-------
of the pads is $6,7io m3 (190/ft3). Annualized mesh pad
replacement costs include the actual replacement costs as well as
the disposal and transportation costs associated with the used
materials. The replacement costs of the pads were calculated
based on the following equation:
Replacement costs, $/yr = [(V)(C)(CRFm)]
where:
V = volume of mesh pad material per unit, m3 (ft3)
C = cost of mesh pads, $/m3 ($/ft3)
CRFm = capital recovery factor of 0.264, based on an
interest rate of 10 percent and a depreciable life of
5 years for the mesh pads
The disposal and transportation costs for the used pads
were calculated as follows:
Disposal and transportation costs, $/yr =
where:
[(N)(dc + tc)(CRFm)]
N = number of 55-gal drums, V/Vd, rounded to the next
higher whole number
V = volume of mesh pad material disposed for each control
device assuming 50 percent compaction, m3 (ft3)
Vd = volume of 55-gal drum, 0.21 m3 (7.35 ft3)
dc = disposal cost, $50.00 + 10 percent tax/drum5
tc = transportation cost, $40.000/drum5
CRFm = capital recovery factor of 0.264, based on an
interest rate of 10 percent and a depreciable life of
5 years for the mesh pad
The annual cost of operating labor is based on the amount
of labor required to operate the control device plus supervision.
B-5
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The operator labor is based on an assumption that it requires
0.5 hour per day for the operator to perform routine maintenance
and turn the control device on and off. The labor rate was
assumed to be $8.37/hour.1(2 The operator labor is independent
of control device size and number of operating hours per day.
The supervisor labor cost is assumed to be 15 percent of the
operator labor cost.
The annual cost of maintenance labor for each control
device is based on vendor estimates of the maintenance hours
required per 2,000 hours of operation and a maintenance labor
•i *}
rate of $9.2I/hour. 'z Maintenance labor is independent of the
control device size. The annual cost of maintenance materials is
assumed to be 100 percent of the maintenance labor cost.
Indirect costs include overhead, property taxes, insurance,
and administration. The overhead cost was calculated based on
60 percent of the sum of the operator, supervisor, and
maintenance labor plus any material costs.3 Property taxes,
insurance, and administration were collectively assumed to be
4 percent of the total capital cost.3
Capital recovery costs associated with the mesh-pad mist
eliminator unit(s) were calculated using the following equation:3
CRC = [TCC] [(i{l + i}n)/({l + i}n-l)]
where:
CRC = capital recovery cost, $/yr
TCC = total capital cost of control device(s), $
i = annual interest rate, 10 percent
n = depreciable life, 10 years9
B.I.2 Model Plant Costs
This section presents the installed capital and annualized
costs of applying mist eliminators with mesh pads in series to
small, medium, and large hard chromium plating model plants.
Model plant costs were compiled for new and existing plants. The
B-6
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capital costs for ventilation hoods and ductwork were not
included in the capital costs for control devices because plants
must typically install ventilation hoods and ductwork to comply
with occupational health standards that regulate employee
exposure to chromium emissions in the workplace.
B.I.2.1 New Facility Costs
B.I.2.1.1 Model plant capital costs. Table B-7 presents
the purchased equipment, installation, startup, and total capital
costs of mist eliminators with mesh pads in series for the hard
chromium plating model plants. The capital cost estimates were
compiled from Table B-5 as described below.
Small model plant = Column A costs
Medium model plant = Column B costs
Large model plant = 2(Column B) costs
B.1.2.1.2 Model plant annualized control costs. The
annualized costs for the model plants are presented in Table B-8.
The annualized cost estimates, with the exception of the labor
requirements, indirect costs, and chromic acid recovery credits,
were compiled from Table B-6 as described below.
Small model plant = Column A costs
Medium model plant = Column B costs
Large model plant = 2 (Column B) costs
The operator, supervisor, and maintenance labor
requirements for each model plant were calculated based on the
assumption that the labor required to operate and maintain more
than one control device increased the labor requirement by only
30 percent for each additional control device, instead of
increasing the labor requirement by 100 percent. For example,
for the model large hard chromium plating plant, which requires a
total of two control devices, the operator and maintenance labor
requirement was calculated as follows:
B-7
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Operator and maintenance labor, $/yr = 4,740 + (0.3) (4,740)
= $6,160
[instead of (2) (4,740) = $9,480]
The maintenance material cost, which is based on 100
percent of the maintenance labor for each control device, was
assumed to increase 100 percent for each additional control
device for the model plants and can be computed from Table B-6.
