                                     0.075
FRED, 2023
Ductwork economic life (years):
                                      20
                                      20
Ferroalloy (EPA, 2015)
Capital recovery factor (system):
                                  0.098092192
                                  0.098092192
Ferroalloy (EPA, 2015)
Taxes, insurance, admin. factor:
                                     0.04
                                     0.04
Ferroalloy (EPA, 2015)
Labor, $/hr 
                                    $29.44
                                    $29.44
BLS, 2023
ANNUAL COSTS
                                       
                                       

Item
                                  Cost ($/yr)
                                  Cost ($/yr)

Electricity
                                    $3,150
                                     $879
Ferroalloy (EPA, 2015)
Taxes, insurance, administrative
                                    $1,350
                                    $1,350
Ferroalloy (EPA, 2015)
Capital recovery
                                    $3,312
                                    $3,312
Ferroalloy (EPA, 2015)
Labor 
                                    $2,438
                                    $2,438
Ferroalloy (EPA, 2015)
Overhead 
                                    $1,463
                                    $1,463
Ferroalloy (EPA, 2015)
Total Annual Cost 
                                    $11,713
                                    $9,442
Ferroalloy (EPA, 2015)

Development of Unit Costs for ACI for BTF Controls for Pushing
 
      The ACI cost model from the Ferroalloy NESHAP RTR (EPA, 2015) was used to develop unit costs for pushing sources using specific data available for the coke industry. Table C-3 shows the ACI unit costs for BTF controls for pushing sources. 

            Table C-3. ACI Unit Costs for BTF Controls for Pushing
                                  Parameters
                                   ByP Value
                                   HNR Value
                               Source/Reference
Annual Operating Hours, hr/yr (H)
                                     8760
                                     8760
Coke oven test data
Exhaust Gas Flow Rate, acfm (Qa)
                                    107,299
                                    29,948
Coke oven test data
Exhaust Gas Flow Rate, dscfm (Q)
                                    91,558
                                    25,555
Coke oven test data
Operating Labor Rate, $/hr (LR)
                                    $29.44
                                    $29.44
BLS, 2023
Activated Carbon Cost, $/lb (ACC)
                                     $0.75
                                     $0.75
Ferroalloy (EPA, 2015)
Dust Disposal Cost, $/Ton (DDC, Non-Hazardous)
                                    $40.00
                                    $40.00
Ferroalloy (EPA, 2015)
Dust Disposal Cost, $/Ton (DDC, Hazardous)
                                    $400.00
                                    $400.00
Ferroalloy (EPA, 2015)
Capital Recovery Factor (CRF)
                                  0.098092192
                                  0.098092192
CRF calculated assuming 20-year equipment life and 7.5% interest (FRED, 2023)
GDP, 2022
                                    126.45
                                    126.45
BEA, 2023
GDP, 2008
                                    94.419
                                    94.419
BEA, 2023
GDP, 1991
                                    65.783
                                    65.783
BEA, 2023
ACI Adjustment Factor (AF)
                                     0.95
                                     0.95
Calculated control efficiency
ACI Injection Rate (lb/MMacf)
                                      2.0
                                      2.0
Ferroalloy (EPA, 2015)
Total Capital Investment, $ (TCI)
                                   $103,692
                                    $48,218
Calculated using algorithm 4,500 x (Q/1,976)0.6 x (1.2 retrofit factor) x CEPCI Adj.
Direct Annual Cost, $/yr (DAC)
                                       
                                       

Operating Labor
                                    $8,059
                                    $8,059
Calculated using (0.25 hr/8-hr shift) x H x LR
Supervisory Labor
                                    $1,209
                                    $1,209
Calculated using 0.15 x Operating Labor
Maintenance
                                    $20,738
                                    $9,644
Calculated using 0.2 x TCI
Activated Carbon
                                    $84,594
                                    $23,611

Dust Disposal (Non-Hazardous)
                                    $2,233
                                     $623
Calculated using ACI injection rate, 99% capture efficiency, and non-hazardous disposal cost
Dust Disposal (Hazardous)
                                    $22,333
                                    $6,233
Calculated using ACI injection rate, 99% capture efficiency, and hazardous disposal cost
Indirect Annual Cost, $/yr (IAC)
                                       
                                       

Overhead
                                    $18,004
                                    $11,347
Calculated using 0.6 x (Labor + Maintenance)
Property Tax, Insurance, & Admin
                                    $4,148
                                    $1,929
Calculated using 0.04 x TCI
Capital Recovery
                                    $10,171
                                    $4,730
Calculated using CRF x TCI
Total Annual Cost (Non-Hazardous)
                                   $149,157
                                    $61,152
Sum of DAC + IAC
Total Annual Cost (Hazardous)
                                   $169,257
                                    $66,762
Sum of DAC + IAC

Development of Unit Costs for WAS for BTF Controls for Pushing

      The WAS cost model from the Portland Cement NESHAP (EPA, 2010) was used to develop unit costs for pushing sources using specific data available for the coke industry. Table C-4 shows the WAS unit costs for pushing sources.
            Table C-4. WAS Unit Costs for BTF Controls for Pushing
                                 Capital Costs
Parameter
                                   ByP Value
                                   HNR Value
                               Source/Reference
Gas flowrate (dscfm)
                                    91,558
                                    25,555
Coke oven test data
GDP 2010
                                    96.166
                                    96.166
BEA, 2023
GDP 2022
                                    126.45
                                    126.45
BEA, 2023
CC = Capital ($2022)
                                  $17,956,355
                                  $8,349,945
Portland Cement (EPA, 2010)
                                 Annual Costs
Parameter
                                     Value
                                       
COSTKWH ($2022/kWhr)
                                  0.095199759
Portland Cement (EPA, 2010)
Annual interest rate (fraction):
                                     0.075
FRED, 2023
Control system life (years):
                                      20
Portland Cement (EPA, 2010)
CRF = Capital recovery factor:
                                  0.098092192
Portland Cement (EPA, 2010)
                                   Facility
                                    Source
                                 Facility Type
                                 Type of Coke
                              Coke Production TPY
                           Operating Hours per year
                                 Fixed Costs 
                         SO2 = lb SO2 per ton of coke
                                   Variable
                                     Costs
                                      TAC
                                       
                                       
                                       
                                       
                                Coke Oven Data
                                  Coke Oven 
                                     Data
                          Portland Cement (EPA, 2010)
                                  Coke Oven 
                                     Data
                Portland Cement (EPA, 2010 & Andover 2009)
                          Portland Cement (EPA, 2010)
ABC-Tarrant-AL
pushing for battery no. 1 baghouse 1
                                      ByP
                                    Foundry
                                    188,803
                                     8670
                                   $773,894
                                   1.88E-02
                                    $4,781
                                  $2,540,054
ABC-Tarrant-AL
pushing for battery no. 1 baghouse 2
                                      ByP
                                    Foundry
                                    188,803
                                     8670
                                   $773,894
                                   1.88E-02
                                    $4,781
                                  $2,540,054
ABC-Tarrant-AL
pushing for batteries no. 5 & 6 baghouse
                                      ByP
                                    Foundry
                                    148,079
                                     8670
                                   $766,347
                                   2.40E-02
                                    $3,760
                                  $2,531,485
CC-Follansbee-WV
baghouse for batteries 1-2-3 co1 (stack 1-14)
                                      ByP
                                 Blast furnace
                                    108,793
                                     8670
                                   $758,225
                                   4.08E-01
                                    $3,306
                                  $2,522,909
CC-Follansbee-WV
venturi scrubber battery #8 (stack 06)
                                      ByP
                                 Blast furnace
                                    453,069
                                     8670
                                   $812,331
                                   9.81E-02
                                    $11,941
                                  $2,585,650
CC-Middletown-OH
b918-3 pec baghouse exhaust stack 1-5
                                      ByP
                                 Blast furnace
                                    401,752
                                     8670
                                   $805,784
                                   7.26E-03
                                    $10,114
                                  $2,577,277
CC-BurnsHarbor-IN
ep512-3018
                                      ByP
                                 Blast furnace
                                    932,178
                                     8670
                                   $863,293
                                   1.08E-01
                                    $24,687
                                  $2,649,358
CC-BurnsHarbor-IN
ep512-3024
                                      ByP
                                 Blast furnace
                                    955,975
                                     8670
                                   $865,503
                                   1.05E-01
                                    $25,284
                                  $2,652,165
CC-Monessen-PA
pro 802
                                      ByP
                                 Blast furnace
                                    336,022
                                     8670
                                   $796,887
                                   8.86E-02
                                    $8,815
                                  $2,567,080
CC-Warren-OH
b901-1 pushing along battery no. 4
                                      ByP
                                 Blast furnace
                                    359,281
                                     8670
                                   $800,109
                                   1.24E-01
                                    $9,588
                                  $2,571,076
BLU-Birmingham-AL
57772612
                                      ByP
                                    Foundry
                                    348,713
                                     8670
                                   $798,656
                                   1.02E-02
                                    $8,792
                                  $2,568,826
EES-RiverRouge-MI
pecs baghouse stack
                                      ByP
                                 Blast furnace
                                    981,765
                                     8670
                                   $867,874
                                   4.52E-02
                                    $25,201
                                  $2,654,452
USS-Clairton-PA
p050
                                      ByP
                                 Blast furnace
                                    651,672
                                     8670
                                   $835,258
                                   6.82E-02
                                    $16,922
                                  $2,613,558
USS-Clairton-PA
p052-pec baghouse 13-15
                                      ByP
                                 Blast furnace
                                    677,172
                                     8670
                                   $837,984
                                   6.56E-02
                                    $17,561
                                  $2,616,924
USS-Clairton-PA
p053
                                      ByP
                                 Blast furnace
                                    848,614
                                     8670
                                   $855,345
                                   5.23E-02
                                    $21,861
                                  $2,638,585
USS-Clairton-PA
p054
                                      ByP
                                 Blast furnace
                                    718,216
                                     8670
                                   $842,287
                                   6.19E-02
                                    $18,591
                                  $2,622,256
USS-Clairton-PA
ACHD permit # 0052-i011 p001
                                      ByP
                                 Blast furnace
                                    880,570
                                     8670
                                   $858,420
                                   5.04E-02
                                    $22,663
                                  $2,642,461
SC-EastChicago-IN
baghouse 204
                                      HNR
                                 Blast furnace
                                   1,300,000
                                     8,760
                                   $511,070
                                   3.85E-02
                                    $33,255
                                  $1,363,389
SC-FranklinFurnace-OH
pushing multiclone stack ab
                                      HNR
                                 Blast furnace
                                    341,657
                                     8,760
                                   $413,419
                                   1.46E-01
                                    $9,219
                                  $1,241,703
SC-FranklinFurnace-OH
pushing multiclone stack cd
                                      HNR
                                 Blast furnace
                                    341,657
                                     8,760
                                   $413,419
                                   1.46E-01
                                    $9,219
                                  $1,241,703
SC-GraniteCity-IL
flat push hot car with multiclone abc
                                      HNR
                                 Blast furnace
                                    428,412
                                     8,760
                                   $424,968
                                   1.17E-01
                                    $11,395
                                  $1,255,428
SC-Middletown-OH
flat push hot car with multiclone abc
                                      HNR
                                 Blast furnace
                                    357,010
                                     8,760
                                   $415,542
                                   1.40E-01
                                    $9,605
                                  $1,244,211
SC-Vansant-VA
cokeside shed settling chamber pushing along battery 2d
                                      HNR
                                 Blast furnace
                                    90,000
                                     8,760
                                   $369,670
                                   5.56E-01
                                    $2,908
                                  $1,191,642
SC-Vansant-VA
cokeside shed settling chamber pushing along battery 2e
                                      HNR
                                 Blast furnace
                                    135,000
                                     8,760
                                   $379,495
                                   3.71E-01
                                    $4,036
                                  $1,202,596
SC-Vansant-VA
cokeside shed settling chamber pushing along battery 3b
                                      HNR
                                 Blast furnace
                                    130,000
                                     8,760
                                   $378,476
                                   3.85E-01
                                    $3,911
                                  $1,201,452
SC-Vansant-VA
cokeside shed settling chamber pushing along battery 3c
                                      HNR
                                 Blast furnace
                                    180,000
                                     8,760
                                   $388,067
                                   2.78E-01
                                    $5,165
                                  $1,212,296
SC-Vansant-VA
cokeside shed settling chamber pushing along battery 3f
                                      HNR
                                 Blast furnace
                                    85,000
                                     8,760
                                   $368,467
                                   5.89E-01
                                    $2,782
                                  $1,190,314
SC-Vansant-VA
Cokeside Shed Settling Chamber Pushing along Battery 3G
                                      HNR
                                 Blast furnace
                                    90,000
                                     8,760
                                   $369,670
                                   5.56E-01
                                    $2,908
                                  $1,191,642
Where:
CC = Capital ($2022) = 14,398*(DSCFM)[0.6]
Fixed costs include labor (operating, supervisory, and maintenance), maintenance materials, replacement parts, taxes, insurance, etc.:
FC = 38 * TPY[0.6] + 0.04 * CC
Variable costs include consumption of limestone, power, and water plus generation of scrubber slurry:
VC = (0.000844 * TPY * COSTKWH) + (0.013 * TPY * SO2) + (TPY * 0.025)
Total annualized cost (TAC) includes fixed annual costs, variable annual costs, and capital recovery interest rate, 20‐year lifetime, and a capital recovery factor:
TAC = FC + VC + CRF * CC
BTF Costs per Facility for Pushing

	It was assumed that the coke facilities will duct each pushing unit to one BTF APCD configuration. The unit APCD costs were multiplied by the required number of APCD configurations to calculate the total BTF pushing costs per facility. The total BTF pushing costs are shown in Table C-5.

                 Table C-5. BTF Costs per Facility for Pushing
                                   Facility
                                 Facility Type
                            No. APCD Configurations
                             Total Capital Cost ($)
                             Total Annual Cost ($)
                                       
                                       
                                       
                                   Ductwork
                                      ACI
                                      WAS
                                     Total
                                   Ductwork
                                      ACI
                                      WAS
                                    Total 
ABC-Tarrant-AL
                                      ByP
                                       3
                                   $101,283
                                   $311,076
                                  $53,869,064
                                  $54,281,423
                                    $35,138
                                   $507,770
                                  $7,611,593
                                  $8,154,502
BLU-Birmingham-AL
                                      ByP
                                       1
                                    $33,761
                                   $103,692
                                  $17,956,355
                                  $18,093,808
                                    $11,713
                                   $169,257
                                  $2,568,826
                                  $2,749,795
CC-Follansbee-WV
                                      ByP
                                       2
                                    $67,522
                                   $207,384
                                  $35,912,710
                                  $36,187,616
                                    $23,426
                                   $338,513
                                  $5,108,559
                                  $5,470,498
CC-Middletown-OH
                                      ByP
                                       1
                                    $33,761
                                   $103,692
                                  $17,956,355
                                  $18,093,808
                                    $11,713
                                   $169,257
                                  $2,577,277
                                  $2,758,246
CC-BurnsHarbor-IN
                                      ByP
                                       2
                                    $67,522
                                   $207,384
                                  $35,912,710
                                  $36,187,616
                                    $23,426
                                   $338,513
                                  $5,301,523
                                  $5,663,462
CC-Monessen-PA
                                      ByP
                                       1
                                    $33,761
                                   $103,692
                                  $17,956,355
                                  $18,093,808
                                    $11,713
                                   $169,257
                                  $2,567,080
                                  $2,748,049
CC-Warren-OH
                                      ByP
                                       1
                                    $33,761
                                   $103,692
                                  $17,956,355
                                  $18,093,808
                                    $11,713
                                   $169,257
                                  $2,571,076
                                  $2,752,045
EES-RiverRouge-MI
                                      ByP
                                       1
                                    $33,761
                                   $103,692
                                  $17,956,355
                                  $18,093,808
                                    $11,713
                                   $169,257
                                  $2,654,452
                                  $2,835,422
USS-Clairton-PA
                                      ByP
                                       5
                                   $168,805
                                   $518,460
                                  $89,781,774
                                  $90,469,039
                                    $58,564
                                   $846,283
                                  $13,133,783
                                  $14,038,630
SC-EastChicago-IN
                                      HNR
                                       1
                                    $33,761
                                    $48,218
                                  $8,349,945
                                  $8,431,924
                                    $9,442
                                    $66,762
                                  $1,363,389
                                  $1,439,593
SC-FranklinFurnace-OH
                                      HNR
                                       2
                                    $67,522
                                    $96,436
                                  $16,699,890
                                  $16,863,849
                                    $18,883
                                   $133,524
                                  $2,483,406
                                  $2,635,813
SC-GraniteCity-IL
                                      HNR
                                       1
                                    $33,761
                                    $48,218
                                  $8,349,945
                                  $8,431,924
                                    $9,442
                                    $66,762
                                  $1,255,428
                                  $1,331,632
SC-Middletown-OH
                                      HNR
                                       1
                                    $33,761
                                    $48,218
                                  $8,349,945
                                  $8,431,924
                                    $9,442
                                    $66,762
                                  $1,244,211
                                  $1,320,414
SC-Vansant-VA
                                      HNR
                                       6
                                   $202,566
                                   $289,309
                                  $50,099,671
                                  $50,591,546
                                    $56,650
                                   $400,571
                                  $7,189,942
                                  $7,647,163
Industry Total
                                   $945,307
                                  $2,293,165
                                 $397,107,428
                                 $400,345,900
                                   $302,976
                                  $3,611,743
                                  $57,630,545
                                  $61,545,264

BTF Emission Reductions for Pushing

      Baseline emissions were estimated from coke oven CAA section 114 requests data. The coke oven stack test data were used to develop industry average Hg, AG, HCN, and PAH lb/ton coke default values per facility type and per coke produced type for the units that were not tested, shown in Table C-6. 
      
      Table C-6. Pushing Default Baseline Emission Factors (lb/ton coke) 
                    by Facility Type and Coke Type Produced
                                   Pollutant
                             ByP - Blast Furnace 
                                 (lb/ton coke)
                                ByP  -  Foundry
                                 (lb/ton coke)
                              HNR - Blast Furnace
                                 (lb/ton coke)
Hg
                                   2.23E-07
                                   1.01E-07
                                   1.22E-07
AG
                                   1.28E-03
                                   1.44E-03
                                   1.66E-03
HCN
                                   5.19E-04
                                   8.99E-04
                                   2.40E-05
PAH
                                   5.01E-05
                                   6.49E-04
                                   4.11E-06
      
      In addition, the coke oven stack test data for similar units at the test facilities were used as "surrogate" data, where appropriate. The lb/ton coke emission factor developed for each pushing source (i.e., coke oven test data, similar unit, or default emission factor) were multiplied by each source's corresponding battery coke production value (TPY), as shown in Table C-7, and then divided by 2,000 to calculate TPY emissions. 
      
   Table C-7. Annual Coke Production Values by Facility and Emission Source
                                   Facility
                               Emission Source 
                                 Process Type
                              Coke Production TPY
ABC-Tarrant-AL
coke pushing operations for batteries 1 baghouse 1
EP-1 BP Pushing (CD)
                                    377,606
ABC-Tarrant-AL
coke pushing operations for batteries 1 baghouse 2
EP-1 BP Pushing (CD)
                                    377,606
ABC-Tarrant-AL
coke pushing operations for batteries 5 and6 baghouse
EP-1 BP Pushing (CD)
                                    148,079
BLU-Birmingham-AL
pushing emissions for coke batteries # 3, 4 & 5
EP-1 BP Pushing (CD)
                                    348,713
CC-Follansbee-WV
pushing baghouse for batteries 1-2-3 co1 (stack 1-14)
EP-1 BP Pushing (CD)
                                    108,793
CC-Follansbee-WV
pushing venturi scrubber battery #8 co2 (stack 06)
EP-1 BP Pushing (CD)
                                    453,069
CC-Middletown-OH
b918-3 pec baghouse exhaust stack 1-5
EP-1 BP Pushing (CD)
                                    401,752
CC-BurnsHarbor-IN
ep512-3018 pushing #1 baghouse
EP-1 BP Pushing (CD)
                                    932,178
CC-BurnsHarbor-IN
ep512-3024 pushing #2 baghouse
EP-1 BP Pushing (CD)
                                    955,975
CC-Monessen-PA
pro 802 pushing baghouse
EP-1 BP Pushing (CD)
                                    336,022
CC-Warren-OH
b901-1 pushing along battery no. 4
EP-1 BP Pushing (CD)
                                    359,281
EES-RiverRouge-MI
pecs baghouse stack
EP-1 BP Pushing (CD)
                                    981,765
USS-Clairton-PA
pec baghouse 1-3
EP-1 BP Pushing (CD)
                                    651,672
USS-Clairton-PA
pec baghouse 13-15
EP-1 BP Pushing (CD)
                                    677,172
USS-Clairton-PA
pec baghouse 19-20
EP-1 BP Pushing (CD)
                                    848,614
USS-Clairton-PA
pec baghouse b
EP-1 BP Pushing (CD)
                                    718,216
USS-Clairton-PA
pec baghouse c
EP-1 BP Pushing (CD)
                                    880,570
SC-EastChicago-IN
pushing machine for batteries a, b, c and d, baghouse 204
EP-9 HNR Pushing (CD)
                                   1,300,000
SC-FranklinFurnace-OH
pushing multiclone stack battery a&b
EP-9 HNR Pushing (CD)
                                    341,657
SC-FranklinFurnace-OH
pushing multiclone stack battery c&d
EP-9 HNR Pushing (CD)
                                    341,657
SC-GraniteCity-IL
flat push hot car with multiclone battery a&b&c
EP-9 HNR Pushing (CD)
                                    428,412
SC-Middletown-OH
flat push hot car with multiclone battery a&b&c
EP-9 HNR Pushing (CD)
                                    357,010
SC-Vansant-VA
cokeside shed settling chamber pushing along battery 2d
EP-9 HNR Pushing (CD)
                                    90,000
SC-Vansant-VA
cokeside shed settling chamber pushing along battery 2e
EP-9 HNR Pushing (CD)
                                    135,000
SC-Vansant-VA
cokeside shed settling chamber pushing along battery 3b
EP-9 HNR Pushing (CD)
                                    130,000
SC-Vansant-VA
cokeside shed settling chamber pushing along battery 3c
EP-9 HNR Pushing (CD)
                                    180,000
SC-Vansant-VA
cokeside shed settling chamber pushing along battery 3f
EP-9 HNR Pushing (CD)
                                    85,000
SC-Vansant-VA
cokeside shed settling chamber pushing along battery 3g
EP-9 HNR Pushing (CD)
                                    90,000
      
      
      The TPY emissions for HNR pushing sources were further adjusted to account for the control device efficiency correction factors, as described in the Coke Ovens Risk and Technology Review: Data Summary memorandum ( EPA, 2023A). The unit baseline HAP emissions for pushing sources were summed for each facility. Table C-8 shows the baseline emissions before BTF controls. 

