Document ID: EPA-HQ-OAR-2008-0708-0541
Agency: epa
Document Type: Supporting & Related Material
Title: 
Posted Date: 2010-08-12T04:00Z

SEQ CHAPTER \h \r 1    

MEMORANDUM

DATE:		August 10, 2010

SUBJECT:	Cost per Ton of HAP Reduced for Existing Stationary SI RICE

FROM:	Bradley Nelson and Tanya Parise, EC/R, Inc.

		

TO:		Melanie King, EPA OAQPS/SPPD/ESG

1.0	PURPOSE

The purpose of this memorandum is to present the cost per ton of
reducing hazardous air pollutants (HAP) emissions from existing
stationary spark ignition (SI) reciprocating internal combustion engines
(RICE).  In addition to HAP, this memorandum also presents the cost per
ton of reducing carbon monoxide (CO), volatile organic compounds (VOC),
and nitrogen oxides (NOx).  In terms of aftertreatment controls that
reduce HAP emissions from stationary SI engines, the applicable
technologies are oxidation catalyst for lean burn SI engines and
non-selective catalytic reduction (NSCR) for rich burn SI engines.

2.0	COST OF CONTROLS

	The capital and annual cost of HAP control technology for SI engines
controls were developed using equipment cost information obtained from
control technology vendors and industry groups, and the estimation
methodology outlined in the EPA Air Pollution Control Cost Manual.  The
development of the cost equations for each of the applicable control
technologies is presented in a control cost memorandum.  EPA determined
that the following cost equations in Table 1 are representative of the
applicable add-on controls to be considered for stationary SI engines.

Table 1.  Annual and Capital Costs Equations

HAP Control Device	Annual Cost ($2009)	Capital Cost ($2009)

Oxidation Catalyst (2SLB)	$11.4 x HP + $13,928	$47.1 x HP + $41,603

Oxidation Catalyst (4SLB)	$1.81 x HP + $3,442	$12.8 x HP + $3,069

NSCR (4SRB)	$4.77 x HP + $5,679	$24.9 x HP + $13,118

3.0	EMISSION REDUCTIONS

	Uncontrolled emissions, i.e., emissions without add-on controls were
calculated using the emission factors presented in Table 2 of this
memorandum and assuming that non-emergency SI engines operate on average
for 2,800 hours per year (hrs/yr) and emergency SI engines operate on
average for 50 hrs/yr.  Emissions reductions for the control
technologies were estimated using control efficiencies presented in a
previous memorandum developed for the 2004 RICE NESHAP.  The memorandum
presents oxidation catalyst and NSCR control efficiencies observed
during testing of a 2-stroke lean burn (2SLB) engines and a 4-stroke
lean burn (4SLB) engine with oxidation catalyst, and a 4-stroke rich
burn (4SRB) engine with NSCR.  EPA used the average percent reduction
observed during testing in order to estimate emissions reductions, which
are also presented in Table 2 of this memorandum.

Table 2.  Summary of SI Engine Emission Factors

Engine Type	Pollutant	Emission Factor (lb/HP-hr)	Percent Reduction

2SLB	HAP	5.96E-04	43%

	CO	1.06E-02	65%

	VOC	3.07E-03	43%

4SLB	HAP	5.41E-04	71%

	CO	3.92E-03	94%

	VOC	2.78E-03	71%

4SRB	HAP	2.43E-04	76%

	CO	1.93E-02	49%

	VOC	1.25E-03	76%

	NOx1	1.47E-02	97%

1Emission factors for NOx are not presented for 2SLB and 4SLB SI
engines, because no emission reductions are expected from the use of an
oxidation catalyst.  

For existing stationary 2SLB and 4SRB engines greater than or equal to
100 horsepower (HP) and less than or equal to 500 HP at major sources,
the maximum achievable control technology (MACT) floor is a numerical
emission limit that is based on emissions data from the best controlled
12 percent of engines in the emissions data set.  These engines were not
equipped with add-on emission controls, therefore, the cost to comply
with the MACT floor would only include the cost of demonstrating that
the requirements are met by performing testing, monitoring,
recordkeeping and reporting, and not the cost of add-on controls.  EPA
looked at going beyond-the-floor for these engines by requiring emission
levels expected with using add-on controls.  Since the cost to
demonstrate compliance is already included at the MACT floor level,
costs associated with going beyond-the-floor would include the cost of
add-on controls.  Consequently, the cost per ton values are estimated
using the cost of add-on controls only.  For stationary 4SLB engines
greater than or equal to 100 HP and less than or equal to 500 HP at
major sources, the best controlled 12 percent of engines in the
emissions data set for 4SLB engines used add on controls, and the MACT
floor reflects this fact.  The cost per ton values for existing
stationary 2SLB, 4SLB and 4SRB engines at major sources are presented in
Tables 3, 4, and 5.  The cost per ton values for stationary 2SLB and
4SRB engines represent the costs for going beyond-the-floor.  The cost
per ton values for 4SLB engines represent the costs at the MACT floor.