The indirect costs for each model plant include overhead,
property taxes, insurance, and administration. The overhead cost
is based on 60 percent of the sum of the operator, supervisor,
and maintenance labor plus the material costs for each model
plant. The property taxes, insurance, and administration are
equal to 4 percent of the total capital cost for each model
plant. For example, for the model large hard chromium plating
plant, the indirect costs were calculated as follows:
overhead taxes, ins., adm.
Indirect costs, $/yr = 0 . 60 [ (1.3) ($4,740)+2($4,140)] + [0.04($143,600)]
= $8,700 + $5,700 = $14,400
The chromic acid recovery credits are calculated based on
the estimated removal efficiency for mist eliminators with mesh
pads in series and 100 percent recovery of the chromic acid
captured by the control device. The chromic acid recovery credit
is calculated using the following equation:
Chromic acid recovery credit, $/yr = [ER] [Eff] [1.923] [C]
where:
ER = uncontrolled hexavalent chromium emission rate per
plant, kg/yr (Ib/yr)
Eff = efficiency of control device, decimal percent
B-8
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1.923 = ratio of chromic acid molecular weight (100) to
hexavalent chromium molecular weight (52)
C = cost of chromic acid (Cr03), $3.28/kg ($1.49/lb)8
B.I.2.2 Existing Facilities Costs. Retrofit costs for
each model plant include costs for ductwork modifications and for
removal and disposal of existing control devices. Actual
retrofit costs will vary and depend on site specific factors such
as plant layout, control device configuration, and adequacy of
existing fan capacity. The retrofit cost estimates presented
here are believed to be representative of expenditures that
existing facilities would incur.
B.I.2.2.1 Model plant retrofit capital costs. Based on
information from vendors of scrubbers and mist eliminators
(chevron-blade and mesh-pad), the average increase in the total
capital cost to retrofit an existing facility is 25 percent.13
Therefore, the estimated retrofit capital costs of mesh-pad mist
eliminator units for model small, medium, and large plants are
$34,000, $89,800, and $179,500, respectively.
B.I.2.2.2 Model plant retrofit annualized costs. Total
annualized retrofit costs of mesh-pad mist eliminator units for
each model hard chromium plating plant are shown in Table B-9.
The annualized retrofit costs are the same as the annualized
costs of a new control system except for the capital recovery
costs and indirect costs, because these costs are a function of
the installed capital cost. Capital recovery costs for a
retrofit situation are higher because the installed capital costs
for retrofit control systems are 25 percent higher than those for
new systems. Indirect costs include overhead, taxes, insurance,
and administration. Taxes, insurance, and administration are
based on 4 percent of the capital costs; thus, these costs are
also higher for retrofit than for new facilities.
B-9
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B.2. PACKED-BED SCRUBBER/MESH-PAD MIST ELIMINATOR SYSTEM
Capital cost estimates for the packed-bed scrubber/mesh-pad
mist eliminator systems applied to two model plants were obtained
from two control device vendors (designated as Vendors A
and C).4'10'14 Table B-10 presents the capital cost estimates
from both vendors. The vendors also provided operating
parameters (e.g., fan and recirculation pump motor horsepower
requirements, water consumption rates, and operator and
maintenance hours that were used to calculate annualized costs.
The costs presented here are based on Vendor A's estimates only
because they are more comprehensive than Vendor C's estimates.
Vendor C's installation costs are significantly lower than
Vendor A's installation costs, which are consistent with previous
estimates for other control devices. A mesh pad useful life of
3 years was assumed by Vendor A and a life of 10 years was
estimated by Vendor C. For purposes of this analysis, a life of
5 years was considered to be realistic.
Model plant capital costs based on Vendor C's estimates are
$25,000 to $62,000 lower than costs based on Vendor A's
estimates. Model plant annualized costs based on Vendor C's
estimates are $9,000 to $26,000 lower than costs based on
Vendor A's estimates.