      Table C-8. Baseline HAP Emissions from Pushing Before BTF Controls
                                   Facility
                                 Facility Type
                         Baseline HAP Emissions (TPY)
                                       
                                       
                                      Hg
                                      AG
                                      HCN
                                      PAH
                                   Total HAP
ABC-Tarrant-AL
                                      ByP
                                    2.7E-05
                                    0.3787
                                     0.24
                                     0.17
                                     0.79
BLU-Birmingham-AL
                                      ByP
                                    1.8E-05
                                    0.2512
                                     0.16
                                     0.11
                                     0.52
CC-Follansbee-WV
                                      ByP
                                    6.3E-05
                                    0.3601
                                     0.15
                                     0.014
                                     0.52
CC-Middletown-OH
                                      ByP
                                    4.5E-05
                                    0.05745
                                     0.023
                                     0.010
                                     0.090
CC-BurnsHarbor-IN
                                      ByP
                                    2.1E-04
                                     2.259
                                     0.79
                                     0.047
                                      3.1
CC-Monessen-PA
                                      ByP
                                    3.7E-05
                                    0.1959
                                     0.12
                                    0.0084
                                     0.33
CC-Warren-OH
                                      ByP
                                    4.0E-05
                                    0.2303
                                     0.093
                                    0.0090
                                     0.33
EES-RiverRouge-MI
                                      ByP
                                    1.1E-04
                                    0.6292
                                     0.25
                                     0.025
                                     0.91
USS-Clairton-PA
                                      ByP
                                    4.2E-04
                                     2.420
                                     0.98
                                     0.095
                                      3.5
SC-EastChicago-IN
                                      HNR
                                    8.0E-05
                                     1.090
                                     0.016
                                    0.0027
                                      1.1
SC-FranklinFurnace-OH
                                      HNR
                                    4.2E-05
                                    0.5671
                                    0.0082
                                    0.0014
                                     0.58
SC-GraniteCity-IL
                                      HNR
                                    2.6E-05
                                    0.3556
                                    0.0051
                                    0.00088
                                     0.36
SC-Middletown-OH
                                      HNR
                                    2.2E-05
                                    0.2963
                                    0.0043
                                    0.00073
                                     0.30
SC-Vansant-VA
                                      HNR
                                    3.3E-05
                                    0.4450
                                    0.0064
                                    0.0011
                                     0.45
Industry Total TPY
                                       
                                    0.0012
                                     9.54
                                      2.8
                                     0.50
                                     12.9

      Table C-9 shows the control efficiencies of each APCD that were used to calculate the BTF emission reductions shown in Table C-10. 
                                         
         Table C-9. Pollutants, APCD, Control Efficiency for BTF Controls
                                   Pollutant
                                     APCD
                              Control Efficiency
Hg
                                      ACI
                                      95%
PAH
                                      ACI
                                      80%
AG
                                      WAS
                                     99.9%
HCN
                                      WAS
                                      95%

    Table C-10. Reductions in HAP Emissions for Pushing due to BTF Controls
                                   Facility
                                 Facility Type
                         HAP Emission Reductions (TPY)
                                       
                                       
                                      Hg
                                      AG
                                      HCN
                                      PAH
                                   Total HAP
ABC-Tarrant-AL
                                      ByP
                                    2.5E-05
                                    0.3784
                                     0.22
                                     0.14
                                     0.74
BLU-Birmingham-AL
                                      ByP
                                    1.7E-05
                                    0.2510
                                     0.15
                                     0.091
                                     0.49
CC-Follansbee-WV
                                      ByP
                                    5.9E-05
                                    0.3597
                                     0.14
                                     0.011
                                     0.51
CC-Middletown-OH
                                      ByP
                                    4.2E-05
                                    0.05739
                                     0.022
                                    0.0080
                                     0.087
CC-BurnsHarbor-IN
                                      ByP
                                    2.0E-04
                                     2.257
                                     0.76
                                     0.038
                                      3.1
CC-Monessen-PA
                                      ByP
                                    3.6E-05
                                    0.1957
                                     0.12
                                    0.0067
                                     0.32
CC-Warren-OH
                                      ByP
                                    3.8E-05
                                    0.2300
                                     0.089
                                    0.0072
                                     0.33
EES-RiverRouge-MI
                                      ByP
                                    1.0E-04
                                    0.6286
                                     0.24
                                     0.020
                                     0.89
USS-Clairton-PA
                                      ByP
                                    4.0E-04
                                     2.418
                                     0.93
                                     0.076
                                      3.4
SC-EastChicago-IN
                                      HNR
                                    7.6E-05
                                     1.089
                                     0.015
                                    0.0022
                                      1.1
SC-FranklinFurnace-OH
                                      HNR
                                    4.0E-05
                                    0.5665
                                    0.0078
                                    0.0011
                                     0.58
SC-GraniteCity-IL
                                      HNR
                                    2.5E-05
                                    0.3552
                                    0.0049
                                    0.00070
                                     0.36
SC-Middletown-OH
                                      HNR
                                    2.1E-05
                                    0.2960
                                    0.0041
                                    0.00059
                                     0.30
SC-Vansant-VA
                                      HNR
                                    3.1E-05
                                    0.4445
                                    0.0061
                                    0.00088
                                     0.45
Industry Total TPY
                                       
                                    0.0011
                                     9.53
                                      2.7
                                     0.40
                                     12.6

      The remaining emissions (TPY) were calculated by subtracting the emission reductions (TPY) from the baseline emissions (TPY) per pollutant, as shown in Table C-11. 
      
      Table C-11. Remaining HAP Emissions for Pushing After BTF Controls
                                   Facility
                                 Facility Type
                Remaining HAP Emissions After BTF Control (TPY)
                                       
                                       
                                      Hg
                                      AG
                                      HCN
                                      PAH
                                   Total HAP
ABC-Tarrant-AL
                                      ByP
                                    1.3E-06
                                    0.00038
                                     0.012
                                     0.034
                                     0.046
BLU-Birmingham-AL
                                      ByP
                                    8.8E-07
                                    0.00025
                                    0.0078
                                     0.023
                                     0.031
CC-Follansbee-WV
                                      ByP
                                    3.1E-06
                                    0.00036
                                    0.0073
                                    0.0028
                                     0.010
CC-Middletown-OH
                                      ByP
                                    2.2E-06
                                   0.000057
                                    0.0011
                                    0.0020
                                    0.0032
CC-BurnsHarbor-IN
                                      ByP
                                    1.1E-05
                                    0.0023
                                     0.040
                                    0.0095
                                     0.051
CC-Monessen-PA
                                      ByP
                                    1.9E-06
                                    0.00020
                                    0.0062
                                    0.0017
                                    0.0081
CC-Warren-OH
                                      ByP
                                    2.0E-06
                                    0.00023
                                    0.0047
                                    0.0018
                                    0.0067
EES-RiverRouge-MI
                                      ByP
                                    5.5E-06
                                    0.00063
                                     0.013
                                    0.0049
                                     0.018
USS-Clairton-PA
                                      ByP
                                    2.1E-05
                                    0.0024
                                     0.049
                                     0.019
                                     0.070
SC-EastChicago-IN
                                      HNR
                                    4.0E-06
                                    0.0011
                                    0.00079
                                    0.00054
                                    0.0024
SC-FranklinFurnace-OH
                                      HNR
                                    2.1E-06
                                    0.00057
                                    0.00041
                                    0.00028
                                    0.0013
SC-GraniteCity-IL
                                      HNR
                                    1.3E-06
                                    0.00036
                                    0.00026
                                    0.00018
                                    0.00079
SC-Middletown-OH
                                      HNR
                                    1.1E-06
                                    0.00030
                                    0.00021
                                    0.00015
                                    0.00066
SC-Vansant-VA
                                      HNR
                                    1.6E-06
                                    0.00044
                                    0.00032
                                    0.00022
                                    0.00099
Industry Total TPY
                                       
                                    5.9E-05
                                    0.0095
                                     0.14
                                     0.10
                                     0.25

BTF Cost Effectiveness for Pushing

      To calculate $/ton cost effectiveness values, the annualized costs (shown in Table C-5 above) were divided by the emission reductions (shown in Table C-10 above). The resulting cost-effectiveness values for each HAP are shown in Table C-12. Note, the values presented were calculated from unrounded emissions.

        Table C-12. BTF Cost Effectiveness for Pushing with BTF Control
                                   Facility
                                 Facility Type
                          Cost Effectiveness ($/Ton)
                                       
                                       
                                   Hg w/ ACI
                                  PAH w/ ACI
                                   AG w/ WAS
                                  HCN w/ WAS
                       Total HAP w/ Ductwork + ACI + WAS
ABC-Tarrant-AL
                                      ByP
                                $20,137,014,535
                                  $3,719,300
                                  $20,117,653
                                  $33,909,877
                                  $11,029,023
BLU-Birmingham-AL
                                      ByP
                                $10,118,852,739
                                  $1,868,949
                                  $10,235,142
                                  $17,252,132
                                  $5,606,573
CC-Follansbee-WV
                                      ByP
                                $5,698,576,651
                                  $30,070,092
                                  $14,201,405
                                  $36,860,370
                                  $10,734,230
CC-Middletown-OH
                                      ByP
                                $3,984,816,088
                                  $21,026,967
                                  $44,909,171
                                 $118,409,951
                                  $31,614,463
CC-BurnsHarbor-IN
                                      ByP
                                $1,695,738,166
                                  $8,948,024
                                  $2,348,951
                                  $7,020,459
                                  $1,856,776
CC-Monessen-PA
                                      ByP
                                $4,764,290,887
                                  $25,140,078
                                  $13,114,861
                                  $21,824,933
                                  $8,584,227
CC-Warren-OH
                                      ByP
                                $4,455,861,992
                                  $23,512,569
                                  $11,177,459
                                  $29,011,584
                                  $8,444,908
EES-RiverRouge-MI
                                      ByP
                                $1,630,641,296
                                  $8,604,523
                                  $4,223,085
                                  $10,961,204
                                  $3,184,078
USS-Clairton-PA
                                      ByP
                                $2,119,707,509
                                  $11,185,214
                                  $5,432,407
                                  $14,100,050
                                  $4,098,626
SC-EastChicago-IN
                                      HNR
                                 $876,065,311
                                  $30,910,109
                                  $1,252,133
                                  $90,946,937
                                  $1,301,526
SC-FranklinFurnace-OH
                                      HNR
                                $3,367,434,787
                                 $118,812,804
                                  $4,383,400
                                 $318,382,147
                                  $4,579,949
SC-GraniteCity-IL
                                      HNR
                                $2,685,513,592
                                  $94,752,659
                                  $3,534,381
                                 $256,714,817
                                  $3,690,526
SC-Middletown-OH
                                      HNR
                                $3,222,616,310
                                 $113,703,191
                                  $4,203,361
                                 $305,305,267
                                  $4,391,325
SC-Vansant-VA
                                      HNR
                                $12,875,859,019
                                 $454,297,415
                                  $16,175,008
                                $1,174,849,175
                                  $16,935,659
Industry Total TPY
                                       
                                $3,246,376,430
                                  $9,053,273
                                  $6,049,479
                                  $21,292,325
                                  $4,871,700
Note: Total HAP=Hg+PAH+AG+HCN
      
C.3 ByP Battery Combustion Stack BTF Analysis

      For ByP battery combustion stack sources, Hg, PM, AG, and HCN MACT limits were developed, as described above in Section 3.0 and Appendix B. The BTF analysis includes the cost of adding ACI and a WAS to each ByP battery combustion stack source to reduce Hg, PM, AG, and HCN emissions further than the MACT limit. 
      
Input Parameters for BTF Controls for ByP Battery Combustion Stacks 

	The actual and standard exhaust flowrates and stack temperatures (°F) were compiled from the coke oven stack testing of Hg, PM, AG, HCN, and D/F TEQ at ByP battery combustion stack sources. Overall average exhaust flowrates and stack temperature were calculated from the stack tests to use as inputs for calculating BTF controls for ByP battery combustion stack sources. Table C-13 shows the average stack parameters for the ByP battery combustion stack sources. Copies of the coke oven stack test data are included in the coke oven PQBS docket (Docket ID No. EPA-HQ-OAR-2002-0085). 
      
      
       Table C-13. Average Stack Parameters for ByP Battery Combustion Stacks
                                   Facility
                                     Unit
                            Pollutant Tested Group
                              Flow Actual (acfm)
                           Flow Dry Standard (dscfm)
                             Temp Stack Gas (°F)
CC-Middletown-OH
Combustion Stack
                                      AG
                                    123,387
                                    76,729
                                      300
CC-Middletown-OH
Combustion Stack
                                      AG
                                    131,462
                                    75,239
                                      361
CC-Middletown-OH
Combustion Stack
                                      AG
                                    132,983
                                    74,360
                                      380
CC-Burnsharbor-IN
Coke Battery No. 2 Underfire Stack
                                      AG
                                    218,408
                                    100,594
                                     454.7
CC-Burnsharbor-IN
Coke Battery No. 2 Underfire Stack
                                      AG
                                    217,541
                                    99,696
                                     455.5
CC-Burnsharbor-IN
Coke Battery No. 2 Underfire Stack
                                      AG
                                    218,067
                                    100,278
                                     452.6
CC-Monessen-PA
Battery Combustion Stack #2
                                      AG
                                    19,397
                                    16,520
                                     492.8
CC-Monessen-PA
Battery Combustion Stack #2
                                      AG
                                    18,890
                                    16,619
                                     490.4
CC-Monessen-PA
Battery Combustion Stack #2
                                      AG
                                    17,731
                                    15,062
                                     492.8
EC-Erie-PA
Battery Combustion Stack (805)
                                      AG
                                    35,579
                                    24,512
                                     239.3
EC-Erie-PA
Battery Combustion Stack (805)
                                      AG
                                    35,503
                                    23,848
                                     247.1
EC-Erie-PA
Battery Combustion Stack (805)
                                      AG
                                    34,260
                                    23,579
                                     243.5
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                      AG
                                    158,169
                                    86,082
                                      383
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                      AG
                                    158,101
                                    83,729
                                      388
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                      AG
                                    155,928
                                    85,521
                                      378
CC-Middletown-OH
Combustion Stack
                                    D/F TEQ
                                    130,165
                                    76,880
                                      360
CC-Middletown-OH
Combustion Stack
                                    D/F TEQ
                                    130,997
                                    76,477
                                      362
CC-Middletown-OH
Combustion Stack
                                    D/F TEQ
                                    130,794
                                    75,905
                                      357
CC-Burnsharbor-IN
Coke Battery No. 2 Underfire Stack
                                    D/F TEQ
                                    208,932
                                    98,710
                                     447.6
CC-Burnsharbor-IN
Coke Battery No. 2 Underfire Stack
                                    D/F TEQ
                                    204,128
                                    97,304
                                      440
CC-Burnsharbor-IN
Coke Battery No. 2 Underfire Stack
                                    D/F TEQ
                                    202,834
                                    95,766
                                     440.1
CC-Monessen-PA
Battery Combustion Stack #2
                                    D/F TEQ
                                    37,657
                                    16,264
                                     540.2
CC-Monessen-PA
Battery Combustion Stack #2
                                    D/F TEQ
                                    34,547
                                    15,527
                                     526.5
CC-Monessen-PA
Battery Combustion Stack #2
                                    D/F TEQ
                                    33,155
                                    15,126
                                     480.5
EC-Erie-PA
Battery Combustion Stack (805)
                                    D/F TEQ
                                    35,436
                                    23,744
                                     245.7
EC-Erie-PA
Battery Combustion Stack (805)
                                    D/F TEQ
                                    38,773
                                    26,127
                                     247.9
EC-Erie-PA
Battery Combustion Stack (805)
                                    D/F TEQ
                                    37,797
                                    25,444
                                     250.2
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                    D/F TEQ
                                    178,713
                                    93,871
                                      387
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                    D/F TEQ
                                    183,768
                                    96,109
                                      394
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                    D/F TEQ
                                    180,255
                                    95,591
                                      388
CC-Middletown-OH
Combustion Stack
                                      HCN
                                    123,062
                                    80,559
                                      288
CC-Middletown-OH
Combustion Stack
                                      HCN
                                    125,023
                                    69,752
                                      360
CC-Middletown-OH
Combustion Stack
                                      HCN
                                    116,407
                                    63,312
                                      380
CC-Burnsharbor-IN
Coke Battery No. 2 Underfire Stack
                                      HCN
                                    218,408
                                    100,594
                                     454.7
CC-Burnsharbor-IN
Coke Battery No. 2 Underfire Stack
                                      HCN
                                    217,541
                                    99,696
                                     455.5
CC-Burnsharbor-IN
Coke Battery No. 2 Underfire Stack
                                      HCN
                                    218,067
                                    100,278
                                     452.6
CC-Monessen-PA
Battery Combustion Stack #2
                                      HCN
                                    32,138
                                    16,492
                                     432.4
CC-Monessen-PA
Battery Combustion Stack #2
                                      HCN
                                    34,774
                                    15,740
                                      526
CC-Monessen-PA
Battery Combustion Stack #2
                                      HCN
                                    34,617
                                    15,035
                                     546.3
EC-Erie-PA
Battery Combustion Stack (805)
                                      HCN
                                    35,579
                                    24,512
                                     239.3
EC-Erie-PA
Battery Combustion Stack (805)
                                      HCN
                                    35,503
                                    23,848
                                     247.1
EC-Erie-PA
Battery Combustion Stack (805)
                                      HCN
                                    34,260
                                    23,579
                                     243.5
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                      HCN
                                    181,355
                                    95,470
                                      393
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                      HCN
                                    191,878
                                    97,164
                                      396
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                      HCN
                                    185,778
                                    98,128
                                      390
CC-Middletown-OH
Combustion Stack
                                      Hg
                                    126,975
                                    78,619
                                      298
CC-Middletown-OH
Combustion Stack
                                      Hg
                                    124,885
                                    78,747
                                      292
CC-Middletown-OH
Combustion Stack
                                      Hg
                                    124,885
                                    78,747
                                      292
CC-Burnsharbor-IN
Coke Battery No. 2 Underfire Stack
                                      Hg
                                    202,185
                                    94,466
                                     451.3
CC-Burnsharbor-IN
Coke Battery No. 2 Underfire Stack
                                      Hg
                                    202,974
                                    96,241
                                     450.1
CC-Burnsharbor-IN
Coke Battery No. 2 Underfire Stack
                                      Hg
                                    201,951
                                    96,973
                                     440.9
CC-Monessen-PA
Battery Combustion Stack #2
                                      Hg
                                    32,134
                                    16,490
                                     432.4
CC-Monessen-PA
Battery Combustion Stack #2
                                      Hg
                                    34,769
                                    15,738
                                      526
CC-Monessen-PA
Battery Combustion Stack #2
                                      Hg
                                    34,626
                                    15,035
                                     546.3
EC-Erie-PA
Battery Combustion Stack (805)
                                      Hg
                                    33,951
                                    23,590
                                      230
EC-Erie-PA
Battery Combustion Stack (805)
                                      Hg
                                    35,394
                                    24,651
                                     231.2
EC-Erie-PA
Battery Combustion Stack (805)
                                      Hg
                                    35,296
                                    24,286
                                     236.5
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                      Hg
                                    175,965
                                    92,953
                                      383
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                      Hg
                                    174,627
                                    92,058
                                      381
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                      Hg
                                    174,436
                                    91,955
                                      387
CC-Middletown-OH
Combustion Stack
                                 PM Filterable
                                    126,975
                                    78,619
                                      311
CC-Middletown-OH
Combustion Stack
                                 PM Filterable
                                    125,146
                                    78,311
                                      302
CC-Middletown-OH
Combustion Stack
                                 PM Filterable
                                    124,623
                                    79,182
                                      281
CC-Burnsharbor-IN
Coke Battery No. 2 Underfire Stack
                                 PM Filterable
                                    202,185
                                    94,466
                                     451.3
CC-Burnsharbor-IN
Coke Battery No. 2 Underfire Stack
                                 PM Filterable
                                    202,974
                                    96,241
                                     450.1
CC-Burnsharbor-IN
Coke Battery No. 2 Underfire Stack
                                 PM Filterable
                                    201,951
                                    96,973
                                     440.9
CC-Monessen-PA
Battery Combustion Stack #2
                                 PM Filterable
                                    32,134
                                    16,490
                                     432.4
CC-Monessen-PA
Battery Combustion Stack #2
                                 PM Filterable
                                    34,769
                                    15,738
                                      526
CC-Monessen-PA
Battery Combustion Stack #2
                                 PM Filterable
                                    34,626
                                    15,035
                                     546.3
EC-Erie-PA
Battery Combustion Stack (805)
                                 PM Filterable
                                    33,951
                                    23,590
                                      230
EC-Erie-PA
Battery Combustion Stack (805)
                                 PM Filterable
                                    35,394
                                    24,651
                                     231.2
EC-Erie-PA
Battery Combustion Stack (805)
                                 PM Filterable
                                    35,296
                                    24,286
                                     236.5
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                 PM Filterable
                                    175,965
                                    92,953
                                      383
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                 PM Filterable
                                    174,627
                                    92,058
                                      381
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                 PM Filterable
                                    174,436
                                    91,955
                                      387
Average

                                       
                                    115,438
                                    61,286
                                      381
      
Development of Unit Costs for Ductwork for BTF Controls for ByP Battery Combustion Stacks

      The ductwork cost model from the Ferroalloy NESHAP RTR (EPA, 2015) was used to develop unit costs for ByP battery combustion stacks using specific data available for the coke industry. Table C-14 shows the ductwork unit costs for coke ByP battery combustion stacks.