For existing stationary 2SLB, 4SLB and 4SRB engines at area sources, the
generally available control technology (GACT) is management practices. 
Performance testing, monitoring, recordkeeping and reporting would not
be necessary with GACT, or management practices.  EPA looked at going
beyond GACT for these engines by requiring emission levels expected with
using add-on controls.  Consequently, the cost per ton values are
estimated using the cost of add-on controls, plus the cost of
demonstrating compliance,  Therefore, the cost per ton values for
engines are area sources include the cost of performance testing,
monitoring, recordkeeping, and reporting, in addition to the cost of
add-on controls for existing stationary engines at area sources.  The
cost per ton values for existing stationary 2SLB, 4SLB, and 4SRB engines
at area sources are presented in Tables 6 through 8.  

4.0	BENEFITS

The benefits per ton of PM2.5 precursors VOC and NOx at 3 percent
interest rate is $1,200 to $3,000 and $4,900 to $12,000 respectively. 
The benefits per ton of VOC and NOx at 7 percent interest rate is $1,100
to $2,700 and $4,400 to $12,000 respectively.  For more information on
the benefits per ton of pollutants reduced and total monetized benefits,
please refer to the “Regulatory Impact Analysis (RIA) for Existing
Stationary Spark Ignition Engines NESHAP,” which can be found in the
docket (EPA-HQ-OAR-2008-0708). 

Table 3.  Cost per ton ($/ton) of HAP, CO, and VOC Reduced per 2SLB
Engine ($2009)-Major Sources

Engine Data	Engine Size (HP)

Average Engine Horsepower	25	100	150	250	300	500	750	1000

Non-Emergency Engine Operating Hours per Year (hr/yr)	2800	2800	2800
2800	2800	2800	2800	2800

Capital Cost of HAP Control ($2009)	$42,781	$46,313	$48,668	$53,378
$55,733	$65,153	$76,928	$88,703

Annual Cost of HAP Control ($2009/yr)	$14,213	$15,068	$15,638	$16,778
$17,348	$19,628	$22,478	$25,328

Non-Emergency Engines - HAP	 	 	 	 	 	 	 	 

Uncontrolled HAP Emissions (Tons/yr)	0.0209	0.0834	0.1252	0.2086	0.2503
0.4172	0.6258	0.8344

HAP Emission Reductions (Tons/yr)	0.0090	0.0360	0.0541	0.0901	0.1081
0.1802	0.2703	0.3605

Annual Cost of Control per Ton of HAP Removed ($/Ton)	$1,577,203
$418,020	$289,222	$186,184	$160,424	$108,905	$83,145	$70,266

Non-Emergency Engines - CO	 	 	 	 	 	 	 	 

Uncontrolled CO Emissions (Tons/yr)	0.37	1.48	2.23	3.71	4.45	7.42	11.13
14.84

CO Emission Reductions (Tons/yr)	0.24	0.96	1.44	2.40	2.88	4.79	7.19	9.59

Annual Cost of Control per Ton of CO Removed ($/Ton)	$59,303	$15,718
$10,875	$7,001	$6,032	$4,095	$3,126	$2,642

Non-Emergency Engines - VOC	 	 	 	 	 	 	 	 

Uncontrolled VOC Emissions (Tons/yr)	0.107	0.429	0.644	1.073	1.288	2.146
3.219	4.292

VOC Emission Reductions (Tons/yr)	0.046	0.185	0.278	0.464	0.556	0.927
1.391	1.854

Annual Cost of Control per Ton of VOC Removed ($/Ton)	$306,608	$81,263
$56,225	$36,194	$31,186	$21,171	$16,163	$13,660

Table 4.  Cost per ton ($/ton) of HAP, CO, and VOC Reduced per 4SLB
Engine ($2009)-Major Sources 