Table C-14. Ductwork Unit Costs for BTF Controls for ByP Battery Combustion Stacks
                                  Parameters
                                   ByP Value
                               Source/Reference
DUCTS: COST BASE DATE:  GDP 1993
                                    68.877
BEA, 2023
COST ESCALATION: GDP 2022
                                    126.45
BEA, 2023
-- Inlet stream flowrate (acfm):
                                    115,438
Coke oven test data
-- Duct velocity (ft/min): 
                                     3,800
Ferroalloy (EPA, 2015)
-- Duct length (ft): 
                                      150
Engineering judgement
-- Material of construction: 
                                 Sheet-galv CS
Ferroalloy (EPA, 2015)
-- Insulation thickness (in.): (text input) 
                                       0
Ferroalloy (EPA, 2015)
-- Duct design: 
                             Circular-longitudinal
Ferroalloy (EPA, 2015)
-- Cost equation parameters: 
                                       

          a:
                                     2.03
Ferroalloy (EPA, 2015)
          b:
                                     0.784
Ferroalloy (EPA, 2015)
-- Cost equation form: 
                                       1
Ferroalloy (EPA, 2015)
-- Control system installation factor: 
                                       0
Ferroalloy (EPA, 2015)
   (if no system, enter '0')
                                       

-- Fan-motor combined efficiency (fraction):
                                      0.6
Ferroalloy (EPA, 2015)
DESIGN PARAMETERS
                                       

-- Duct diameter (in.):
                                      76
Ferroalloy (EPA, 2015)
-- Pressure drop (in. w.c.): 
                                       0
Ferroalloy (EPA, 2015)
CAPITAL COSTS
                                       

Ductwork Cost ($)--base:
                                    $9,081
Ferroalloy (EPA, 2015)
Ductwork Cost ($)--escalated:
                                    $16,672
Ferroalloy (EPA, 2015)
Purchased Equipment Cost ($):
                                    $18,006
Ferroalloy (EPA, 2015)
Retrofit Adjustment (25%)
                                    $22,507
Ferroalloy (EPA, 2015)
Total Capital Investment ($): 
                                    $33,761
Ferroalloy (EPA, 2015)
ANNUAL COST INPUTS
                                       

Operating factor (hours/year):
                                     8760
Coke oven test data
Electricity price ($/kWhr):
                                     0.067
Ferroalloy (EPA, 2015)
Annual interest rate (fractional):
                                     0.075
FRED, 2023
Ductwork economic life (years):
                                      20
Ferroalloy (EPA, 2015)
Capital recovery factor (system):
                                  0.098092192
Ferroalloy (EPA, 2015)
Taxes, insurance, admin. factor:
                                     0.04
Ferroalloy (EPA, 2015)
Labor, $/hr 
                                    $29.44
BLS, 2023
ANNUAL COSTS
                                       

Item
                                  Cost ($/yr)

Electricity
                                    $3,389
Ferroalloy (EPA, 2015)
Taxes, insurance, administrative
                                    $1,350
Ferroalloy (EPA, 2015)
Capital recovery
                                    $3,312
Ferroalloy (EPA, 2015)
Labor 
                                    $2,438
Ferroalloy (EPA, 2015)
Overhead 
                                    $1,463
Ferroalloy (EPA, 2015)
Total Annual Cost 
                                    $11,952
Ferroalloy (EPA, 2015)

Development of Unit Costs for ACI for BTF Controls for ByP Battery Combustion Stacks
 
      The ACI cost model from the Ferroalloy NESHAP RTR (EPA, 2015) was used to develop unit costs for ByP battery combustion stacks using specific data available for the coke industry. Table C-15 shows the ACI unit costs for BTF controls for ByP battery combustion stacks. 
 Table C-15. ACI Unit Costs for BTF Controls for ByP Battery Combustion Stacks
                                  Parameters
                                     Value
                               Source/Reference
Annual Operating Hours, hr/yr (H)
                                     8760
Coke oven test data
Exhaust Gas Flow Rate, acfm (Qa)
                                    115,438
Coke oven test data
Exhaust Gas Flow Rate, dscfm (Q)
                                    61,286
Coke oven test data
Operating Labor Rate, $/hr (LR)
                                    $29.44
BLS, 2023
Activated Carbon Cost, $/lb (ACC)
                                     $0.75
Ferroalloy (EPA, 2015)
Dust Disposal Cost, $/Ton (DDC, Non-Hazardous)
                                    $40.00
Ferroalloy (EPA, 2015)
Dust Disposal Cost, $/Ton (DDC, Hazardous)
                                    $400.00
Ferroalloy (EPA, 2015)
Capital Recovery Factor (CRF)
                                  0.098092192
CRF calculated assuming 20-year equipment life and 7.5% interest (FRED, 2023)
GDP, 2022
                                    126.45
BEA, 2023
GDP, 2008
                                    94.419
BEA, 2023
GDP, 1991
                                    65.783
BEA, 2023
ACI Adjustment Factor (AF)
                                     0.95
Calculated control efficiency
ACI Injection Rate (lb/MMacf)
                                      2.0
Ferroalloy (EPA, 2015)
Total Capital Investment, $ (TCI)
                                    $81,498
Calculated using algorithm 4,500 x (Q/1,976)0.6 x (1.2 retrofit factor) x CEPCI Adj.
Direct Annual Cost, $/yr (DAC)
                                       

Operating Labor
                                    $8,059
Calculated using (0.25 hr/8-hr shift) x H x LR
Supervisory Labor
                                    $1,209
Calculated using 0.15 x Operating Labor
Maintenance
                                    $16,300
Calculated using 0.2 x TCI
Activated Carbon
                                    $91,011

Dust Disposal (Non-Hazardous)
                                    $2,403
Calculated using ACI injection rate, 99% capture efficiency, and non-hazardous disposal cost
Dust Disposal (Hazardous)
                                    $24,027
Calculated using ACI injection rate, 99% capture efficiency, and hazardous disposal cost
Indirect Annual Cost, $/yr (IAC)
                                       

Overhead
                                    $15,341
Calculated using 0.6 x (Labor + Maintenance)
Property Tax, Insurance, & Admin
                                    $3,260
Calculated using 0.04 x TCI
Capital Recovery
                                    $7,994
Calculated using CRF x TCI
Total Annual Cost (Non-Hazardous)
                                   $145,576
Sum of DAC + IAC
Total Annual Cost (Hazardous)
                                   $167,201
Sum of DAC + IAC

Development of Unit Costs for WAS for BTF Controls for ByP Battery Combustion Stacks
 
      The WAS cost model from the Portland Cement NESHAP (EPA, 2010) was used to develop unit costs for ByP battery combustion stacks using specific data available for the coke industry. Table C-16 shows the WAS unit costs for BTF controls for coke ByP battery combustion stacks.
                                       
                                       
                                       

 Table C-16. WAS Unit Costs for BTF Controls for ByP Battery Combustion Stacks
                                 Capital Costs
Parameter
                                     Value
                               Source/Reference
Gas flowrate (dscfm)
                                    61,286
Coke oven test data
GDP 2010
                                    96.166
(BEA, 2023)
GDP 2022
                                    126.45
(BEA, 2023)
CC = Capital ($2022)
                                  $14,112,933
Portland Cement (EPA, 2010)
                                 Annual Costs
                                       
Parameter
                                     Value
                               Source/Reference
COSTKWH ($2022/kWhr)
                                  0.095199759
Portland Cement (EPA, 2010)
Annual interest rate (fraction):
                                     0.075
(FRED, 2023)
Control system life (years):
                                      20
Portland Cement (EPA, 2010)
CRF = Capital recovery factor:
                                  0.098092192
Portland Cement (EPA, 2010)
                                   Facility
                                    Source
                                 Type of Coke
                              Coke Production TPY
                           Operating Hours per year
                                      FC 
                               SO2 (lb/ton coke)
                                      VC
                                      TAC
                                       
                                       
                                       
                                Coke Oven Data
                                  Coke Oven 
                                     Data
                          Portland Cement (EPA, 2010)
                                Coke Oven Data
                Portland Cement (EPA, 2010 & Andover 2009)
                          Portland Cement (EPA, 2010)
ABC-Tarrant-AL
underfiring stack #4, serving batteries #5 and #6
                                    Foundry
                                    148,079
                                     8760
                                   $612,610
                                     0.55
                                    $4,773
                                  $2,001,752
ABC-Tarrant-AL
underfiring stack #1, serving battery #1
                                    Foundry
                                    377,606
                                     8760
                                   $648,852
                                     0.22
                                    $10,530
                                  $2,043,750
BLU-Birmingham-AL
underfiring stack of coke batteries no. 3 & 4
                                    Foundry
                                    203,045
                                     8760
                                   $622,639
                                     0.40
                                    $6,152
                                  $2,013,159
BLU-Birmingham-AL
underfiring stack of coke battery no. 5
                                    Foundry
                                    145,668
                                     8760
                                   $612,139
                                     0.56
                                    $4,712
                                  $2,001,220
CC-Follansbee-WV
Battery #1 Combustion
                                 Blast Furnace
                                    36,264
                                     8760
                                   $585,194
                                      49
                                    $23,861
                                  $1,993,423
CC-Follansbee-WV
Battery #2 Combustion
                                 Blast Furnace
                                    36,264
                                     8760
                                   $585,194
                                      49
                                    $23,861
                                  $1,993,423
CC-Follansbee-WV
Battery #3 Combustion
                                 Blast Furnace
                                    36,264
                                     8760
                                   $585,194
                                      49
                                    $23,861
                                  $1,993,423
CC-Follansbee-WV
Battery #8 Combustion
                                 Blast Furnace
                                    453,069
                                     8760
                                   $658,594
                                      3.9
                                    $34,314
                                  $2,077,277
CC-Middletown-OH
Wilputte Coke Oven Battery - Combustion Stack
                                 Blast Furnace
                                    401,752
                                     8760
                                   $652,048
                                      4.2
                                    $31,977
                                  $2,068,393
CC-BurnsHarbor-IN
EU512-08 battery #1 underfire
                                 Blast Furnace
                                    932,178
                                     8760
                                   $709,556
                                      5.2
                                    $86,279
                                  $2,180,203
CC-BurnsHarbor-IN
EU512-16 battery #2 underfire
                                 Blast Furnace
                                    955,975
                                     8760
                                   $711,766
                                      5.1
                                    $86,876
                                  $2,183,011
CC-Monessen-PA
Coke Oven Battery 1B Underfiring (Combustion Stack)
                                 Blast Furnace
                                    222,015
                                     8760
                                   $625,839
                                      1.3
                                    $9,266
                                  $2,019,473
CC-Monessen-PA
Coke Oven Battery 2 Underfiring (Combustion Stack)
                                 Blast Furnace
                                    114,007
                                     8760
                                   $605,627
                                      2.5
                                    $6,557
                                  $1,996,552
CC-Warren-OH
No. 4 Coke oven battery - Oven Underfiring
                                 Blast Furnace
                                    359,281
                                     8760
                                   $646,372
                                      4.9
                                    $31,962
                                  $2,062,703
EES-RiverRouge-MI
Battery Heating Stack
                                 Blast Furnace
                                    981,765
                                     8760
                                   $714,137
                                      1.8
                                    $47,574
                                  $2,146,079
USS-Clairton-PA
Coke Oven Battery 1 Underfiring
                                 Blast Furnace
                                    217,224
                                     8760
                                   $625,041
                                      1.2
                                    $8,754
                                  $2,018,164
USS-Clairton-PA
Coke Oven Battery 2 Underfiring
                                 Blast Furnace
                                    217,224
                                     8760
                                   $625,041
                                      1.2
                                    $8,754
                                  $2,018,164
USS-Clairton-PA
Coke Oven Battery 3 Underfiring
                                 Blast Furnace
                                    217,224
                                     8760
                                   $625,041
                                      1.2
                                    $8,754
                                  $2,018,164
USS-Clairton-PA
Coke Oven Battery 13 Underfiring
                                 Blast Furnace
                                    225,724
                                     8760
                                   $626,451
                                      1.1
                                    $8,968
                                  $2,019,788
USS-Clairton-PA
Coke Oven Battery 14 Underfiring
                                 Blast Furnace
                                    225,724
                                     8760
                                   $626,451
                                      1.1
                                    $8,968
                                  $2,019,788
USS-Clairton-PA
Coke Oven Battery 15 Underfiring
                                 Blast Furnace
                                    225,724
                                     8760
                                   $626,451
                                      1.1
                                    $8,968
                                  $2,019,788
USS-Clairton-PA
Coke Oven Battery 19 Underfiring
                                 Blast Furnace
                                    424,307
                                     8760
                                   $654,964
                                     0.60
                                    $13,948
                                  $2,053,280
USS-Clairton-PA
Coke Oven Battery 20 Underfiring
                                 Blast Furnace
                                    424,307
                                     8760
                                   $654,964
                                     0.60
                                    $13,948
                                  $2,053,280
USS-Clairton-PA
Coke Oven B Battery Underfiring
                                 Blast Furnace
                                    718,216
                                     8760
                                   $688,550
                                     0.35
                                    $21,319
                                  $2,094,238
USS-Clairton-PA
Coke Oven C Battery Underfiring
                                 Blast Furnace
                                    880,570
                                     8760
                                   $704,683
                                     0.29
                                    $25,391
                                  $2,114,443
Where:
CC = Capital ($2022) = 14,398*(DSCFM)[0.6]
Fixed costs (FC) include labor (operating, supervisory, and maintenance), maintenance materials, replacement parts, taxes, insurance, etc.:
FC = 38 * TPY[0.6] + 0.04 * CC
Variable costs (VC) include consumption of limestone, power, and water plus generation of scrubber slurry:
VC = (0.000844 * TPY * COSTKWH) + (0.013 * TPY * SO2) + (TPY * 0.025)
Total annualized cost (TAC) includes fixed annual costs, variable annual costs, and capital recovery interest rate, 20‐year lifetime, and a capital recovery factor:
TAC = FC + VC + CRF * CC

      
BTF Costs per Facility for ByP Battery Combustion Stacks

      It was assumed that the coke facilities will duct each ByP battery combustion stack to one APCD configuration. The unit APCD costs were multiplied by the required number of APCD configurations to calculate the total BTF costs for ByP battery combustion stacks per facility. The total BTF costs are shown in Table C-17.

     Table C-17. BTF Costs per Facility for ByP Battery Combustion Stacks
                                   Facility
                            No. APCD Configurations
                            Total Capital Cost ($)
                             Total Annual Cost ($)
                                       
                                       
                                   Ductwork
                                     ACI 
                                     WAS 
                                    Total 
                                   Ductwork
                                     ACI 
                                     WAS 
                                    Total 
ABC-Tarrant-AL
                                       2
                                    $67,522
                                   $162,995
                                  $28,225,867
                                  $28,456,384
                                    $23,904
                                   $334,401
                                  $4,045,502
                                  $4,403,807
BLU-Birmingham-AL
                                       2
                                    $67,522
                                   $162,995
                                  $28,225,867
                                  $28,456,384
                                    $23,904
                                   $334,401
                                  $4,014,379
                                  $4,372,684
CC-Follansbee-WV
                                       4
                                   $135,044
                                   $325,990
                                  $56,451,734
                                  $56,912,768
                                    $47,807
                                   $668,803
                                  $8,057,545
                                  $8,774,155
CC-Middletown-OH
                                       1
                                    $33,761
                                    $81,498
                                  $14,112,933
                                  $14,228,192
                                    $11,952
                                   $167,201
                                  $2,068,393
                                  $2,247,546
CC-BurnsHarbor-IN
                                       2
                                    $67,522
                                   $162,995
                                  $28,225,867
                                  $28,456,384
                                    $23,904
                                   $334,401
                                  $4,363,214
                                  $4,721,519
CC-Monessen-PA
                                       2
                                    $67,522
                                   $162,995
                                  $28,225,867
                                  $28,456,384
                                    $23,904
                                   $334,401
                                  $4,016,025
                                  $4,374,330
CC-Warren-OH
                                       1
                                    $33,761
                                    $81,498
                                  $14,112,933
                                  $14,228,192
                                    $11,952
                                   $167,201
                                  $2,062,703
                                  $2,241,855
EES-RiverRouge-MI
                                       1
                                    $33,761
                                    $81,498
                                  $14,112,933
                                  $14,228,192
                                    $11,952
                                   $167,201
                                  $2,146,079
                                  $2,325,232
USS-Clairton-PA
                                      10
                                   $337,610
                                   $814,976
                                 $141,129,335
                                 $142,281,920
                                   $119,518
                                  $1,672,007
                                  $20,429,098
                                  $22,220,623
Industry Total
                                       
                                   $844,024
                                  $2,037,439
                                 $352,823,337
                                 $355,704,800
                                   $298,795
                                  $4,180,016
                                  $51,202,939
                                  $55,681,750

BTF Emission Reductions for ByP Battery Combustion Stacks
      
      Baseline emissions for ByP battery combustion stacks were estimated from coke oven CAA section 114 requests data. The coke oven stack test data were used to develop industry average Hg, PM, Non-Hg metal HAP, AG, and HCN lb/ton coke default values per coke produced type, which were used to estimate emissions for the units that were not tested, as shown in Table C-18. 
      
              Table C-18. ByP Combustion Stack Default Baseline 
             Emission Factors (lb/ton coke) by Coke Type Produced
                                   Pollutant
                                 Blast Furnace
                                 (lb/ton coke)
                                   Foundry 
                                 (lb/ton coke)
Hg
                                   1.19E-05
                                   4.99E-06
PM
                                   4.14E-01
                                   1.00E-01
Non-Hg Metal HAP
                                   4.27E-04
                                   4.39E-04
AG
                                   2.57E-02
                                   8.56E-03
HCN
                                   1.54E-03
                                   3.77E-03
      
      In addition, the coke oven stack test data for similar units at the test facilities were used as "surrogate" data, where appropriate. The lb/ton coke emission factor developed for each battery combustion stack source (i.e., coke oven test data, similar unit, or default emission factor) were multiplied by each source's corresponding battery coke production value (TPY), as shown in Table C-19, and then divided by 2,000 to calculate TPY emissions. 
      
   Table C-19. Annual Coke Production Values by Facility and Emission Source
                                   Facility
                               Emission Source 
                              Coke Production TPY
ABC-Tarrant-AL
underfiring stack #4, serving batteries #5 and #6
                                    148,079
ABC-Tarrant-AL
underfiring stack #1, serving battery #1
                                    377,606
BLU-Birmingham-AL
underfiring stack of coke batteries no. 3 & 4
                                    203,045
BLU-Birmingham-AL
underfiring stack of coke battery no. 5
                                    145,668
CC-Follansbee-WV
battery #1 combustion
                                    36,264
CC-Follansbee-WV
battery #2 combustion
                                    36,264
CC-Follansbee-WV
battery #3 combustion
                                    36,264
CC-Follansbee-WV
battery #8 combustion
                                    453,069
CC-Middletown-OH
Wilputte coke oven battery - combustion stack
                                    401,752
CC-BurnsHarbor-IN
EU512-08 battery #1 underfire
                                    932,178
CC-BurnsHarbor-IN
EU512-16 battery #2 underfire
                                    955,975
CC-Monessen-PA
coke oven battery 1b underfiring (combustion stack)
                                    222,015
CC-Monessen-PA
coke oven battery 2 underfiring (combustion stack)
                                    114,007
CC-Warren-OH
no. 4 coke oven battery - oven underfiring
                                    359,281
EES-RiverRouge-MI
battery heating stack
                                    981,765
USS-Clairton-PA
coke oven battery 1 underfiring
                                    217,224
USS-Clairton-PA
coke oven battery 2 underfiring
                                    217,224
USS-Clairton-PA
coke oven battery 3 underfiring
                                    217,224
USS-Clairton-PA
coke oven battery 13 underfiring
                                    225,724
USS-Clairton-PA
coke oven battery 14 underfiring
                                    225,724
USS-Clairton-PA
coke oven battery 15 underfiring
                                    225,724
USS-Clairton-PA
coke oven battery 19 underfiring
                                    424,307
USS-Clairton-PA
coke oven battery 20 underfiring
                                    424,307
USS-Clairton-PA
coke oven b battery underfiring
                                    718,216
USS-Clairton-PA
coke oven c battery underfiring
                                    880,570
                                          
      
      The baseline PM and HAP emissions for all ByP battery combustion stacks at each facility were summed to produce a facility total for ByP battery combustion stacks. Table C-20 shows the baseline ByP battery combustion stack emissions for each facility. 

Table C-20. Baseline PM and HAP Emissions from ByP Battery Combustion Stacks Before BTF Controls
                                   Facility
                                       
                      Baseline PM and HAP Emissions (TPY)
                                       
                                      PM
                                      Hg
                               Non-Hg Metal HAP
                                      AG
                                      HCN
                                   Total HAP
ABC-Tarrant-AL
                                      26
                                    0.0013
                                     0.12
                                     2.250
                                     0.99
                                      3.4
BLU-Birmingham-AL
                                      17
                                    0.00087
                                     0.077
                                     1.493
                                     0.66
                                      2.2
CC-Follansbee-WV
                                      116
                                    0.0033
                                     0.12
                                     7.23
                                     0.43
                                      7.8
CC-Middletown-OH
                                      248
                                    0.00084
                                     0.079
                                     12.27
                                     0.61
                                      13
CC-BurnsHarbor-IN
                                      309
                                     0.030
                                     1.11
                                     15.44
                                      2.3
                                      19
CC-Monessen-PA
                                      3.9
                                    0.00065
                                     0.013
                                     1.743
                                     0.087
                                      1.8
CC-Warren-OH
                                      74
                                    0.0021
                                     0.077
                                     4.622
                                     0.28
                                      5.0
EES-RiverRouge-MI
                                      203
                                    0.0058
                                     0.21
                                     12.63
                                     0.75
                                      14
USS-Clairton-PA
                                      132
                                     0.013
                                     0.113
                                     28.53
                                     0.32
                                      29
Industry Total
                                     1,132
                                     0.059
                                      1.9
                                     86.2
                                      6.4
                                      95

      
      Table C-21 shows the control efficiencies of each APCD that were used to calculate the BTF emission reductions as shown in Table C-22. 
      
        Table C-21. Pollutants, APCD, Control Efficiency for BTF Controls
                                   Pollutant
                                     APCD
                              Control Efficiency
Hg
                                      ACI
                                      95%
PM
                                      WAS
                                      95%
Non-Hg Metal HAP
                                      WAS
                                      95%
AG
                                      WAS
                                     99.9%
HCN
                                      WAS
                                      95%

                                       
Table C-22. Reductions in PM and HAP Emissions for ByP Battery Combustion Stacks due to BTF Controls
                                   Facility
                   BTF PM and HAP Emission Reductions (TPY)
                                       
                                      PM
                                      Hg
                               Non-Hg Metal HAP
                                      AG
                                      HCN
                                   Total HAP
ABC-Tarrant-AL
                                      25
                                    0.0012
                                     0.11
                                     2.248
                                     0.94
                                      3.3
BLU-Birmingham-AL
                                      17
                                    0.00083
                                     0.073
                                     1.491
                                     0.62
                                      2.2
CC-Follansbee-WV
                                      111
                                    0.0032
                                     0.11
                                     7.22
                                     0.41
                                      7.7
CC-Middletown-OH
                                      236
                                    0.00080
                                     0.075
                                     12.26
                                     0.58
                                      13
CC-BurnsHarbor-IN
                                      294
                                     0.029
                                     1.05
                                     15.43
                                      2.2
                                      19
CC-Monessen-PA
                                       4
                                    0.00062
                                     0.012
                                     1.742
                                     0.083
                                      1.8
CC-Warren-OH
                                      71
                                    0.0020
                                     0.073
                                     4.617
                                     0.26
                                      5.0
EES-RiverRouge-MI
                                      193
                                    0.0055
                                     0.20
                                     12.62
                                     0.72
                                      14
USS-Clairton-PA
                                      126
                                     0.013
                                     0.108
                                     28.51
                                     0.31
                                      29
Industry Total
                                     1,076
                                     0.056
                                      1.8
                                     86.1
                                      6.1
                                      94

      The remaining emissions (TPY) shown in Table C-23 were calculated by subtracting the emission reductions (TPY) from the baseline emission values (TPY) per pollutant. 
                                       
Table C-23. Remaining PM and HAP Emissions for ByP Battery Combustion Stacks After BTF Controls
                                   Facility
            Remaining PM and HAP Emissions After BTF Control (TPY)
                                       
                                      PM
                                      Hg
                               Non-Hg Metal HAP
                                      AG
                                      HCN
                                   Total HAP
ABC-Tarrant-AL
                                      1.3
                                    6.6E-05
                                    0.0058
                                    0.0023
                                     0.050
                                     0.058
BLU-Birmingham-AL
                                     0.87
                                    4.4E-05
                                    0.0038
                                    0.0015
                                     0.033
                                     0.038
CC-Follansbee-WV
                                      5.8
                                    1.7E-04
                                    0.0060
                                    0.0072
                                     0.022
                                     0.035
CC-Middletown-OH
                                      12
                                    4.2E-05
                                    0.0040
                                     0.012
                                     0.030
                                     0.047
CC-BurnsHarbor-IN
                                      15
                                    1.5E-03
                                     0.055
                                     0.015
                                     0.12
                                     0.19
CC-Monessen-PA
                                     0.19
                                    3.2E-05
                                    0.00065
                                    0.0017
                                    0.0043
                                    0.0068
CC-Warren-OH
                                      3.7
                                    1.1E-04
                                    0.0038
                                    0.0046
                                     0.014
                                     0.022
EES-RiverRouge-MI
                                      10
                                    2.9E-04
                                     0.010
                                     0.013
                                     0.038
                                     0.061
USS-Clairton-PA
                                      6.6
                                    6.7E-04
                                    0.0057
                                     0.029
                                     0.016
                                     0.051
Industry Total
                                      57
                                    0.0029
                                     0.10
                                     0.086
                                     0.32
                                     0.51

BTF Cost Effectiveness for ByP Battery Combustion Stacks

      To calculate $/ton cost effectiveness values, annualized costs (shown in Table C-17 above) were divided by the emission reductions (shown in Table C-22 above), as shown in Table C-24. Note, the values presented were calculated from unrounded emissions.

Table C-24. BTF Cost Effectiveness for ByP Battery Combustion Stacks due to BTF Controls
                                   Facility
                          Cost Effectiveness ($/Ton)
                                       
                                   PM w/ WAS
                                   Hg w/ ACI
                            Non-Hg Metal HAP w/ WAS
                                   AG w/ WAS
                                  HCN w/ WAS
                       Total HAP w/ Ductwork + ACI + WAS
ABC-Tarrant-AL
                                   $161,942
                                 $268,348,778
                                  $36,919,417
                                  $1,797,626
                                  $4,084,754
                                  $1,334,522
BLU-Birmingham-AL
                                   $242,250
                                 $404,535,900
                                  $55,227,864
                                  $2,689,074
                                  $6,110,396
                                  $1,997,575
CC-Follansbee-WV
                                    $72,853
                                 $211,250,772
                                  $70,738,879
                                  $1,114,772
                                  $18,659,499
                                  $1,132,434
CC-Middletown-OH
                                    $8,765
                                 $209,769,848
                                  $27,504,449
                                   $168,611
                                  $3,407,155
                                   $174,124
CC-BurnsHarbor-IN
                                    $14,840
                                  $11,549,337
                                  $4,137,742
                                   $282,551
                                  $1,895,434
                                   $252,527
CC-Monessen-PA
                                  $1,089,924
                                 $542,136,384
                                 $325,126,362
                                  $2,303,642
                                  $46,213,136
                                  $2,381,080
CC-Warren-OH
                                    $29,166
                                  $82,591,175
                                  $28,319,618
                                   $446,288
                                  $7,470,148
                                   $452,492
EES-RiverRouge-MI
                                    $11,105
                                  $30,224,585
                                  $10,782,594
                                   $169,923
                                  $2,844,232
                                   $171,750
USS-Clairton-PA
                                   $162,510
                                 $130,823,571
                                 $189,882,137
                                   $715,952
                                  $63,377,305
                                   $768,024
Industry Total
                                    $47,607
                                  $74,718,217
                                  $28,169,513
                                   $593,933
                                  $7,965,453
                                   $591,704
Note: Total HAP=Hg+Non-Hg Metal HAP+AG+HCN
C.4 HNR HRSG Main Stack BTF Analysis

       For HNR HRSG main stack sources, Hg, PM, AG, and PAH MACT limits were developed, as described above in Section 3.0 and Appendix B. The BTF analysis includes the cost of adding ACI followed by a WAS to each HNR HRSG main stack. Note, HNR HRSG main stacks have existing controls (e.g., flue-gas desulfurization (FGD) and baghouses).
      
Input Parameters for BTF Controls for HNR HRSG Main Stacks 

	The actual and standard exhaust flowrates and stack temperatures (°F) were compiled from the coke oven stack testing of Hg, PM, AG, and PAH at HNR HRSG main stack sources. Overall average exhaust flowrates and stack temperature were calculated from the stack tests to use as inputs for calculating BTF controls for HNR HRSG main stack sources. Table C-25 shows the average stack parameters for the HNR HRSG main stack sources. Copies of the coke oven stack test data are included in the coke oven PQBS docket (Docket ID No. EPA-HQ-OAR-2002-0085). 
      
         Table C-25. Average Stack Parameters for HNR HRSG Main Stacks
                                   Facility
                                     Unit
                               Pollutant Tested
                              Flow Actual (acfm)
                           Flow Dry Standard (dscfm)
                             Temp Stack Gas (°F)
SC-Middletown-OH
P901- Coke Oven (Battery A-C) - Main Stack
                                      PAH
                                    390,869
                                    237,659
                                      243
SC-Middletown-OH
P901- Coke Oven (Battery A-C) - Main Stack
                                      PAH
                                    402,815
                                    242,390
                                      244
SC-Middletown-OH
P901- Coke Oven (Battery A-C) - Main Stack
                                      PAH
                                    388,639
                                    238,788
                                      241
SC-Middletown-OH
P901- Coke Oven (Battery A-C) - Main Stack
                                 PM Filterable
                                    382,427
                                    226,979
                                      248
SC-Middletown-OH
P901- Coke Oven (Battery A-C) - Main Stack
                                 PM Filterable
                                    388,162
                                    232,635
                                      247
SC-Middletown-OH
P901- Coke Oven (Battery A-C) - Main Stack
                                 PM Filterable
                                    386,648
                                    227,660
                                      247
SC-Middletown-OH
P901- Coke Oven (Battery A-C) - Main Stack
                                      Hg
                                       
                                    226,979
                                      248
SC-Middletown-OH
P901- Coke Oven (Battery A-C) - Main Stack
                                      Hg
                                       
                                    232,635
                                      247
SC-Middletown-OH
P901- Coke Oven (Battery A-C) - Main Stack
                                      Hg
                                       
                                    227,660
                                      247
SC-Middletown-OH
P901- Coke Oven (Battery A-C) - Main Stack
                                      AG
                                       
                                    231,980
                                      247
SC-Middletown-OH
P901- Coke Oven (Battery A-C) - Main Stack
                                      AG
                                       
                                    229,410
                                      248
SC-Middletown-OH
P901- Coke Oven (Battery A-C) - Main Stack
                                      AG
                                       
                                    229,448
                                      247
Average

                                       
                                    389,927
                                    232,019
                                      246
      
Development of Unit Costs for Ductwork for BTF Controls for HNR HRSG Main Stacks 

      The ductwork cost model from the Ferroalloy NESHAP RTR (EPA, 2015) was used to develop unit costs for HNR HRSG main stacks using specific data available for the coke industry. Table C-26 shows the ductwork unit costs for HNR HRSG main stacks.

   Table C-26. Ductwork Unit Costs for BTF Controls for HNR HRSG Main Stacks
                                  Parameters
                                   HNR Value
                               Source/Reference
DUCTS: COST BASE DATE:  GDP 1993
                                    68.877
BEA, 2023
COST ESCALATION: GDP 2022 
                                    126.45
BEA, 2023
-- Inlet stream flowrate (acfm):
                                    389,927
Coke oven test data
-- Duct velocity (ft/min): 
                                     3,800
Ferroalloy (EPA, 2015)
-- Duct length (ft): 
                                      150
Engineering judgement
-- Material of construction: 
                                 Sheet-galv CS
Ferroalloy (EPA, 2015)
-- Insulation thickness (in.): (text input) 
                                       0
Ferroalloy (EPA, 2015)
-- Duct design: 
                             Circular-longitudinal
Ferroalloy (EPA, 2015)
-- Cost equation parameters: 
                                       

          a:
                                     2.03
Ferroalloy (EPA, 2015)
          b:
                                     0.784
Ferroalloy (EPA, 2015)
-- Cost equation form: 
                                       1
Ferroalloy (EPA, 2015)
-- Control system installation factor: 
                                       0
Ferroalloy (EPA, 2015)
   (if no system, enter '0')
                                       

-- Fan-motor combined efficiency (fraction):
                                      0.6
Ferroalloy (EPA, 2015)
DESIGN PARAMETERS
                                       

-- Duct diameter (in.):
                                      76
Ferroalloy (EPA, 2015)
-- Pressure drop (in. w.c.): 
                                       0
Ferroalloy (EPA, 2015)
CAPITAL COSTS
                                       

Ductwork Cost ($)--base:
                                    $9,081
Ferroalloy (EPA, 2015)
Ductwork Cost ($)--escalated:
                                    $16,672
Ferroalloy (EPA, 2015)
Purchased Equipment Cost ($):
                                    $18,006
Ferroalloy (EPA, 2015)
Retrofit Adjustment (25%)
                                    $22,507
Ferroalloy (EPA, 2015)
Total Capital Investment ($): 
                                    $33,761
Ferroalloy (EPA, 2015)
ANNUAL COST INPUTS
                                       

Operating factor (hours/year):
                                     8760
Coke oven test data
Electricity price ($/kWhr):
                                     0.067
Ferroalloy (EPA, 2015)
Annual interest rate (fractional):
                                     0.075
FRED, 2023
Ductwork economic life (years):
                                      20
Ferroalloy (EPA, 2015)
Capital recovery factor (system):
                                  0.098092192
Ferroalloy (EPA, 2015)
Taxes, insurance, admin. factor:
                                     0.04
Ferroalloy (EPA, 2015)
Labor, $/hr 
                                    $29.44
BLS, 2023
ANNUAL COSTS
                                       

Item
                                  Cost ($/yr)

Electricity
                                    $11,449
Ferroalloy (EPA, 2015)
Taxes, insurance, administrative
                                    $1,350
Ferroalloy (EPA, 2015)
Capital recovery
                                    $3,312
Ferroalloy (EPA, 2015)
Labor 
                                    $2,438
Ferroalloy (EPA, 2015)
Overhead 
                                    $1,463
Ferroalloy (EPA, 2015)
Total Annual Cost 
                                    $20,011
Ferroalloy (EPA, 2015)

Development of Unit Costs for ACI for BTF controls for HNR HRSG Main Stacks
 
      The ACI cost model from the Ferroalloy NESHAP RTR (EPA, 2015) was used to develop unit costs for HNR HRSG main stacks using specific data available for the coke industry. Table C-27 shows the ACI unit costs for HNR HRSG main stacks. 

     Table C-27. ACI Unit Costs for BTF Controls for HNR HRSG Main Stacks
                                  Parameters
                                     Value
                               Source/Reference
Annual Operating Hours, hr/yr (H)
                                     8760
Coke oven test data
Exhaust Gas Flow Rate, acfm (Qa)
                                    389,927
Coke oven test data
Exhaust Gas Flow Rate, dscfm (Q)
                                    232,019
Coke oven test data
Operating Labor Rate, $/hr (LR)
                                    $29.44
BLS, 2023
Activated Carbon Cost, $/lb (ACC)
                                     $0.75
Ferroalloy (EPA, 2015)
Dust Disposal Cost, $/Ton (DDC, Non-Hazardous)
                                    $40.00
Ferroalloy (EPA, 2015)
Dust Disposal Cost, $/Ton (DDC, Hazardous)
                                    $400.00
Ferroalloy (EPA, 2015)
Capital Recovery Factor (CRF)
                                  0.098092192
CRF calculated assuming 20-year equipment life and 7.5% interest (FRED, 2023)
GDP, 2022
                                    126.45
BEA, 2023
GDP, 2008
                                    94.419
BEA, 2023
GDP, 1991
                                    65.783
BEA, 2023
ACI Adjustment Factor (AF)
                                     0.95
Calculated control efficiency
ACI Injection Rate (lb/MMacf)
                                      2.0
Ferroalloy (EPA, 2015)
Total Capital Investment, $ (TCI)
                                   $181,151
Calculated using algorithm 4,500 x (Q/1,976)0.6 x (1.2 retrofit factor) x CEPCI Adj.
Direct Annual Cost, $/yr (DAC)
                                       

Operating Labor
                                    $8,059
Calculated using (0.25 hr/8-hr shift) x H x LR
Supervisory Labor
                                    $1,209
Calculated using 0.15 x Operating Labor
Maintenance
                                   $36,230 
Calculated using 0.2 x TCI
Activated Carbon
                                   $307,418

Dust Disposal (Non-Hazardous)
                                    $8,116
Calculated using ACI injection rate, 99% capture efficiency, and non-hazardous disposal cost
Dust Disposal (Hazardous)
                                    $81,158
Calculated using ACI injection rate, 99% capture efficiency, and hazardous disposal cost
Indirect Annual Cost, $/yr (IAC)
                                       

Overhead
                                    $27,299
Calculated using 0.6 x (Labor + Maintenance)
Property Tax, Insurance, & Admin
                                    $7,246 
Calculated using 0.04 x TCI
Capital Recovery
                                   $17,769 
Calculated using CRF x TCI
Total Annual Cost (Non-Hazardous)
                                   $413,347
Sum of DAC + IAC
Total Annual Cost (Hazardous)
                                   $486,389
Sum of DAC + IAC

Development of Unit Costs for WAS for BTF Controls for HNR HRSG Main Stacks 

      The WAS cost model from the Portland Cement NESHAP (EPA, 2010) was used to develop unit costs for HNR HRSG main stacks using specific data available for the coke industry. Table C-27 shows the WAS unit costs for HNR HRSG main stacks.
      