Engine Data	Engine Size (HP)

Average Engine Horsepower	25	50	150	250	300	500	750	1000

Non-Emergency Engine Operating Hours per Year (hr/yr)	2800	2800	2800
2800	2800	2800	2800	2800

Capital Cost of HAP Control ($2009)	$3,389	$3,709	$4,989	$6,269	$6,909
$9,469	$12,669	$15,869

Annual Cost of HAP Control ($2009/yr)	$3,487	$3,533	$3,714	$3,895	$3,985
$4,347	$4,800	$5,252

Non-Emergency Engines - HAP	 	 	 	 	 	 	 	 

Uncontrolled HAP Emissions (Tons/yr)	0.0189	0.0379	0.1136	0.1894	0.2272
0.3787	0.5681	0.7574

HAP Emission Reductions (Tons/yr)	0.0135	0.0269	0.0808	0.1346	0.1616
0.2693	0.4039	0.5385

Annual Cost of Control per Ton of HAP Removed ($/Ton)	$259,029	$131,195
$45,972	$28,928	$24,667	$16,145	$11,883	$9,753

Non-Emergency Engines - CO	 	 	 	 	 	 	 	 

Uncontrolled CO Emissions (Tons/yr)	0.14	0.27	0.82	1.37	1.65	2.74	4.12
5.49

CO Emission Reductions (Tons/yr)	0.13	0.26	0.77	1.29	1.55	2.58	3.87	5.16

Annual Cost of Control per Ton of CO Removed ($/Ton)	$27,040	$13,695
$4,799	$3,020	$2,575	$1,685	$1,240	$1,018

Non-Emergency Engines - VOC	 	 	 	 	 	 	 	 

Uncontrolled VOC Emissions (Tons/yr)	0.10	0.19	0.58	0.97	1.17	1.95	2.92
3.90

VOC Emission Reductions (Tons/yr)	0.07	0.14	0.42	0.69	0.83	1.39	2.08
2.77

Annual Cost of Control per Ton of VOC Removed ($/Ton)	$50,355	$25,504
$8,937	$5,624	$4,795	$3,138	$2,310	$1,896

 Table 5.  Cost per ton ($/ton) of HAP, CO, VOC, and NOx Reduced per
4SRB Engine ($2009)-Major Sources

Engine Data	Engine Size (HP)

Average Engine Horsepower	25	50	150	250	300	500	750	1000

Non-Emergency Engine Operating Hours per Year (hr/yr)	2800	2800	2800
2800	2800	2800	2800	2800

Capital Cost of HAP Control ($2009)	$13,741	$14,363	$16,853	$19,343
$20,588	$25,568	$31,793	$38,018

Annual Cost of HAP Control ($2009/yr)	$5,798	$5,918	$6,395	$6,872	$7,110
$8,064	$9,257	$10,449

Non-Emergency Engines - HAP	 	 	 	 	 	 	 	 

Uncontrolled HAP Emissions (Tons/yr)	0.0085	0.0170	0.0510	0.0851	0.1021
0.1701	0.2552	0.3402

HAP Emission Reductions (Tons/yr)	0.0065	0.0129	0.0388	0.0647	0.0777
0.1294	0.1942	0.2589

Annual Cost of Control per Ton of HAP Removed ($/Ton)	$895,855	$457,140
$164,663	$106,168	$91,544	$62,296	$47,672	$40,360

Non-Emergency Engines - CO	 	 	 	 	 	 	 	 

Uncontrolled CO Emissions (Tons/yr)	0.68	1.35	4.05	6.76	8.11	13.51	20.27
27.02

CO Emission Reductions (Tons/yr)	0.33	0.66	1.98	3.30	3.96	6.61	9.91
13.21

Annual Cost of Control per Ton of CO Removed ($/Ton)	$17,553	$8,957
$3,226	$2,080	$1,794	$1,221	$934	$791

Non-Emergency Engines - VOC	 	 	 	 	 	 	 	 

Uncontrolled VOC Emissions (Tons/yr)	0.04	0.09	0.26	0.44	0.53	0.88	1.31
1.75

VOC Emission Reductions (Tons/yr)	0.03	0.07	0.20	0.33	0.40	0.67	1.00
1.33

Annual Cost of Control per Ton of VOC Removed ($/Ton)	$174,154	$88,868
$32,011	$20,639	$17,796	$12,110	$9,268	$7,846