     Table C-27. WAS Unit Costs for BTF Controls for HNR HRSG Main Stacks
                                 Capital Costs
Parameter
                                     Value
                               Source/Reference
Gas flowrate (dscfm)
                                    389,927
Coke oven test data
GDP 2010
                                    96.166
BEA, 2023
GDP 2022
                                    126.45
BEA, 2023
CC = Capital ($2022)
                                  $42,834,066
Portland Cement 
(EPA, 2010)
                                 Annual Costs
Parameter
                                     Value
                                       
COSTKWH ($2022/kWhr)
                                  0.095199759
Portland Cement 
(EPA, 2010)
Annual interest rate (fraction):
                                     0.075
FRED, 2023
Control system life (years):
                                      20
Portland Cement 
(EPA, 2010)
CRF = Capital recovery factor:
                                  0.098092192
Portland Cement 
(EPA, 2010)
                                   Facility
                                 Facility Type
                                 Type of Coke
                              Coke Production TPY
                           Operating Hours per year
                                 Fixed Costs 
                         SO2 = lb SO2 per ton of coke
                                   Variable
                                     Costs
                                      TAC
                                       
                                       
                                       
                                Coke Oven Data
                                  Coke Oven 
                                     Data
                          Portland Cement (EPA, 2010)
                                  Coke Oven 
                                     Data
                Portland Cement (EPA, 2010 & Andover 2009)
                          Portland Cement (EPA, 2010)
SC-EastChicago-IN
                                      HNR
                                 Blast furnace
                                   1,300,000
                                     8,760
                                  $1,890,435
                                     1.17
                                    $52,420
                                  $6,144,542
SC-FranklinFurnace-OH
                                      HNR
                                 Blast furnace
                                    341,657
                                     8,760
                                  $1,792,784
                                     4.46
                                    $28,385
                                  $6,022,856
SC-GraniteCity-IL
                                      HNR
                                 Blast furnace
                                    428,412
                                     8,760
                                  $1,804,333
                                     3.56
                                    $30,561
                                  $6,036,581
SC-Middletown-OH
                                      HNR
                                 Blast furnace
                                    357,010
                                     8,760
                                  $1,794,907
                                     4.27
                                    $28,770
                                  $6,025,364
Note: CC = Capital ($2022) = 14,398*(DSCFM)[0.6]. 
Fixed costs include labor (operating, supervisory, and maintenance), maintenance materials, replacement parts, taxes, insurance, etc. FC = 38 * TPY[0.6] + 0.04 * CC. 
Variable costs (VC) include consumption of limestone, power, and water plus generation of scrubber slurry. VC = (0.000844 * TPY * COSTKWH) + (0.013 * TPY * SO2) + (TPY * 0.025). 
Total annualized cost (TAC) includes fixed annual costs, variable annual costs, and capital recovery interest rate, 20‐year lifetime, and a capital recovery factor: TAC = FC + VC + CRF * CC

BTF Costs per Facility for HNR HRSG Main Stacks

      It was assumed that the coke facilities will duct each HNR HRSG main stack to one BTF APCD configuration. The unit APCD costs were multiplied by the required number of APCD configurations to calculate the total BTF HNR HRSG main stack costs per facility. The Total BTF HNR HRSG main stack costs are shown in Table C-28.

                                       
          Table C-28. BTF Costs per Facility for HNR HRSG Main Stacks
                                   Facility
                            No. APCD Configurations
                            Total Capital Cost ($)
                             Total Annual Cost ($)
                                       
                                       
                                   Ductwork
                                      ACI
                                      WAS
                                     Total
                                   Ductwork
                                      ACI
                                      WAS
                                     Total
SC-EastChicago-IN
                                       1
                                    $33,761
                                   $181,151
                                  $42,834,066
                                  $43,048,978
                                    $20,011
                                   $486,389
                                  $6,144,542
                                  $6,650,943
SC-FranklinFurnace-OH
                                       2
                                    $67,522
                                   $362,302
                                  $85,668,132
                                  $86,097,956
                                    $40,022
                                   $972,779
                                  $12,045,712
                                  $13,058,514
SC-GraniteCity-IL
                                       1
                                    $33,761
                                   $181,151
                                  $42,834,066
                                  $43,048,978
                                    $20,011
                                   $486,389
                                  $6,036,581
                                  $6,542,982
SC-Middletown-OH
                                       1
                                    $33,761
                                   $181,151
                                  $42,834,066
                                  $43,048,978
                                    $20,011
                                   $486,389
                                  $6,025,364
                                  $6,531,764
Industry Total
                                       
                                   $168,805
                                   $905,754
                                 $214,170,330
                                 $215,244,889
                                   $100,056
                                  $2,431,947
                                  $30,252,200
                                  $32,784,203

BTF Emission Reductions for HNR HRSG Main Stacks

      Baseline emissions were estimated from coke oven CAA section 114 requests data. The coke oven stack test data were used to develop industry average Hg, PM, Non-Hg metal HAP, AG, and total PAH lb/hr default values for the units that were not tested, as shown in Table C-29. 
      
                   Table C-29. HNR HRSG Main Stack Default 
                      Baseline Emission Factors (lb/hr) 
                                   Pollutant
                              HNR HRSG Main Stack
                                    (lb/hr)
Hg
                                   6.50E-03
PM 
                                   3.76E+00
Non-Hg Metal HAP
                                   1.90E-02
AG
                                   2.92E+01
PAH
                                   1.29E-03
      
      The lb/hr coke emission factor developed for each HNR HRSG main stack source (i.e., coke oven test data or default emission factor) were multiplied by each source's corresponding annual operating hours (hours/year), as shown in Table C-30, and then divided by 2,000 to calculate TPY emissions. 
      
          Table C-30. Annual Operating Hours per HNR HRSG Main Stack
                                   Facility
                                Emission Source
                            Annual Operating Hours
SC-EastChicago-IN
HRCCF MAIN STACK 001
                                     8,760
SC-FranklinFurnace-OH
P901- Coke Ovens (Battery A&B) - Main Stack AB
                                     8,760
SC-FranklinFurnace-OH
P902- Coke Ovens (Battery C&D) - Main Stack CD
                                     8,760
SC-GraniteCity-IL
0005 -Coke Ovens (Battery A&B&C) - Main Stack
                                     8,760
SC-Middletown-OH
P901- Coke Oven (Battery A-C) - Main Stack
                                     8,760
      
      The baseline PM and HAP emissions for HNR HRSG main stacks were summed for each facility. Table C-31 shows the baseline emissions. 

Table C-31. Baseline PM and HAP Emissions from HNR HRSG Main Stacks Before BTF Controls
                                   Facility
                      Baseline PM and HAP Emissions (TPY)
                                       
                                      PM
                                      Hg
                               Non-Hg Metal HAP
                                      AG
                                      PAH
                                   Total HAP
SC-EastChicago-IN
                                      10
                                     0.049
                                     0.049
                                     236.3
                                    0.0079
                                      236
SC-FranklinFurnace-OH
                                      33
                                     0.057
                                     0.167
                                     255.5
                                     0.011
                                      256
SC-GraniteCity-IL
                                      16
                                     0.028
                                     0.083
                                     127.7
                                    0.0056
                                      128
SC-Middletown-OH
                                      23
                                    0.0077
                                     0.12
                                     19.2
                                    0.0034
                                      19
Industry Total
                                      82
                                     0.14
                                     0.42
                                     638.7
                                     0.028
                                      639

      Table C-32 shows the control efficiencies of each APCD that were used to calculate the BTF emission reductions as shown in Table C-33. 

       Table C-32. Pollutants, APCD, Control Efficiency for BTF Controls
                                   Pollutant
                                     APCD
                              Control Efficiency
Hg
                                      ACI
                                      95%
PAH
                                      ACI
                                      80%
PM
                                      WAS
                                      95%
Non-Hg Metal HAP
                                      WAS
                                      95%
AG
                                      WAS
                                     99.9%

Table C-33. Reductions in PM and HAP Emissions for HNR HRSG Main Stacks due to BTF Controls 
                                   Facility
                   BTF PM and HAP Emission Reductions (TPY)
                                       
                                      PM 
                                      Hg
                               Non-Hg Metal HAP)
                                      AG
                                     PAH 
                                  Total HAP 
SC-EastChicago-IN
                                      10
                                     0.047
                                     0.046
                                     236.0
                                    0.0063
                                      236
SC-FranklinFurnace-OH
                                      31
                                     0.054
                                     0.16
                                     255.2
                                    0.0090
                                      255
SC-GraniteCity-IL
                                      16
                                     0.027
                                     0.079
                                     127.6
                                    0.0045
                                      128
SC-Middletown-OH
                                      22
                                    0.0074
                                     0.11
                                     19.2
                                    0.0027
                                      19
Industry Total
                                      78
                                     0.14
                                     0.40
                                     638.1
                                     0.023
                                      639

      The remaining emissions (TPY) were calculated by subtracting the emission reductions (TPY) from the baseline emission values (TPY) per pollutant, as shown in Table C-34. 

Table C-34. Remaining PM and HAP Emissions for HNR HRSG Main Stacks After BTF Controls
                                   Facility
            Remaining PM and HAP Emissions After BTF Control (TPY)
                                       
                                      PM
                                      Hg
                               Non-Hg Metal HAP 
                                      AG
                                     PAH 
                                   Total HAP
SC-EastChicago-IN
                                     0.51
                                    0.0025
                                    0.0024
                                     0.24
                                    0.0016
                                     0.24
SC-FranklinFurnace-OH
                                      1.6
                                    0.0028
                                    0.0083
                                     0.26
                                    0.0023
                                     0.27
SC-GraniteCity-IL
                                     0.82
                                    0.0014
                                    0.0042
                                     0.13
                                    0.0011
                                     0.13
SC-Middletown-OH
                                      1.1
                                    0.00039
                                    0.0059
                                     0.019
                                    0.00068
                                     0.026
Industry Total
                                      4.1
                                    0.0071
                                     0.021
                                     0.64
                                    0.0056
                                     0.67

BTF Cost Effectiveness for HNR HRSG Main Stacks

      To calculate $/ton cost effectiveness values, annualized costs (shown in Table C-28 above) were divided by the emission reductions (shown in Table C-33 above), as shown in Table C-35. Note, the values presented were calculated from unrounded emissions and cost values.

Table C-35. BTF Cost Effectiveness for HNR HRSG Main Stacks due to BTF Controls
                                   Facility
                          Cost Effectiveness ($/Ton)
                                       
                                   PM w/ WAS
                                   Hg w/ ACI
                            Non-Hg Metal HAP w/ WAS
                                   AG w/ WAS
                                  PAH w/ ACI
                       Total HAP w/ Ductwork + ACI + WAS
SC-EastChicago-IN
                                   $638,671
                                  $10,403,650
                                 $132,439,323
                                    $26,035
                                  $77,048,210
                                    $28,168
SC-FranklinFurnace-OH
                                   $385,193
                                  $17,980,159
                                  $76,047,707
                                    $47,196
                                 $107,654,422
                                    $51,120
SC-GraniteCity-IL
                                   $386,071
                                  $17,980,159
                                  $76,221,005
                                    $47,304
                                 $107,654,422
                                    $51,227
SC-Middletown-OH
                                   $278,294
                                  $66,165,532
                                  $53,797,105
                                   $313,627
                                 $178,600,852
                                   $337,839
Industry Total
                                   $386,957
                                  $66,165,532
                                  $54,020,996
                                   $314,932
                                 $178,600,852
                                   $339,136
Note: Total HAP=Hg+Non-Hg Metal HAP+AG

C.5 HNR HRSG Bypass/Waste Heat Stack BTF Analysis

      For HNR HRSG bypass/waste heat stack sources, Hg, PM, AG, Total PAH, and Formaldehyde MACT limits were developed, as described above in Section 3.0 and Appendix B. The BTF analysis includes the cost of adding ACI, WAS, and regenerative thermal oxidizer (RTO) to HNR HRSG bypass/waste heat stacks ducted together to reduce Hg, PM, AG, Total PAH, and Formaldehyde emissions further than the MACT limit.
      
Input Parameters for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks 

	The actual and standard exhaust flowrates and stack temperatures (°F) were compiled from the coke oven stack testing of Hg, PM, AG, Total PAH, and Formaldehyde at the HNR HRSG bypass/waste heat stack sources. Overall average exhaust flowrates and stack temperature were calculated from the stack tests to use as inputs for calculating BTF controls for HNR HRSG bypass/waste heat stack sources. Table C-36 shows the average stack parameters for the HNR HRSG bypass/waste heat stack sources. Copies of the coke oven stack test data are included in the coke oven PQBS docket (Docket ID No. EPA-HQ-OAR-2002-0085). The flowrates used for SC-Vansant-VA waste heat stacks were further adjusted to account for the oven per stack ratio, similarly to how the TPY emissions were adjusted, as described in the Coke Ovens Risk and Technology Review: Data Summary memorandum ( EPA, 2023A).
      
  Table C-36. Average Stack Parameters for HNR HRSG Bypass/Waste Heat Stacks
                                   Facility
                                     Unit
                               Pollutant Tested
                              Flow Actual (acfm)
                           Flow Dry Standard (dscfm)
                             Temp Stack Gas (°F)
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      Hg
                                       
                                    52,474
                                     1,275
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      Hg
                                       
                                    48,744
                                     1,353
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      Hg
                                       
                                    54,456
                                     1,322
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                 PM Filterable
                                       
                                    52,474
                                     1,275
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                 PM Filterable
                                       
                                    48,744
                                     1,353
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                 PM Filterable
                                       
                                    54,456
                                     1,322
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      AG
                                    199,250
                                    49,898
                                     1,402
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      AG
                                    206,413
                                    48,646
                                     1,517
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      AG
                                    212,791
                                    56,009
                                     1,303
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      HCN
                                    199,752
                                    49,475
                                     1,408
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      HCN
                                    202,042
                                    46,157
                                     1,505
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      HCN
                                    205,236
                                    49,979
                                     1,416
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      PAH
                                       
                                    52,658
                                     1,376
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      PAH
                                       
                                    52,292
                                     1,371
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      PAH
                                       
                                    53,545
                                     1,487
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                    D/F TEQ
                                       
                                    52,658
                                     1,376
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                    D/F TEQ
                                       
                                    52,292
                                     1,371
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                    D/F TEQ
                                       
                                    53,545
                                     1,487
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                     VOHAP
                                    202,369
                                    50,021
                                     1,408
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                     VOHAP
                                    201,547
                                    46,112
                                     1,505
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                     VOHAP
                                    211,675
                                    51,493
                                     1,409
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                 Formaldehyde
                                       
                                    50,566
                                     1,408
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                 Formaldehyde
                                       
                                    46,067
                                     1,505
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                 Formaldehyde
                                       
                                    53,007
                                     1,402
Average

                                    204,564
                                    51,134
                                     1,410
      
      
Development of Unit Costs for Ductwork for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks 
      
      It was assumed that SC-EastChicago-IN and SC-Vansant-VA will duct eight of their sixteen HNR HRSG bypass/waste heat stacks together and route to a series of air pollution control devices, for a set of two APCD configurations per facility; SC-GraniteCity-IL will duct their six HNR HRSG bypass/waste heat stacks together and route to a series of air pollution control devices, for one APCD configuration; SC-FranklinFurnace-OH will duct five of their ten HNR HRSG bypass/waste heat stacks together and route to a series of air pollution control devices, for a set of two APCD configurations; and SC-Middletown-OH will duct their five HNR HRSG bypass/waste heat stacks together and route to a series of air pollution control devices, for one APCD configuration.
      
      The ductwork cost model from the Ferroalloy NESHAP RTR (EPA, 2015) was used to develop unit costs for HNR HRSG bypass/waste heat stacks using specific data available for the coke industry. Table C-37 shows the ductwork unit costs for HNR HRSG bypass/waste heat stacks.
Table C-37. Ductwork Unit Costs for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks
                                  Parameters
                           Ductwork Unit Cost Values
                               Source/Reference
                                       
                               SC-EastChicago-IN
                          Ducting 8 Stacks Together 
                                 SC-Vansant-VA
         Ducting 8 Stacks Together, adjusted for Oven-to-Stack Ratio 
                 SC-GraniteCity-IL Ducting 6 Stacks Together 
                             SC-FranklinFurnace-OH
                          Ducting 5 Stacks Together 
                               SC-Middletown-OH
                          Ducting 5 Stacks Together 
                                       
Ducts: Cost Base Date:  GDP 1993
                                    68.877
                                    68.877
                                    68.877
                                    68.877
                                    68.877
BEA, 2023
Cost Escalation: GDP 2022 
                                    126.45
                                    126.45
                                    126.45
                                    126.45
                                    126.45
BEA, 2023
-- Inlet stream flowrate (acfm):
                                   1,636,512
                                    731,316
                                   1,227,384
                                   1,022,820
                                   1,022,820
Coke oven test data
-- Duct velocity (ft/min): 
                                     3,800
                                     3,800
                                     3,800
                                     3,800
                                     3,800
Ferroalloy (EPA, 2015)
-- Duct length (ft): 
                                     1200
                                     1200
                                      900
                                      750
                                      750
Engineering judgement
-- Material of construction: 
                                 Sheet-galv CS
                                 Sheet-galv CS
                                 Sheet-galv CS
                                 Sheet-galv CS
                                 Sheet-galv CS
Ferroalloy (EPA, 2015)
-- Insulation thickness (in.): (text input) 
                                       0
                                       0
                                       0
                                       0
                                       0
Ferroalloy (EPA, 2015)
-- Duct design: 
                             Circular-longitudinal
                             Circular-longitudinal
                             Circular-longitudinal
                             Circular-longitudinal
                             Circular-longitudinal
Ferroalloy (EPA, 2015)
-- Cost equation parameters: 
                                       
                                       
                                       
                                       
                                       

          a:
                                     2.03
                                     2.03
                                     2.03
                                     2.03
                                     2.03
Ferroalloy (EPA, 2015)
          b:
                                     0.784
                                     0.784
                                     0.784
                                     0.784
                                     0.784
Ferroalloy (EPA, 2015)
-- Cost equation form: 
                                       1
                                       1
                                       1
                                       1
                                       1
Ferroalloy (EPA, 2015)
-- Control system installation factor: 
                                       0
                                       0
                                       0
                                       0
                                       0
Ferroalloy (EPA, 2015)
   (if no system, enter '0')
                                       
                                       
                                       
                                       
                                       

-- Fan-motor combined efficiency (fraction):
                                      0.6
                                      0.6
                                      0.6
                                      0.6
                                      0.6
Ferroalloy (EPA, 2015)
Design Parameters
                                       
                                       
                                       
                                       
                                       

-- Duct diameter (in.):
                                      76
                                      76
                                      76
                                      76
                                      76
Ferroalloy (EPA, 2015)
-- Pressure drop (in. w.c.): 
                                       2
                                       2
                                       2
                                       2
                                       2
Ferroalloy (EPA, 2015)
CAPITAL COSTS
                                       
                                       
                                       
                                       
                                       

Ductwork Cost ($)--base:
                                    $72,650
                                    $72,650
                                    $54,487
                                    $45,406
                                    $45,406
Ferroalloy (EPA, 2015)
Ductwork Cost ($)--escalated:
                                   $133,377
                                   $133,377
                                   $100,032
                                    $83,360
                                    $83,360
Ferroalloy (EPA, 2015)
Purchased Equipment Cost ($):
                                   $144,047
                                   $144,047
                                   $108,035
                                    $90,029
                                    $90,029
Ferroalloy (EPA, 2015)
Retrofit Adjustment (25%)
                                   $180,058
                                   $180,058
                                   $135,044
                                   $112,537
                                   $112,537
Ferroalloy 
(EPA, 2015)
Total Capital Investment ($): 
                                   $270,088
                                   $270,088
                                   $202,566
                                   $168,805
                                   $168,805
Ferroalloy (EPA, 2015)
ANNUAL COST INPUTS
                                       
                                       
                                       
                                       
                                       

Operating factor (hours/year):
                                    1138.8
                                     8760
                                      312
                                      192
                                      312
Coke oven test data
Electricity price ($/kWhr):
                                     0.067
                                     0.067
                                     0.067
                                     0.067
                                     0.067
Ferroalloy 
(EPA, 2015)
Annual interest rate (fractional):
                                     0.075
                                     0.075
                                     0.075
                                     0.075
                                     0.075
FRED, 2023
Ductwork economic life (years):
                                      20
                                      20
                                      20
                                      20
                                      20
Ferroalloy 
(EPA, 2015)
Capital recovery factor (system):
                                  0.098092192
                                  0.098092192
                                  0.098092192
                                  0.098092192
                                  0.098092192
Ferroalloy (EPA, 2015)
Taxes, insurance, admin. factor:
                                     0.04
                                     0.04
                                     0.04
                                     0.04
                                     0.04
Ferroalloy (EPA, 2015)
Labor, $/hr 
                                    $29.44
                                    $29.44
                                    $29.44
                                    $29.44
                                    $29.44
BLS, 2023
ANNUAL COSTS
                                       
                                       
                                       
                                       
                                       

Item
                                  Cost ($/yr)
                                  Cost ($/yr)
                                  Cost ($/yr)
                                  Cost ($/yr)
                                  Cost ($/yr)

Electricity
                                    $49,973
                                   $171,781
                                    $7,701
                                    $3,291
                                    $5,348
Ferroalloy (EPA, 2015)
Taxes, insurance, administrative
                                    $10,804
                                    $10,804
                                    $8,103
                                    $6,752
                                    $6,752
Ferroalloy (EPA, 2015)
Capital recovery
                                    $26,493
                                    $26,493
                                    $19,870
                                    $16,558
                                    $16,558
Ferroalloy (EPA, 2015)
Labor 
                                    $2,438
                                    $2,438
                                    $2,438
                                    $2,438
                                    $2,438
Ferroalloy (EPA, 2015)
Overhead 
                                    $1,463
                                    $1,463
                                    $1,463
                                    $1,463
                                    $1,463
Ferroalloy (EPA, 2015)
TOTAL ANNUAL COST 
                                    $91,170
                                   $212,978
                                    $39,574
                                    $30,502
                                    $32,559
Ferroalloy (EPA, 2015)

Development of Unit Costs for ACI for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks 
 
      The ACI cost model from the Ferroalloy NESHAP RTR (EPA, 2015) was used to develop unit costs for HNR HRSG bypass/waste heat stacks using specific data available for the coke industry. Table C-38 shows the ACI unit costs for HNR HRSG bypass/waste heat stacks. 

                                       
Table C-38. ACI Unit Costs for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks
                                  Parameters
                             ACI Unit Cost Values
                               Source/Reference
                                       
                               SC-EastChicago-IN
                          Ducting 8 Stacks Together 
                                 SC-Vansant-VA
          Ducting 8 Stacks Together, Adjusted for Oven-to-Stack Ratio
                 SC-GraniteCity-IL Ducting 6 Stacks Together 
                             SC-FranklinFurnace-OH
                          Ducting 5 Stacks Together 
                               SC-Middletown-OH
                          Ducting 5 Stacks Together 
                                       
Annual Operating Hours, hr/yr (H)
                                    1138.8
                                     8760
                                      312
                                      192
                                      312
Coke oven test data
Exhaust Gas Flow Rate, acfm (Qa)
                                   1,636,512
                                    731,316
                                   1,227,384
                                   1,022,820
                                   1,022,820
Coke oven test data
Exhaust Gas Flow Rate, dscfm (Q)
                                    409,074
                                    182,805
                                    306,805
                                    255,671
                                    255,671
Coke oven test data
Operating Labor Rate, $/hr (LR)
                                    $29.44
                                    $29.44
                                    $29.44
                                    $29.44
                                    $29.44
BLS, 2023
Activated Carbon Cost, $/lb (ACC)
                                     $0.75
                                     $0.75
                                     $0.75
                                     $0.75
                                     $0.75
Ferroalloy (EPA, 2015)
Dust Disposal Cost, $/Ton (DDC, Non-Hazardous)
                                    $40.00
                                    $40.00
                                    $40.00
                                    $40.00
                                    $40.00
Ferroalloy (EPA, 2015)
Dust Disposal Cost, $/Ton (DDC, Hazardous)
                                    $400.00
                                    $400.00
                                    $400.00
                                    $400.00
                                    $400.00
Ferroalloy (EPA, 2015)
Capital Recovery Factor (CRF)
                                  0.098092192
                                  0.098092192
                                  0.098092192
                                  0.098092192
                                  0.098092192
CRF calculated assuming 20-year equipment life and 7.5% interest (FRED, 2023)
GDP, 2022
                                    126.45
                                    126.45
                                    126.45
                                    126.45
                                    126.45
BEA, 2023
GDP, 2008
                                    94.419
                                    94.419
                                    94.419
                                    94.419
                                    94.419
BEA, 2023
GDP, 1991
                                    65.783
                                    65.783
                                    65.783
                                    65.783
                                    65.783
BEA, 2023
ACI Adjustment Factor (AF)
                                     0.95
                                     0.95
                                     0.95
                                     0.95
                                     0.95
Calculated control efficiency
ACI Injection Rate (lb/MMacf)
                                      2.0
                                      2.0
                                      2.0
                                      2.0
                                      2.0
Ferroalloy (EPA, 2015)
Total Capital Investment, $ (TCI)
                                   $254,570
                                   $157,007
                                   $214,212
                                   $192,015
                                   $192,015
Calculated using algorithm 4,500 x (Q/1,976)0.6 x (1.2 retrofit factor) x CEPCI Adj.
Direct Annual Cost, $/yr (DAC)
                                       
                                       
                                       
                                       
                                       

Operating Labor
                                    $1,048
                                    $8,059
                                     $287
                                     $177
                                     $287
Calculated using (0.25 hr/8-hr shift) x H x LR
Supervisory Labor
                                     $157
                                    $1,209
                                      $43
                                      $26
                                      $43
Calculated using 0.15 x Operating Labor
Maintenance
                                    $50,914
                                   $31,401 
                                   $42,842 
                                   $38,403 
                                   $38,403 
Calculated using 0.2 x TCI
Activated Carbon
                                  $1,290,226
                                   $576,570
                                   $967,669
                                   $806,391
                                   $806,391

Dust Disposal (Non-Hazardous)
                                    $4,428
                                    $15,221
                                     $910
                                     $467
                                     $758
Calculated using ACI injection rate, 99% capture efficiency, and non-hazardous disposal cost
Dust Disposal (Hazardous)
                                    $44,281
                                   $152,214
                                    $9,099
                                    $4,666
                                    $7,582
Calculated using ACI injection rate, 99% capture efficiency, and hazardous disposal cost
Indirect Annual Cost, $/yr (IAC)
                                       
                                       
                                       
                                       
                                       

Overhead
                                    $31,271
                                    $24,402
                                    $25,904
                                    $23,164
                                    $23,240
Calculated using 0.6 x (Labor + Maintenance)
Property Tax, Insurance, & Admin
                                   $10,183 
                                    $6,280 
                                    $8,568 
                                    $7,681 
                                    $7,681 
Calculated using 0.04 x TCI
Capital Recovery
                                   $24,971 
                                   $15,401 
                                   $21,013 
                                   $18,835 
                                   $18,835 
Calculated using CRF x TCI
Total Annual Cost (Hazardous)
                                  $1,453,051
                                   $815,537
                                  $1,075,425
                                   $899,343
                                   $902,462
Sum of DAC + IAC

Development of Unit Costs for WAS for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks 

      The WAS cost model from the Portland Cement NESHAP (EPA, 2010) was used to develop unit costs for HNR HRSG bypass/waste heat stacks using specific data available for the coke industry. Table C-39 shows the WAS unit costs for HNR HRSG bypass/waste heat stacks.
Table C-39. WAS Unit Costs for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks
                                   Parameter
                              Capital Cost Value
                                       
                               SC-EastChicago-IN
                          Ducting 8 Stacks Together 
                                 SC-Vansant-VA
          Ducting 8 Stacks Together, Adjusted for Oven-to-Stack Ratio
                 SC-GraniteCity-IL Ducting 6 Stacks Together 
                             SC-FranklinFurnace-OH
                          Ducting 5 Stacks Together 
                               SC-Middletown-OH
                          Ducting 5 Stacks Together 
                               Source/Reference
Gas flowrate (dscfm)
                                    409,074
                                    182,805
                                    306,805
                                    255,671
                                    255,671
Coke oven test data
GDP 2010
                                    96.166
                                    96.166
                                    96.166
                                    96.166
                                    96.166
BEA, 2023
GDP 2022
                                    126.45
                                    126.45
                                    126.45
                                    126.45
                                    126.45
BEA, 2023
CC = Capital ($2022)
                                  $44,083,937
                                  $27,188,923
                                  $37,095,150
                                  $33,251,281
                                  $33,251,281
Portland Cement (EPA, 2010)
                                 Annual Costs
                                   Parameter
                                     Value
                               Source/Reference
COSTKWH ($2022/kWhr)
                                  0.095199759
Portland Cement (EPA, 2010)
Annual interest rate (fraction):
                                     0.075
FRED, 2023
Control system life (years):
                                      20
Portland Cement (EPA, 2010)
Capital recovery factor:
                                  0.098092192
Portland Cement (EPA, 2010)
                                   Parameter
                               SC-EastChicago-IN
                        Ducting 8 Stacks Together Value
                                 SC-Vansant-VA
                           Ducting 8 Stacks Together
               SC-GraniteCity-IL Ducting 6 Stacks Together Value
                             SC-FranklinFurnace-OH
                        Ducting 5 Stacks Together Value
                               SC-Middletown-OH
                        Ducting 5 Stacks Together Value
                               Source/Reference
Coke Production TPY
                                    650,000
                                    372,500
                                    428,412
                                    341,657
                                    357,010
Coke oven test data
Operating Hours per year
                                    1138.8
                                     8760
                                      312
                                      192
                                      312
Coke oven test data
Fixed Cost
                                  $1,880,181
                                  $1,171,206
                                  $1,574,777
                                  $1,409,473
                                  $1,411,595
Portland Cement (EPA, 2010)
SO2 = lb SO2 per ton of coke
                                     0.30
                                      1.8
                                     0.13
                                     0.098
                                     0.15
Coke oven test data
Variable Cost
                                    $18,878
                                       
                                    $18,198
                                       
                                    $11,450
                                       
                                    $9,003
                                       
                                    $9,660
                                       
Portland Cement (EPA, 2010 & Andover 2009)
Total Annual Costs
                                  $6,223,350
                                  $3,856,424
                                  $5,224,972
                                  $4,680,167
                                  $4,682,946
Portland Cement (EPA, 2010)
Note: CC = Capital ($2022) = 14,398*(DSCFM)[0.6][.] Fixed costs include labor (operating, supervisory, and maintenance), maintenance materials, replacement parts, taxes, insurance, etc.: FC = 38 * TPY[0.6] + 0.04 * CC. Variable costs include consumption of limestone, power, and water plus generation of scrubber slurry: VC = (0.000844 * TPY * COSTKWH) + (0.013 * TPY * SO2) + (TPY * 0.025). Total annualized cost (TAC) includes fixed annual costs, variable annual costs, and capital recovery interest rate, 20‐year lifetime, and a capital recovery factor: TAC = FC + VC + CRF * CC

Development of Unit Costs for RTO for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks 
      
      The RTO cost model from the Portland Cement NESHAP (EPA, 2010) was used to develop unit costs for HNR HRSG bypass/waste heat stacks using specific data available for the coke industry. Table C-40 shows the RTO unit costs for HNR HRSG bypass/waste heat stacks.

Table C-40. RTO Unit Costs for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks
                                   Parameter
                               SC-EastChicago-IN
                          Ducting 8 Stacks Together 
                                 SC-Vansant-VA
          Ducting 8 Stacks Together, Adjusted for Oven-to-Stack Ratio
                 SC-GraniteCity-IL Ducting 6 Stacks Together 
                             SC-FranklinFurnace-OH
                          Ducting 5 Stacks Together 
                               SC-Middletown-OH
                          Ducting 5 Stacks Together 
                                    Source/
                                   Reference
Flowrate (dscfm)
                                    409,074
                                    182,805
                                    306,805
                                    255,671
                                    255,671
Coke oven test data
GDP 2010
                                    96.166
                                    96.166
                                    96.166
                                    96.166
                                    96.166
BEA, 2023
GDP 2022
                                    126.45
                                    126.45
                                    126.45
                                    126.45
                                    126.45
BEA, 2023
Total Capital Investment (TCI)
                                  $29,388,075
                                  $18,125,199
                                  $24,729,077
                                  $22,166,604
                                  $22,166,604
Portland Cement (EPA, 2010)
Total Annual Costs (TAC)
                                  $11,531,628
                                  $6,360,886
                                  $9,298,077
                                  $8,125,425
                                  $8,125,425
Portland Cement (EPA, 2010)
Note: TCI = 25280000 * (DSCFM/502312)^0.6 * GDP2022/GDP2010. TAC = 14177 + 8.3 * DSCFM + 0.1824 * TCI * GDP2022/GDP2010

BTF Costs per Facility for HNR HRSG Bypass/Waste Heat Stacks

      It was assumed that the coke facilities will duct either five, six, or eight of their HNR HRSG bypass/waste heat stacks together and route to one BTF APCD configuration. The unit APCD costs were multiplied by the required number of APCD configurations to calculate the total BTF HNR HRSG bypass/waste heat stack costs per facility. The total BTF HNR HRSG bypass/waste heat stack costs are shown in Table C-41.

                                       
   Table C-41. BTF Costs per Facility for HNR HRSG Bypass/Waste Heat Stacks
                                   Facility
                               No. APCD Configs
                            Total Capital Cost ($)
                             Total Annual Cost ($)
                                       
                                       
                                   Ductwork
                                     ACI 
                                     WAS 
                                     RTO 
                                    Total 
                                   Ductwork
                                     ACI 
                                     WAS 
                                     RTO 
                                    Total 
SC-EastChicago-IN 
                                       2
                                   $540,175
                                   $509,141
                                  $88,167,875
                                  $58,776,151
                                 $147,993,341
                                   $182,340
                                  $2,906,102
                                  $12,446,699
                                  $23,063,255
                                  $38,598,396
SC-FranklinFurnace-OH 
                                       2
                                   $337,610
                                   $384,030
                                  $66,502,563
                                  $44,333,207
                                 $111,557,410
                                    $61,004
                                  $1,798,686
                                  $9,360,334
                                  $16,250,849
                                  $27,470,873
SC-GraniteCity-IL 
                                       1
                                   $202,566
                                   $214,212
                                  $37,095,150
                                  $24,729,077
                                  $62,241,005
                                    $39,574
                                  $1,075,425
                                  $5,224,972
                                  $9,298,077
                                  $15,638,048
SC-Middletown-OH 
                                       1
                                   $168,805
                                   $192,015
                                  $33,251,281
                                  $22,166,604
                                  $55,778,705
                                    $32,559
                                   $902,462
                                  $4,682,946
                                  $8,125,425
                                  $13,743,392
SC-Vansant-VA 
                                       2
                                   $540,175
                                   $314,014
                                  $54,377,847
                                  $36,250,398
                                  $91,482,434
                                   $425,956
                                  $1,631,074
                                  $7,712,849
                                  $12,721,773
                                  $22,491,652
Industry Total
                                       
                                  $1,789,331
                                  $1,613,413
                                 $279,394,716
                                 $186,255,436
                                 $469,052,896
                                   $741,433
                                  $8,313,749
                                  $39,427,800
                                  $69,459,379
                                 $117,942,361
                                       

BTF Emission Reductions for HNR HRSG Bypass/Waste Heat Stacks

      Baseline emissions were estimated from coke oven CAA section 114 requests data. The coke oven stack test data were used to develop industry average Hg, PM, non-Hg metal HAP, AG, PAH, and formaldehyde lb/hr default values for the units that were not tested, as shown in Table C-42. 
      
                 Table C-42. HNR HRSG Bypass/Waste Heat Stack 
                  Default Baseline Emission Factors (lb/hr) 
                               Pollutant Tested
                       HNR HRSG Bypass/Waste Heat Stack
                                    (lb/hr)
Hg 
                                   2.55E-03
PM
                                   7.59E+00
Non-Hg Metal HAP
                                   1.29E-01
AG 
                                   3.05E+01
PAH
                                   2.91E-04
Formaldehyde 
                                   2.35E-02
      
      
      The lb/hr coke emission factor for each HNR HRSG bypass/waste heat stack source (i.e., coke oven test data or default emission factor) were multiplied by each source's corresponding annual operating hours (hours/year), as shown in Table C-43, and then divided by 2,000 to calculate TPY emissions. 
      
    Table C-43. Annual Operating Hours per HNR HRSG Bypass/Waste Heat Stack
                                   Facility
                                Emission Source
                            Annual Operating Hours
SC-EastChicago-IN
                              Venting Stack 1-14
                                    1,138.8
SC-FranklinFurnace-OH
                          HRSG Bypass Vent Stack 1-10
                                      192
SC-GraniteCity-IL
                          HRSG Bypass Vent Stack 1-6
                                      312
SC-Middletown-OH
                          HRSG Bypass Vent Stack 1-5
                                      312
SC-Vansant-VA
                              Venting Stack 1-16
                                     8,760
      
      The TPY emissions for SC-Vansant-VA were further adjusted to account for the oven per stack ratio, as described in the Coke Ovens Risk and Technology Review: Data Summary memorandum ( EPA, 2023A). The baseline PM and HAP emissions for HNR HRSG bypass/waste heat stacks were summed for each facility. Table C-44 shows the baseline emissions. 
      
                  Table C-44. Baseline PM and HAP Emissions 
          from HNR HRSG Bypass/Waste Heat Stacks Before BTF Controls
                                   Facility
                      Baseline PM and HAP Emissions (TPY)
                                       
                                      PM 
                                      Hg
                               Non-Hg Metal HAP
                                      AG
                                      PAH
                                     Form
                                   Total HAP
SC-EastChicago-IN 
                                     69.10
                                     0.023
                                     1.17
                                    278.02
                                    0.0026
                                     0.21
                                      279
SC-FranklinFurnace-OH 
                                     9.12
                                    0.0027
                                     0.12
                                     33.79
                                    0.00028
                                     0.043
                                      34
SC-GraniteCity-IL 
                                     5.31
                                    0.0022
                                     0.12
                                     24.18
                                    0.00027
                                    0.0018
                                      24
SC-Middletown-OH 
                                     5.92
                                    0.0020
                                     0.10
                                     23.80
                                    0.00023
                                     0.018
                                      24
SC-Vansant-VA 
                                    237.54
                                     0.080
                                     4.03
                                    955.71
                                    0.0091
                                     0.74
                                      961
Industry Total
                                    326.99
                                     0.11
                                     5.55
                                   1,315.51
                                     0.013
                                      1.0
                                     1,322

      Table C-45 shows the control efficiencies of each APCD that were used to calculate the BTF emission reductions as shown in Table C-46. 

       Table C-45. Pollutants, APCD, Control Efficiency for BTF Controls
                                   Pollutant
                                     APCD
                              Control Efficiency
Hg
                                     ACI 
                                      95%
PM
                                      WAS
                                      95%
Non-Hg Metal HAP
                                      WAS
                                      95%
AG
                                      WAS
                                     99.9%
PAH
                                      RTO
                                      98%
Formaldehyde
                                      RTO
                                      98%

              Table C-46. Reductions in PM and HAP Emissions for 
             HNR HRSG Bypass/Waste Heat Stacks due to BTF Controls
                                   Facility
                   BTF PM and HAP Emission Reductions (TPY)
                                       
                                      PM
                                      Hg
                               Non-Hg Metal HAP
                                      AG
                                      PAH
                                     Form
                                   Total HAP
SC-EastChicago-IN
                                     65.65
                                     0.022
                                     1.12
                                    277.75
                                    0.0026
                                     0.21
                                    279.09
SC-FranklinFurnace-OH
                                     8.66
                                    0.0025
                                     0.11
                                     33.76
                                    0.00027
                                     0.042
                                     33.92
SC-GraniteCity-IL
                                     5.04
                                    0.0021
                                     0.12
                                     24.16
                                    0.00027
                                    0.0018
                                     24.28
SC-Middletown-OH
                                     5.62
                                    0.0019
                                     0.10
                                     23.78
                                    0.00022
                                     0.018
                                     23.90
SC-Vansant-VA 
                                    225.66
                                     0.076
                                     3.83
                                    954.75
                                    0.0089
                                     0.72
                                    959.39
Industry Total
                                    310.64
                                     0.10
                                     5.28
                                   1,314.19
                                     0.012
                                     0.99
                                   1,320.57
                                       
      The remaining emissions (TPY) were calculated by subtracting the emission reductions (TPY) from the baseline emission values (TPY) per pollutant, as shown in Table C-47. 
                                          
                   Table C-47. Remaining PM and HAP Emissions for
             HNR HRSG Bypass/Waste Heat Stacks After BTF Controls
                                   Facility
             Remaining PM and HAP Emission After BTF Control (TPY)

                                      PM
                                      Hg
                               Non-Hg Metal HAP
                                      AG
                                      PAH
                                 Formaldehyde
                                   Total HAP
SC-EastChicago-IN 
                                     3.46
                                    0.0012
                                     0.059
                                     0.28
                                   0.000053
                                    0.0043
                                     0.34
SC-FranklinFurnace-OH
                                     0.46
                                    0.00013
                                    0.0060
                                     0.034
                                   0.0000056
                                    0.00086
                                     0.041
SC-GraniteCity-IL
                                     0.27
                                    0.00011
                                    0.0062
                                     0.024
                                   0.0000054
                                   0.000037
                                     0.031
SC-Middletown-OH 
                                     0.30
                                    0.00010
                                    0.0050
                                     0.024
                                   0.0000045
                                    0.00037
                                     0.029
SC-Vansant-VA 
                                     11.88
                                    0.0040
                                     0.20
                                     0.96
                                    0.00018
                                     0.015
                                     1.18
Industry Total
                                     16.35
                                    0.0055
                                     0.28
                                     1.32
                                    0.00025
                                     0.020
                                     1.62

BTF Cost Effectiveness for HNR HRSG Bypass/Waste Heat Stacks
      
      To calculate $/ton cost effectiveness values, annualized costs (shown in Table C-41 above) were divided by the emission reductions (shown in Table C-46 above), as shown in Table C-48. Note, the values presented were calculated from unrounded emissions and cost values.
Table C-48. BTF Cost Effectiveness for HNR HRSG Bypass/Waste Heat Stacks due to BTF Controls
                                   Facility
                          Cost Effectiveness ($/Ton)
                                       