Non-Emergency Engines - NOx	 	 	 	 	 	 	 	 

Uncontrolled NOx Emissions (Tons/yr)	0.51	1.03	3.09	5.15	6.17	10.29
15.44	20.58

NOx Emission Reductions (Tons/yr)	0.50	1.00	3.00	5.00	6.00	10.00	15.00
20.00

Annual Cost of Control per Ton of NOx Removed ($/Ton)	$11,594	$5,916
$2,131	$1,374	$1,185	$806	$617	$522



Table 6.  Cost per ton ($/ton) of HAP, CO, and VOC Reduced per 2SLB
Engine ($2009)-Area Sources

Engine Data	Engine Size (HP)

Average Engine Horsepower	25	100	150	250	300	500	750	1000

Non-Emergency Engine Operating Hours per Year (hr/yr)	2800	2800	2800
2800	2800	2800	2800	2800

Capital Cost of HAP Control ($2009)	$43,349	$46,881	$49,236	$53,946
$56,301	$65,721	$77,496	$89,271

Annual Cost of HAP Control ($2009/yr)	$17,659	$18,514	$19,084	$20,224
$20,794	$23,074	$25,924	$28,774

Non-Emergency Engines - HAP	 	 	 	 	 	 	 	 

Uncontrolled HAP Emissions (Tons/yr)	0.0209	0.0834	0.1252	0.2086	0.2503
0.4172	0.6258	0.8344

HAP Emission Reductions (Tons/yr)	0.0090	0.0360	0.0541	0.0901	0.1081
0.1802	0.2703	0.3605

Total Annual Cost per Ton of HAP Removed ($/Ton)	$1,959,602	$513,620
$352,956	$224,424	$192,291	$128,025	$95,892	$79,826

Non-Emergency Engines - CO	 	 	 	 	 	 	 	 

Uncontrolled CO Emissions (Tons/yr)	0.37	1.48	2.23	3.71	4.45	7.42	11.13
14.84

CO Emission Reductions (Tons/yr)	0.24	0.96	1.44	2.40	2.88	4.79	7.19	9.59

Total Annual Cost per Ton of CO Removed ($/Ton)	$73,682	$19,312	$13,271
$8,438	$7,230	$4,814	$3,606	$3,001

Non-Emergency Engines - VOC	 	 	 	 	 	 	 	 

Uncontrolled VOC Emissions (Tons/yr)	0.107	0.429	0.644	1.073	1.288	2.146
3.219	4.292

VOC Emission Reductions (Tons/yr)	0.046	0.185	0.278	0.464	0.556	0.927
1.391	1.854

Total Annual Cost per Ton of VOC Removed ($/Ton)	$380,947	$99,848
$68,615	$43,628	$37,381	$24,888	$18,641	$15,518



Table 7.  Cost per ton ($/ton) of HAP, CO, and VOC Reduced per 4SLB
Engine ($2009)-Area Sources

Engine Data	Engine Size (HP)

Average Engine Horsepower	25	50	150	250	300	500	750	1000

Non-Emergency Engine Operating Hours per Year (hr/yr)	2800	2800	2800
2800	2800	2800	2800	2800

Capital Cost of HAP Control ($2009)	$3,957	$4,277	$5,557	$6,837	$7,477
$10,037	$13,237	$16,437

Annual Cost of HAP Control ($2009/yr)	$6,933	$6,978	$7,159	$7,340	$7,431
$7,793	$8,245	$8,698

Non-Emergency Engines - HAP	 	 	 	 	 	 	 	 

Uncontrolled HAP Emissions (Tons/yr)	0.0189	0.0379	0.1136	0.1894	0.2272
0.3787	0.5681	0.7574

HAP Emission Reductions (Tons/yr)	0.0135	0.0269	0.0808	0.1346	0.1616
0.2693	0.4039	0.5385

Total Annual Cost per Ton of HAP Removed ($/Ton)	$514,993	$259,177
$88,633	$54,524	$45,997	$28,943	$20,416	$16,152

Non-Emergency Engines - CO	 	 	 	 	 	 	 	 

Uncontrolled CO Emissions (Tons/yr)	0.14	0.27	0.82	1.37	1.65	2.74	4.12
5.49

CO Emission Reductions (Tons/yr)	0.13	0.26	0.77	1.29	1.55	2.58	3.87	5.16

Total Annual Cost per Ton of CO Removed ($/Ton)	$53,759	$27,055	$9,252
$5,692	$4,802	$3,021	$2,131	$1,686