                                   PM w/ WAS
                                   Hg w/ ACI
                            Non-Hg Metal HAP w/ WAS
                                   AG w/ WAS
                                  PAH w/ RTO
                              Formaldehyde w/ RTO
                            Total HAP [w/ Ductwork+
                                   Controls
SC-EastChicago-IN
                                   $189,600
                                 $131,590,893
                                  $11,162,357
                                    $44,813
                                $8,882,552,721
                                 $110,032,417
                                   $138,298
SC-FranklinFurnace-OH
                                  $1,080,371
                                 $712,001,179
                                  $82,032,503
                                   $277,294
                                $59,396,309,423
                                 $383,854,149
                                   $809,987
SC-GraniteCity-IL
                                  $1,036,338
                                 $518,327,230
                                  $44,328,487
                                   $216,275
                                $34,855,547,239
                                $5,189,372,387
                                   $644,046
SC-Middletown-OH
                                   $833,193
                                 $477,295,054
                                  $49,052,789
                                   $196,931
                                $36,551,575,029
                                 $452,781,792
                                   $575,155
SC-Vansant-VA
                                    $34,179
                                  $21,485,519
                                  $2,012,212
                                    $8,078
                                $1,425,351,964
                                  $17,656,515
                                    $23,444
Industry Total
                                   $126,926
                                  $79,564,097
                                  $7,473,726
                                    $30,002
                                $5,654,236,871
                                  $70,005,993
                                    $89,311
Note: Total HAP=Hg+Non-Hg Metal HAP+AG+PAH+formaldehyde
C.6 References for Appendix C

Andover, 2009. Memorandum. J. Staudt, Andover Technology Partners, Costs and Performance of Controls  -  revised from comments, prepared for EPA, March 10, 2009.
BEA, 2023 From BEA Table 1.1.9: "Implicit Price Deflators for Gross Domestic Product." U.S. Bureau of Economic Analysis. https://apps.bea.gov/iTable/iTable.cfm?reqid=19&step=2#reqid=19&step=2&isuri=1&1921=survey), accessed 1/5/2023.
BLS, 2023. Mean hourly wage from the Bureau of Labor Statistics, May 2021, for Industrial Engineering Technologists and Technicians, 17-3026 Occupation code. https://www.bls.gov/oes/current/oes_nat.htm, accessed 1/5/2023
FRED, 2023. Federal Reserve Economic Data (FRED). Bank Prime Loan Rate Changes: Historical Dates of Changes and Rates. https://fred.stlouisfed.org/series/PRIME, accessed 1/5/2023.
EPA, 2010. Summary of Environmental and Cost Impacts of Final Amendments to Portland Cement NESHAP (40 CFR Part 63, subpart LLL) U.S. Environmental Protection Agency, Research Triangle Park, NC. August 6, 2010. Docket Number EPA‐HQ‐OAR‐2002‐0051.
EPA, 2015. Air Pollution Control Costs Developed for NESHAP Residual Risk and Technology Review for Ferroalloys Production. U.S. Environmental Protection Agency, Research Triangle Park, NC. Docket ID Item Number EPA-HQ-OAR-2010-0895-0280.
EPA, 2023. Coke Ovens Risk and Technology Review: Data Summary. D.L. Jones, U.S. Environmental Protection Agency, Research Triangle Park, NC, and G. Raymond, RTI International, Research Triangle Park, NC. May 1, 2023. Docket ID No. EPA-HQ-OAR-2002-0085 (subpart CCCCC).
                                  APPENDIX D:
              BTF ANALYSIS FOR HNR HRSG BYPASS/WASTE HEAT STACKS 

	An additional BTF analysis for the HNR HRSG bypass/waste heat stacks was conducted based on ACI control for Hg and baghouse control for non-Hg metal HAP. Calculations are provided in the accompanying Microsoft Excel(R) file.

D.1 Input Parameters for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks 

	The actual and standard exhaust flowrates and stack temperatures (°F) were compiled from the coke oven stack testing of Hg, PM, AG, Total PAH, and Formaldehyde at the HNR HRSG bypass/waste heat stack sources. Overall average exhaust flowrates and stack temperature were calculated from the stack tests to use as inputs for calculating BTF controls for HNR HRSG bypass/waste heat stack sources. Table D-1 shows the average stack parameters for the HNR HRSG bypass/waste heat stack sources. Copies of the coke oven stack test data are included in the coke oven PQBS docket (Docket ID No. EPA-HQ-OAR-2002-0085). The flowrates used for SC-Vansant-VA waste heat stacks were further adjusted to account for the oven per stack ratio, similarly to how the TPY emissions were adjusted, as described in the Coke Ovens Risk and Technology Review: Data Summary memorandum ( EPA, 2023A).
                                       
   Table D-1. Average Stack Parameters for HNR HRSG Bypass/Waste Heat Stacks
                                   Facility
                                     Unit
                               Pollutant Tested
                              Flow Actual (acfm)
                           Flow Dry Standard (dscfm)
                             Temp Stack Gas (°F)
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      Hg
                                       
                                    52,474
                                     1,275
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      Hg
                                       
                                    48,744
                                     1,353
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      Hg
                                       
                                    54,456
                                     1,322
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                 PM Filterable
                                       
                                    52,474
                                     1,275
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                 PM Filterable
                                       
                                    48,744
                                     1,353
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                 PM Filterable
                                       
                                    54,456
                                     1,322
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      AG
                                    199,250
                                    49,898
                                     1,402
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      AG
                                    206,413
                                    48,646
                                     1,517
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      AG
                                    212,791
                                    56,009
                                     1,303
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      HCN
                                    199,752
                                    49,475
                                     1,408
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      HCN
                                    202,042
                                    46,157
                                     1,505
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      HCN
                                    205,236
                                    49,979
                                     1,416
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      PAH
                                       
                                    52,658
                                     1,376
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      PAH
                                       
                                    52,292
                                     1,371
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      PAH
                                       
                                    53,545
                                     1,487
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                    D/F TEQ
                                       
                                    52,658
                                     1,376
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                    D/F TEQ
                                       
                                    52,292
                                     1,371
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                    D/F TEQ
                                       
                                    53,545
                                     1,487
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                     VOHAP
                                    202,369
                                    50,021
                                     1,408
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                     VOHAP
                                    201,547
                                    46,112
                                     1,505
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                     VOHAP
                                    211,675
                                    51,493
                                     1,409
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                 Formaldehyde
                                       
                                    50,566
                                     1,408
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                 Formaldehyde
                                       
                                    46,067
                                     1,505
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                 Formaldehyde
                                       
                                    53,007
                                     1,402
Average

                                    204,564
                                    51,134
                                     1,410
      
      
D.2 Development of Unit Costs for Ductwork for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks 
      
      It was assumed that SC-EastChicago-IN and SC-Vansant-VA will duct eight of their sixteen HNR HRSG bypass/waste heat stacks together and route to a series of air pollution control devices, for a set of two APCD configurations per facility; SC-GraniteCity-IL will duct their six HNR HRSG bypass/waste heat stacks together and route to a series of air pollution control devices, for one APCD configuration; SC-FranklinFurnace-OH will duct five of their ten HNR HRSG bypass/waste heat stacks together and route to a series of air pollution control devices, for a set of two APCD configurations; and SC-Middletown-OH will duct their five HNR HRSG bypass/waste heat stacks together and route to a series of air pollution control devices, for one APCD configuration.
      
      The ductwork cost model from the Ferroalloy NESHAP RTR (EPA, 2015) was used to develop unit costs for HNR HRSG bypass/waste heat stacks using specific data available for the coke industry. Table D-2 shows the ductwork unit costs for HNR HRSG bypass/waste heat stacks. 
      
                                       
Table D-2. Ductwork Unit Costs for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks
                                  Parameters
                           Ductwork Unit Cost Values
                               Source/Reference
                                       
                               SC-EastChicago-IN
                          Ducting 8 Stacks Together 
                                 SC-Vansant-VA
         Ducting 8 Stacks Together, adjusted for Oven-to-Stack Ratio 
                 SC-GraniteCity-IL Ducting 6 Stacks Together 
                             SC-FranklinFurnace-OH
                          Ducting 5 Stacks Together 
                               SC-Middletown-OH
                          Ducting 5 Stacks Together 
                                       
Ducts: Cost Base Date:  GDP 1993
                                    68.877
                                    68.877
                                    68.877
                                    68.877
                                    68.877
BEA, 2023
Cost Escalation: GDP 2022 
                                    126.45
                                    126.45
                                    126.45
                                    126.45
                                    126.45
BEA, 2023
-- Inlet stream flowrate (acfm):
                                   1,636,512
                                    731,316
                                   1,227,384
                                   1,022,820
                                   1,022,820
Coke oven test data
-- Duct velocity (ft/min): 
                                     3,800
                                     3,800
                                     3,800
                                     3,800
                                     3,800
Ferroalloy (EPA, 2015)
-- Duct length (ft): 
                                     1200
                                     1200
                                      900
                                      750
                                      750
Engineering judgement
-- Material of construction: 
                                 Sheet-galv CS
                                 Sheet-galv CS
                                 Sheet-galv CS
                                 Sheet-galv CS
                                 Sheet-galv CS
Ferroalloy (EPA, 2015)
-- Insulation thickness (in.): (text input) 
                                       0
                                       0
                                       0
                                       0
                                       0
Ferroalloy (EPA, 2015)
-- Duct design: 
                             Circular-longitudinal
                             Circular-longitudinal
                             Circular-longitudinal
                             Circular-longitudinal
                             Circular-longitudinal
Ferroalloy (EPA, 2015)
-- Cost equation parameters: 
                                       
                                       
                                       
                                       
                                       

          a:
                                     2.03
                                     2.03
                                     2.03
                                     2.03
                                     2.03
Ferroalloy (EPA, 2015)
          b:
                                     0.784
                                     0.784
                                     0.784
                                     0.784
                                     0.784
Ferroalloy (EPA, 2015)
-- Cost equation form: 
                                       1
                                       1
                                       1
                                       1
                                       1
Ferroalloy (EPA, 2015)
-- Control system installation factor: 
                                       0
                                       0
                                       0
                                       0
                                       0
Ferroalloy (EPA, 2015)
   (if no system, enter '0')
                                       
                                       
                                       
                                       
                                       

-- Fan-motor combined efficiency (fraction):
                                      0.6
                                      0.6
                                      0.6
                                      0.6
                                      0.6
Ferroalloy (EPA, 2015)
Design Parameters
                                       
                                       
                                       
                                       
                                       

-- Duct diameter (in.):
                                      76
                                      76
                                      76
                                      76
                                      76
Ferroalloy (EPA, 2015)
-- Pressure drop (in. w.c.): 
                                       2
                                       2
                                       2
                                       2
                                       2
Ferroalloy (EPA, 2015)
CAPITAL COSTS
                                       
                                       
                                       
                                       
                                       

Ductwork Cost ($)--base:
                                    $72,650
                                    $72,650
                                    $54,487
                                    $45,406
                                    $45,406
Ferroalloy (EPA, 2015)
Ductwork Cost ($)--escalated:
                                   $133,377
                                   $133,377
                                   $100,032
                                    $83,360
                                    $83,360
Ferroalloy (EPA, 2015)
Purchased Equipment Cost ($):
                                   $144,047
                                   $144,047
                                   $108,035
                                    $90,029
                                    $90,029
Ferroalloy (EPA, 2015)
Retrofit Adjustment (25%)
                                   $180,058
                                   $180,058
                                   $135,044
                                   $112,537
                                   $112,537
Ferroalloy 
(EPA, 2015)
Total Capital Investment ($): 
                                   $270,088
                                   $270,088
                                   $202,566
                                   $168,805
                                   $168,805
Ferroalloy (EPA, 2015)
ANNUAL COST INPUTS
                                       
                                       
                                       
                                       
                                       

Operating factor (hours/year):
                                    1138.8
                                     8760
                                      312
                                      192
                                      312
Coke oven test data
Electricity price ($/kWhr):
                                     0.067
                                     0.067
                                     0.067
                                     0.067
                                     0.067
Ferroalloy 
(EPA, 2015)
Annual interest rate (fractional):
                                     0.075
                                     0.075
                                     0.075
                                     0.075
                                     0.075
FRED, 2023
Ductwork economic life (years):
                                      20
                                      20
                                      20
                                      20
                                      20
Ferroalloy 
(EPA, 2015)
Capital recovery factor (system):
                                  0.098092192
                                  0.098092192
                                  0.098092192
                                  0.098092192
                                  0.098092192
Ferroalloy (EPA, 2015)
Taxes, insurance, admin. factor:
                                     0.04
                                     0.04
                                     0.04
                                     0.04
                                     0.04
Ferroalloy (EPA, 2015)
Labor, $/hr 
                                    $29.44
                                    $29.44
                                    $29.44
                                    $29.44
                                    $29.44
BLS, 2023
ANNUAL COSTS
                                       
                                       
                                       
                                       
                                       

Item
                                  Cost ($/yr)
                                  Cost ($/yr)
                                  Cost ($/yr)
                                  Cost ($/yr)
                                  Cost ($/yr)

Electricity
                                    $49,973
                                   $171,781
                                    $7,701
                                    $3,291
                                    $5,348
Ferroalloy (EPA, 2015)
Taxes, insurance, administrative
                                    $10,804
                                    $10,804
                                    $8,103
                                    $6,752
                                    $6,752
Ferroalloy (EPA, 2015)
Capital recovery
                                    $26,493
                                    $26,493
                                    $19,870
                                    $16,558
                                    $16,558
Ferroalloy (EPA, 2015)
Labor 
                                    $2,438
                                    $2,438
                                    $2,438
                                    $2,438
                                    $2,438
Ferroalloy (EPA, 2015)
Overhead 
                                    $1,463
                                    $1,463
                                    $1,463
                                    $1,463
                                    $1,463
Ferroalloy (EPA, 2015)
TOTAL ANNUAL COST 
                                    $91,170
                                   $212,978
                                    $39,574
                                    $30,502
                                    $32,559
Ferroalloy (EPA, 2015)

D.3 Development of Unit Costs for BTF Controls for ACI and BH for HNR HRSG Bypass/Waste Heat Stacks
 
      The ACI and shaker BH cost models from the Ferroalloy NESHAP RTR (EPA, 2015) was used to develop unit costs for HNR HRSG bypass/waste heat stacks using specific data available for the coke industry. Tables D-3 and D-4 show the ACI and BH unit costs for HNR HRSG bypass/waste heat stacks. 

Table D-3. ACI Unit Costs for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks
                                  Parameters
                             ACI Unit Cost Values
                               Source/Reference
                                       
                               SC-EastChicago-IN
                          Ducting 8 Stacks Together 
                                 SC-Vansant-VA
          Ducting 8 Stacks Together, Adjusted for Oven-to-Stack Ratio
                 SC-GraniteCity-IL Ducting 6 Stacks Together 
                             SC-FranklinFurnace-OH
                          Ducting 5 Stacks Together 
                               SC-Middletown-OH
                          Ducting 5 Stacks Together 
                                       
Annual Operating Hours, hr/yr (H)
                                    1138.8
                                     8760
                                      312
                                      192
                                      312
Coke oven test data
Exhaust Gas Flow Rate, acfm (Qa)
                                   1,636,512
                                    731,316
                                   1,227,384
                                   1,022,820
                                   1,022,820
Coke oven test data
Exhaust Gas Flow Rate, dscfm (Q)
                                    409,074
                                    182,805
                                    306,805
                                    255,671
                                    255,671
Coke oven test data
Operating Labor Rate, $/hr (LR)
                                    $29.44
                                    $29.44
                                    $29.44
                                    $29.44
                                    $29.44
BLS, 2023
Activated Carbon Cost, $/lb (ACC)
                                     $0.75
                                     $0.75
                                     $0.75
                                     $0.75
                                     $0.75
Ferroalloy (EPA, 2015)
Dust Disposal Cost, $/Ton (DDC, Non-Hazardous)
                                    $40.00
                                    $40.00
                                    $40.00
                                    $40.00
                                    $40.00
Ferroalloy (EPA, 2015)
Dust Disposal Cost, $/Ton (DDC, Hazardous)
                                    $400.00
                                    $400.00
                                    $400.00
                                    $400.00
                                    $400.00
Ferroalloy (EPA, 2015)
Capital Recovery Factor (CRF)
                                  0.098092192
                                  0.098092192
                                  0.098092192
                                  0.098092192
                                  0.098092192
CRF calculated assuming 20-year equipment life and 7.5% interest (FRED, 2023)
GDP, 2022
                                    126.45
                                    126.45
                                    126.45
                                    126.45
                                    126.45
BEA, 2023
GDP, 2008
                                    94.419
                                    94.419
                                    94.419
                                    94.419
                                    94.419
BEA, 2023
GDP, 1991
                                    65.783
                                    65.783
                                    65.783
                                    65.783
                                    65.783
BEA, 2023
ACI Adjustment Factor (AF)
                                     0.95
                                     0.95
                                     0.95
                                     0.95
                                     0.95
Calculated control efficiency
ACI Injection Rate (lb/MMacf)
                                      2.0
                                      2.0
                                      2.0
                                      2.0
                                      2.0
Ferroalloy (EPA, 2015)
Total Capital Investment, $ (TCI)
                                   $254,570
                                   $157,007
                                   $214,212
                                   $192,015
                                   $192,015
Calculated using algorithm 4,500 x (Q/1,976)0.6 x (1.2 retrofit factor) x CEPCI Adj.
Direct Annual Cost, $/yr (DAC)
                                       
                                       
                                       
                                       
                                       

Operating Labor
                                    $1,048
                                    $8,059
                                     $287
                                     $177
                                     $287
Calculated using (0.25 hr/8-hr shift) x H x LR
Supervisory Labor
                                     $157
                                    $1,209
                                      $43
                                      $26
                                      $43
Calculated using 0.15 x Operating Labor
Maintenance
                                    $50,914
                                   $31,401 
                                   $42,842 
                                   $38,403 
                                   $38,403 
Calculated using 0.2 x TCI
Activated Carbon
                                  $1,290,226
                                   $576,570
                                   $967,669
                                   $806,391
                                   $806,391

Dust Disposal (Non-Hazardous)
                                    $4,428
                                    $15,221
                                     $910
                                     $467
                                     $758
Calculated using ACI injection rate, 99% capture efficiency, and non-hazardous disposal cost
Dust Disposal (Hazardous)
                                    $44,281
                                   $152,214
                                    $9,099
                                    $4,666
                                    $7,582
Calculated using ACI injection rate, 99% capture efficiency, and hazardous disposal cost
Indirect Annual Cost, $/yr (IAC)
                                       
                                       
                                       
                                       
                                       

Overhead
                                    $31,271
                                    $24,402
                                    $25,904
                                    $23,164
                                    $23,240
Calculated using 0.6 x (Labor + Maintenance)
Property Tax, Insurance, & Admin
                                   $10,183 
                                    $6,280 
                                    $8,568 
                                    $7,681 
                                    $7,681 
Calculated using 0.04 x TCI
Capital Recovery
                                   $24,971 
                                   $15,401 
                                   $21,013 
                                   $18,835 
                                   $18,835 
Calculated using CRF x TCI
Total Annual Cost (Hazardous)
                                  $1,453,051
                                   $815,537
                                  $1,075,425
                                   $899,343
                                   $902,462
Sum of DAC + IAC

                                       
                Table D-4. BH Unit Costs for BTF Controls for 
                       HNR HRSG Bypass/Waste Heat Stacks
                                   Parameter
                              BH Unit Cost Values
                               Source/Reference
                                       
                               SC-EastChicago-IN
                          Ducting 8 Stacks Together 
                                 SC-Vansant-VA
          Ducting 8 Stacks Together, Adjusted for Oven-to-Stack Ratio
                 SC-GraniteCity-IL Ducting 6 Stacks Together 
                             SC-FranklinFurnace-OH
                          Ducting 5 Stacks Together 
                               SC-Middletown-OH
                          Ducting 5 Stacks Together 
                                       
Input Parameters:
                                       
                                       
                                       
                                       
                                       
                                       
GDP (2022)
                                    126.45
                                    126.45
                                    126.45
                                    126.45
                                    126.45
                                   BEA, 2023
GDP (1998)
                                    75.236
                                    75.236
                                    75.236
                                    75.236
                                    75.236
                                   BEA, 2023
-- Inlet stream flowrate (acfm):
                                   1,636,512
                                    731,316
                                   1,227,384
                                   1,022,820
                                   1,022,820
                              Coke oven test data
-- Inlet stream temperature (°F):
                                     1,410
                                     1,410
                                     1,410
                                     1,410
                                     1,410
                              Coke oven test data
-- Inlet stream temperature, adjusted, pulse jet only (°F):
                                      275
                                      275
                                      275
                                      275
                                      275
Calculated, if the inlet stream temperature is greater than 275°F, use 275°F, otherwise use the inlet stream temperature
-- Dust type:
                               Activated Carbon
                               Activated Carbon
                               Activated Carbon
                               Activated Carbon
                               Activated Carbon
                                       