Non-Emergency Engines - VOC	 	 	 	 	 	 	 	 

Uncontrolled VOC Emissions (Tons/yr)	0.10	0.19	0.58	0.97	1.17	1.95	2.92
3.90

VOC Emission Reductions (Tons/yr)	0.07	0.14	0.42	0.69	0.83	1.39	2.08
2.77

Total Annual Cost per Ton of VOC Removed ($/Ton)	$100,115	$50,384
$17,230	$10,600	$8,942	$5,626	$3,969	$3,140



Table 8.  Cost per ton ($/ton) of HAP, CO, VOC, and NOx Reduced per 4SRB
Engine ($2009)-Area Sources

Engine Data	Engine Size (HP)

Average Engine Horsepower	25	50	150	250	300	500	750	1000

Non-Emergency Engine Operating Hours per Year (hr/yr)	2800	2800	2800
2800	2800	2800	2800	2800

Capital Cost of HAP Control ($2009)	$14,309	$14,931	$17,421	$19,911
$21,156	$26,136	$32,361	$38,586

Annual Cost of HAP Control ($2009/yr)	$9,744	$9,863	$10,340	$10,817
$11,056	$12,010	$13,202	$14,395

Non-Emergency Engines - HAP	 	 	 	 	 	 	 	 

Uncontrolled HAP Emissions (Tons/yr)	0.0085	0.0170	0.0510	0.0851	0.1021
0.1701	0.2552	0.3402

HAP Emission Reductions (Tons/yr)	0.0065	0.0129	0.0388	0.0647	0.0777
0.1294	0.1942	0.2589

Total Annual Cost per Ton of HAP Removed ($/Ton)	$1,505,529	$761,977
$266,275	$167,135	$142,350	$92,780	$67,995	$55,602

Non-Emergency Engines - CO	 	 	 	 	 	 	 	 

Uncontrolled CO Emissions (Tons/yr)	0.68	1.35	4.05	6.76	8.11	13.51	20.27
27.02

CO Emission Reductions (Tons/yr)	0.33	0.66	1.98	3.30	3.96	6.61	9.91
13.21

Total Annual Cost per Ton of CO Removed ($/Ton)	$29,499	$14,930	$5,217
$3,275	$2,789	$1,818	$1,332	$1,089

Non-Emergency Engines - VOC	 	 	 	 	 	 	 	 

Uncontrolled VOC Emissions (Tons/yr)	0.04	0.09	0.26	0.44	0.53	0.88	1.31
1.75

VOC Emission Reductions (Tons/yr)	0.03	0.07	0.20	0.33	0.40	0.67	1.00
1.33

Total Annual Cost per Ton of VOC Removed ($/Ton)	$292,675	$148,128
$51,764	$32,491	$27,673	$18,036	$13,218	$10,809

Non-Emergency Engines - NOx	 	 	 	 	 	 	 	 

Uncontrolled NOx Emissions (Tons/yr)	0.51	1.03	3.09	5.15	6.17	10.29
15.44	20.58

NOx Emission Reductions (Tons/yr)	0.50	1.00	3.00	5.00	6.00	10.00	15.00
20.00

Total Annual Cost per Ton of NOx Removed ($/Ton)	$19,485	$9,862	$3,446
$2,163	$1,842	$1,201	$880	$720

 EPA Air Pollution Control Cost Manual Sixth Edition, January 2002,
EPA/452/B-02-001.

 Memorandum from Bradley Nelson, EC/R Inc., to Melanie King, EPA
OAQPS/SPPD/ESG, Control Costs for Existing Stationary SI RICE, June 29,
2010 .

 Memorandum from Melanie Taylor and Jennifer Snyder, AGTI to Sims Roy,
EPA OAQPS ESD Combustion Group, CO Removal Efficiency as a Surrogate for
HAP removal Efficiency, January 7, 2004.

E C/R Incorporated	Providing Environmental Technical Support Since 1989

	

501 Eastowne Drive, Suite 325  (  Chapel Hill, North Carolina 27514

Telephone:  (919) 484-0222  (  Fax:  (919) 484-0122

  PAGE   \* MERGEFORMAT  15 

  PAGE   \* MERGEFORMAT  3 

  PAGE   \* MERGEFORMAT  9