-- Inlet dust loading (gr/ft3):
                                     0.014
                                     0.014
                                     0.014
                                     0.014
                                     0.014
                            Ferroalloy (EPA, 2015)
-- Dust mass median diameter (microns):
                                       7
                                       7
                                       7
                                       7
                                       7
                            Ferroalloy (EPA, 2015)
-- Filtration time (min):
                                      10
                                      10
                                      10
                                      10
                                      10
                            Ferroalloy (EPA, 2015)
-- Dust specific resistance (in.H2O/fpm/lb/ft2):
                                      15
                                      15
                                      15
                                      15
                                      15
                            Ferroalloy (EPA, 2015)
-- G/C ratio factors (shaker & reverse-air):
                                       
                                       
                                       
                                       
                                       
                            Ferroalloy (EPA, 2015)
A:
                                       2
                                       2
                                       2
                                       2
                                       2
                            Ferroalloy (EPA, 2015)
B:
                                      0.9
                                      0.9
                                      0.9
                                      0.9
                                      0.9
                            Ferroalloy (EPA, 2015)
C:
                                      1.2
                                      1.2
                                      1.2
                                      1.2
                                      1.2
                            Ferroalloy (EPA, 2015)
-- Fraction of bags cleaned (shaker & rev-air):
                                      0.1
                                      0.1
                                      0.1
                                      0.1
                                      0.1
                            Ferroalloy (EPA, 2015)
-- Insulation required? ('yes'=1;'no'=0):
                                       0
                                       0
                                       0
                                       0
                                       0
                            Ferroalloy (EPA, 2015)
-- Stainless steel required? ('yes'=1;'no'=0):
                                       0
                                       0
                                       0
                                       0
                                       0
                            Ferroalloy (EPA, 2015)
-- Bag material:
                                  Fiberglass
                                  Fiberglass
                                  Fiberglass
                                  Fiberglass
                                  Fiberglass
                            Ferroalloy (EPA, 2015)
-- Fabric effective residual drag (in. H2O/fpm):
                                      1.1
                                      1.1
                                      1.1
                                      1.1
                                      1.1
                            Ferroalloy (EPA, 2015)
-- Bag prices ($/ft2): shaker 
                                     0.63
                                     0.63
                                     0.63
                                     0.63
                                     0.63
    Ferroalloy (EPA, 2015) Cleaning Mech. Shaker -- strap; Bag Diam. 5 (in.)
-- Bag prices ($/ft2): shaker
                                     0.61
                                     0.61
                                     0.61
                                     0.61
                                     0.61
    Ferroalloy (EPA, 2015) Cleaning Mech. Shaker -- loop; Bag Diam. 5 (in.)
-- Cost of auxiliary equipment (ductwork, fan, stack, etc.), ($):
                                     89500
                                       
                                     89500
                                     89500
                                       
                                     89500
                                       
                                     89500
                                       
                            Ferroalloy (EPA, 2015)
Design Parameters:
                                       
                                       
                                       
                                       
                                       
                                       
-- Gas-to-cloth ratio (acfm/ft2 cloth area): shaker
                                       6
                                       
                                       6
                                       6
                                       
                                       6
                                       
                                       6
                                       
                            Ferroalloy (EPA, 2015)
-- Net cloth area required (ft2): shaker
                                  272751.9732
                                       
                                  121886.038
                                  204563.9799
                                       
                                  170469.9833
                                       
                                  170469.9833
                                       
Calculated using Inlet stream flowrate (ACFM) / Gas-to-cloth ratio (acfm/ft2 cloth area):
-- Gross cloth area required (ft2): shaker
                                  283662.0521
                                       
                                  129199.2003
                                  212746.5391
                                       
                                  178993.4824
                                       
                                  178993.4824
                                       
Calculated using Gross/Net Area Ratio Value 1.1 * Net cloth area required (ft2)
-- Area per bag--shaker (ft2) (5-in x 8-ft):
                                    10.472
                                    10.472
                                    10.472
                                    10.472
                                    10.472
                            Ferroalloy (EPA, 2015)
-- Number of bags--shaker
                                     27088
                                     12338
                                     20316
                                     17093
                                     17093
                            Ferroalloy (EPA, 2015)
-- Bag pressure drop (in. w.c.): Shaker
                                    6.6108
                                       
                                    6.6108
                                    6.6108
                                       
                                    6.6108
                                       
                                    6.6108
                                       
                            Ferroalloy (EPA, 2015)
-- Baghouse shell pressure drop (in. w.c.):
                                       3
                                       3
                                       3
                                       3
                                       3
                            Ferroalloy (EPA, 2015)
-- Ductwork pressure drop (in. w.c.):
                                       4
                                       4
                                       4
                                       4
                                       4
                            Ferroalloy (EPA, 2015)
                                 Capital Costs
Equipment Costs ($): shaker
                                       
                                       
                                       
                                       
                                       
                                       
Baghouse
                                   1,040,825
                                    526,463
                                    804,676
                                    692,278
                                    692,278
                            Ferroalloy (EPA, 2015)
Bags--small
                                    173,034
                                    78,812
                                    129,775
                                    109,186
                                    109,186
                            Ferroalloy (EPA, 2015)
Bags--large
                                       
                                       
                                       
                                       
                                       
                            Ferroalloy (EPA, 2015)
Insulation
                                       0
                                       0
                                       0
                                       0
                                       0
                            Ferroalloy (EPA, 2015)
Stainless
                                       0
                                       0
                                       0
                                       0
                                       0
                            Ferroalloy (EPA, 2015)
Cages-small 
                                       0
                                       0
                                       0
                                       0
                                       0
                            Ferroalloy (EPA, 2015)
    "   -large
                                       0
                                       0
                                       0
                                       0
                                       0
                            Ferroalloy (EPA, 2015)
Auxiliaries
                                    89,500
                                    89,500
                                    89,500
                                    89,500
                                    89,500
                            Ferroalloy (EPA, 2015)
Total--small
                                   1,303,358
                                    694,775
                                   1,023,951
                                    890,964
                                    890,964
                            Ferroalloy (EPA, 2015)
   "  --large:
                                       
                                       
                                       
                                       
                                       
                            Ferroalloy (EPA, 2015)
PEC($)-base:
                                   1,537,963
                                    819,834
                                   1,208,263
                                   1,051,338
                                   1,051,338
                            Ferroalloy (EPA, 2015)
 ' ' -esc.:
                                   2,866,623
                                   1,528,096
                                   2,252,091
                                   1,959,598
                                   1,959,598
                            Ferroalloy (EPA, 2015)
TCI ($):
                                   6,220,572
                                   3,315,969
                                   4,887,038
                                   4,252,328
                                   4,252,328
                            Ferroalloy (EPA, 2015)
ANNUAL COST INPUTS:
                                       
                                       
                                       
                                       
                                       
                                       
Operating factor (hr/yr):
                                    1138.8
                                     8760
                                      312
                                      192
                                      312
                            Ferroalloy (EPA, 2015)
Operating labor rate ($/hr):
                                    $29.44
                                    $29.44
                                    $29.44
                                    $29.44
                                    $29.44
                                   BLS, 2023
Maintenance labor rate ($/hr):
                                    $29.44
                                    $29.44
                                    $29.44
                                    $29.44
                                    $29.44
                                   BLS, 2023
Operating labor factor (hr/sh):
                                       2
                                       2
                                       2
                                       2
                                       2
                            Ferroalloy (EPA, 2015)
Maintenance labor factor (hr/sh):
                                       1
                                       1
                                       1
                                       1
                                       1
                            Ferroalloy (EPA, 2015)
Electricity price ($/kWhr):
                                    0.0671
                                    0.0671
                                    0.0671
                                    0.0671
                                    0.0671
                            Ferroalloy (EPA, 2015)
Compressed air ($/1000 scf):
                                     0.25
                                     0.25
                                     0.25
                                     0.25
                                     0.25
                            Ferroalloy (EPA, 2015)
Dust disposal ($/ton):
                                      25
                                      25
                                      25
                                      25
                                      25
                            Ferroalloy (EPA, 2015)
Annual interest rate (fraction):
                                     0.075
                                     0.075
                                     0.075
                                     0.075
                                     0.075
                                  FRED, 2023
Control system life (years):
                                      20
                                      20
                                      20
                                      20
                                      20
                            Ferroalloy (EPA, 2015)
Capital recovery factor:
                                  0.098092192
                                  0.098092192
                                  0.098092192
                                  0.098092192
                                  0.098092192
                            Ferroalloy (EPA, 2015)
Bag life (years):
                                       2
                                       2
                                       2
                                       2
                                       2
                            Ferroalloy (EPA, 2015)
Capital recovery factor (bags):
                                  0.556927711
                                  0.556927711
                                  0.556927711
                                  0.556927711
                                  0.556927711
                            Ferroalloy (EPA, 2015)
Taxes, insurance, admin. factor:
                                     0.04
                                     0.04
                                     0.04
                                     0.04
                                     0.04
                            Ferroalloy (EPA, 2015)
                          Annual Costs ($/yr): shaker
Oper. labor
                                     8,382
                                    64,474
                                     2,296
                                     1,413
                                     2,296
                            Ferroalloy (EPA, 2015)
Supv. labor
                                     1,257
                                     9,671
                                      344
                                      212
                                      344
                            Ferroalloy (EPA, 2015)
Maint. labor
                                     4,191
                                    32,237
                                     1,148
                                      707
                                     1,148
                            Ferroalloy (EPA, 2015)
Maint. matl.
                                     4,191
                                    32,237
                                     1,148
                                      707
                                     1,148
                            Ferroalloy (EPA, 2015)
Electricity
                                    149,762
                                    514,816
                                    30,773
                                    15,781
                                    25,644
                            Ferroalloy (EPA, 2015)
Compressed air
                                       0
                                       0
                                       0
                                       0
                                       0
                            Ferroalloy (EPA, 2015)
Bag replacement
                                    283,436
                                    129,098
                                    212,577
                                    178,852
                                    178,852
                            Ferroalloy (EPA, 2015)
Dust disposal
                                     2,795
                                     9,609
                                      574
                                      295
                                      479
                            Ferroalloy (EPA, 2015)
Overhead
                                    10,812
                                    83,171
                                     2,962
                                     1,823
                                     2,962
                            Ferroalloy (EPA, 2015)
Tax,ins.,adm
                                    248,823
                                    132,639
                                    195,482
                                    170,093
                                    170,093
                            Ferroalloy (EPA, 2015)
Cap. recov.
                                    560,268
                                    302,533
                                    441,939
                                    385,619
                                    385,619
                            Ferroalloy (EPA, 2015)
Total Annual Costs
                                   1,273,917
                                   1,310,484
                                    889,244
                                    755,501
                                    768,587
                            Ferroalloy (EPA, 2015)

D.4 BTF Costs for HNR HRSG Bypass/Waste Heat Stacks

      It was assumed that the coke facilities will duct either five, six, or eight of their HNR HRSG bypass/waste heat stacks together and route to one BTF APCD configuration. The unit APCD costs were multiplied by the required number of APCD configurations to calculate the total BTF HNR HRSG bypass/waste heat stack costs per facility. The total BTF HNR HRSG bypass/waste heat stack costs are shown in Table D-5.

    Table D-5. BTF Costs per Facility for HNR HRSG Bypass/Waste Heat Stacks
                                   Facility
                               No. APCD Configs
                            Total Capital Cost ($)
                             Total Annual Cost ($)
                                       
                                       
                                   Ductwork
                                     ACI 
                                      BH
                                     Total
                                   Ductwork
                                     ACI 
                                      BH
                                    Total 
SC-EastChicago-IN 
                                       2
                                   $540,175
                                   $509,141
                                  $12,441,144
                                  $13,490,459
                                   $182,340
                                  $2,906,102
                                  $2,547,834
                                  $5,636,276
SC-FranklinFurnace-OH 
                                       2
                                   $337,610
                                   $384,030
                                  $8,504,656
                                  $9,226,296
                                    $61,004
                                  $1,798,686
                                  $1,511,002
                                  $3,370,692
SC-GraniteCity-IL 
                                       1
                                   $202,566
                                   $214,212
                                  $4,887,038
                                  $5,303,816
                                    $39,574
                                  $1,075,425
                                   $889,244
                                  $2,004,244
SC-Middletown-OH 
                                       1
                                   $168,805
                                   $192,015
                                  $4,252,328
                                  $4,613,148
                                       
                                    $32,559
                                   $902,462
                                   $768,587
                                  $1,703,608
SC-Vansant-VA 
                                       2
                                   $540,175
                                   $314,014
                                  $6,631,939
                                  $7,486,128
                                   $425,956
                                  $1,631,074
                                  $2,620,969
                                  $4,677,999
Industry Total
                                       
                                  $1,789,331
                                  $1,613,413
                                  $36,717,104
                                  $40,119,848
                                   $741,433
                                  $8,313,749
                                  $8,337,636
                                  $17,392,818

D.5 BTF Emission Reductions for HNR HRSG Bypass/Waste Heat Stacks

      Baseline emissions were estimated from coke oven CAA section 114 requests data. The coke oven stack test data were used to develop industry average Hg, PM, and non-Hg metal HAP lb/hr default values for the units that were not tested, as shown in Table D-6. 
      
                 Table D-6. HNR HRSG Bypass/Waste Heat Stack 
                  Default Baseline Emission Factors (lb/hr) 
                               Pollutant Tested
                       HNR HRSG Bypass/Waste Heat Stack
                                    (lb/hr)
Hg 
                                   2.55E-03
PM
                                   7.59E+00
Non-Hg Metal HAP
                                   1.29E-01
                                       
      The lb/hr coke emission factor for each HNR HRSG bypass/waste heat stack source (i.e., coke oven test data or default emission factor) were multiplied by each source's corresponding annual operating hours (hours/year), as shown in Table D-7, and then divided by 2,000 to calculate TPY emissions. 
      
    Table D-7. Annual Operating Hours per HNR HRSG Bypass/Waste Heat Stack
                                   Facility
                                Emission Source
                            Annual Operating Hours
SC-EastChicago-IN
                              Venting Stack 1-14
                                    1,138.8
SC-FranklinFurnace-OH
                          HRSG Bypass Vent Stack 1-10
                                      192
SC-GraniteCity-IL
                          HRSG Bypass Vent Stack 1-6
                                      312
SC-Middletown-OH
                          HRSG Bypass Vent Stack 1-5
                                      312
SC-Vansant-VA
                              Venting Stack 1-16
                                     8,760
      
      The TPY emissions for SC-Vansant-VA were further adjusted to account for the oven per stack ratio, as described in the Coke Ovens Risk and Technology Review: Data Summary memorandum ( EPA, 2023A). The baseline PM and HAP emissions for HNR HRSG bypass/waste heat stacks were summed for each facility. Table D-8 shows the baseline emissions. 
      
                   Table D-8. Baseline PM and HAP Emissions 
          from HNR HRSG Bypass/Waste Heat Stacks Before BTF Controls
                                   Facility
                      Baseline PM and HAP Emissions (TPY)
                                       
                                      PM 
                                      Hg
                               Non-Hg Metal HAP
                                   Total HAP
SC-EastChicago-IN 
                                     69.10
                                     0.023
                                     1.17
                                     1.20
SC-FranklinFurnace-OH 
                                     9.12
                                    0.0027
                                     0.12
                                     0.12
SC-GraniteCity-IL 
                                     5.31
                                    0.0022
                                     0.12
                                     0.13
SC-Middletown-OH 
                                     5.92
                                    0.0020
                                     0.10
                                     0.10
SC-Vansant-VA 
                                    237.54
                                     0.080
                                     4.03
                                     4.11
Industry Total
                                    326.99
                                     0.11
                                     5.55
                                     5.66

      Table D-9 shows the control efficiencies of each APCD that were used to calculate the BTF emission reductions as shown in Table D-10. 

       Table D-9. Pollutants, APCD, Control Efficiency for BTF Controls
                                   Pollutant
                                     APCD
                              Control Efficiency
Hg
                                    ACI+BH
                                      90%
PM
                                      BH
                                     99.9%
Non-Hg Metal HAP
                                      BH
                                     99.9%

              Table D-10. Reductions in PM and HAP Emissions for 
             HNR HRSG Bypass/Waste Heat Stacks due to BTF Controls
                                   Facility
                   BTF PM and HAP Emission Reductions (TPY)
                                       
                                      PM 
                                      Hg
                               Non-Hg Metal HAP
                                   Total HAP
SC-EastChicago-IN 
                                     69.03
                                     0.021
                                     1.17
                                     1.19
SC-FranklinFurnace-OH 
                                     9.11
                                    0.0024
                                     0.12
                                     0.12
SC-GraniteCity-IL 
                                     5.30
                                    0.0020
                                     0.12
                                     0.13
SC-Middletown-OH 
                                     5.91
                                    0.0018
                                     0.10
                                     0.10
SC-Vansant-VA 
                                    237.30
                                     0.072
                                     4.03
                                     4.10
Industry Total
                                    326.66
                                     0.099
                                     5.55
                                     5.65
                                       
      The remaining emissions (TPY) were calculated by subtracting the emission reductions (TPY) from the baseline emission values (TPY) per pollutant, as shown in Table D-11. 
                   Table D-11. Remaining PM and HAP Emissions for
             HNR HRSG Bypass/Waste Heat Stacks After BTF Controls
                                   Facility
             Remaining PM and HAP Emission After BTF Control (TPY)
                                       
                                      PM 
                                      Hg
                               Non-Hg Metal HAP
                                   Total HAP
SC-EastChicago-IN 
                                     0.069
                                    0.0023
                                    0.0012
                                    0.0035
SC-FranklinFurnace-OH 
                                    0.0091
                                    0.00027
                                    0.00012
                                    0.00039
SC-GraniteCity-IL 
                                    0.0053
                                    0.00022
                                    0.00012
                                    0.00034
SC-Middletown-OH 
                                    0.0059
                                    0.00020
                                    0.00010
                                    0.00030
SC-Vansant-VA 
                                     0.24
                                    0.0080
                                    0.0040
                                     0.012
Industry Total
                                     0.33
                                     0.011
                                    0.0056
                                     0.017
                                       
D.6 BTF Cost Effectiveness for HNR HRSG Bypass/Waste Heat Stacks
      
      To calculate $/ton cost effectiveness values, annualized costs (shown in Table D-5 above) were divided by the emission reductions (shown in Table D-10 above), as shown in Table D-12. Note, the values presented were calculated from unrounded emissions and cost values.
Table D-12. BTF Cost Effectiveness for HNR HRSG Bypass/Waste Heat Stacks due to BTF Controls
                                   Facility
                          Cost Effectiveness ($/Ton)
                                       
                                   PM w/ BH
                                   Hg w/ ACI
                            Non-Hg Metal HAP w/ BH
                            Total HAP [w/ Ductwork+
                                   Controls
SC-EastChicago-IN 
                                    $36,907
                                 $138,901,498
                                  $2,172,856
                                  $4,722,493
SC-FranklinFurnace-OH 
                                   $165,846
                                 $751,556,800
                                  $12,592,671
                                  $27,541,959
SC-GraniteCity-IL 
                                   $167,725
                                 $547,123,188
                                  $7,174,279
                                  $15,917,491
SC-Middletown-OH 
                                   $130,040
                                 $503,811,446
                                  $7,655,888
                                  $16,672,150
SC-Vansant-VA 
                                    $11,045
                                  $22,679,159
                                   $650,248
                                  $1,140,241
Industry Total
                                    $25,524
                                  $83,984,324
                                  $1,502,919
                                  $3,080,218
Note: Total HAP=Hg+Non-Hg Metal HAP

D.7 References for Appendix D

Andover, 2009. Memorandum. J. Staudt, Andover Technology Partners, Costs and Performance of Controls  -  revised from comments, prepared for EPA, March 10, 2009.
BEA, 2023 From BEA Table 1.1.9: "Implicit Price Deflators for Gross Domestic Product." U.S. Bureau of Economic Analysis. https://apps.bea.gov/iTable/iTable.cfm?reqid=19&step=2#reqid=19&step=2&isuri=1&1921=survey), accessed 1/5/2023.
BLS, 2023. Mean hourly wage from the Bureau of Labor Statistics, May 2021, for Industrial Engineering Technologists and Technicians, 17-3026 Occupation code. https://www.bls.gov/oes/current/oes_nat.htm, accessed 1/5/2023
FRED, 2023. Federal Reserve Economic Data (FRED). Bank Prime Loan Rate Changes: Historical Dates of Changes and Rates. https://fred.stlouisfed.org/series/PRIME, accessed 1/5/2023.
EPA, 2010. Summary of Environmental and Cost Impacts of Final Amendments to Portland Cement NESHAP (40 CFR Part 63, subpart LLL) U.S. Environmental Protection Agency, Research Triangle Park, NC. August 6, 2010. Docket Number EPA‐HQ‐OAR‐2002‐0051.
EPA, 2015. Air Pollution Control Costs Developed for NESHAP Residual Risk and Technology Review for Ferroalloys Production. U.S. Environmental Protection Agency, Research Triangle Park, NC. Docket ID Item Number EPA-HQ-OAR-2010-0895-0280.
EPA, 2023. Coke Ovens Risk and Technology Review: Data Summary. D.L. Jones, U.S. Environmental Protection Agency, Research Triangle Park, NC, and G. Raymond, RTI International, Research Triangle Park, NC. May 1, 2023.