B.2.1 Unit Costs
This section presents the installed capital and annualized
cost estimates for the two different sizes of packed-bed
scrubber/mesh-pad mist eliminator systems specified in the model
plants.
B.2.1.1 Capital Costs. Table B-ll presents the capital
costs for the two different sizes of packed-bed scrubber/mesh-pad
mist eliminator systems specified in the model plants. As
indicated in Table B-ll, Unit A represents a design gas flow rate
of 340 m3/min (12,000 ft3/min), and Unit B represents a design
gas flow rate of 990 m3/min (35,000 ft3/min). The capital costs
include the purchase cost of the control device and auxiliaries
such as inlet and outlet transition zones, exhaust fans and
B-10
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motors, recirculation tank, recirculation pump and motor, packing
material, mesh pads, and stack; direct installation costs for
erection, electrical panels and wiring, instrumentation and
controls, and piping; and startup costs. Installation costs are
based on the assumption that no major structural modifications
are necessary. The purchased equipment cost also includes taxes
and freight costs, which are assumed to be 3 and 5 percent of the
base equipment cost, respectively.3 The startup cost is assumed
to be 1 percent of the purchased equipment cost.3
B.2.1.2 Annualized Costs. Table B-12 presents the
annualized costs for the two different sizes of packed-bed
scrubber/mesh-pad mist eliminator systems specified in the model
plants. The annualized costs include direct operating costs such
as utilities; operator, supervisor, and maintenance labor and
materials; packing material and mesh pad replacement; indirect
operating costs such as overhead, property taxes, insurance and
administration; and capital recovery costs.
Utility costs include the costs of electricity and water
required to operate the packed-bed scrubber/mesh-pad mist
eliminator system. The annual electrical cost results from the
additional horsepower needed to operate the fan motor to overcome
the pressure drop added to the ventilation system by the control
device and the horsepower needed to operate the scrubber
recirculation pumps. The incremental fan and recirculation pump
electrical costs were calculated using the following equation:
Electrical cost, $/yr = [(0.746 kW/hp)(hp)f(t)](c) +
[(
where,
(0.746 kW/hp)(hp)p(t)J (c)
kW = kilowatt
(hp)f = incremental horsepower of fan motor
(hp) = horsepower requirement of pump motor
t = operating time, hr/yr
c = electrical cost, $0.046l/kWh6
B-ll
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Water consumption costs were calculated based on the
assumption that scrubber water is recirculated for 8 hours of
operation, at which time the water in the recirculation basin is
drained to the process, and the basin is replenished with clean
water. The water costs were calculated using the following
equation:
Water cost, $/yr = [(v)(f) + (FR)(60 min/hr)(t)](c)
where,
v = recirculation tank volume, L (gal)
f = frequency of washdowns, number per year
FR = makeup water flow rate, L/min (gal/min)
t = operating time, hr/yr
c = water cost, $0.20/1,000 L ($0.77/1,000 gal)7
The annual cost of operating labor is based on the amount
of labor required to operate the control device plus supervision.
The operator labor is based on vendor estimates for labor hours
required per day and a labor rate of $8.37/hour.1'2 Based on
vendor estimates, the operator labor is independent of both the
control device size and the number of operating hours per day
because the amount of time required to inspect and startup the
control device is not a function of its size or how long it
operates. The supervisor labor cost is assumed to be 15 percent
of the operator labor cost.3
The annual cost of maintenance labor for each control
device is based on vendor estimates of the maintenance hours
required per 2,000 hours of operation and a maintenance labor
rate of $9.21/hour.lf2 Based on vendor estimates, the
maintenance labor is independent of the control device size. The
amount of labor does not vary according to the size of the
control device because the amount of time to repair damaged parts
(spray nozzles, water pumps, etc.) is independent of the size of
those parts for these systems. The annual cost of maintenance
B-12
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materials is assumed to be 100 percent of the maintenance labor
cost.3
The costs of replacement packing and mesh pad materials
were included in the annualized costs because the life expectancy
of these materials is less than the life expectancy of the
control device. The life expectancy of the packing is 10 years
and the replacement cost of the packing material is $640/m3
($18/ft3). The life expectancy of the mesh pads is 5 years and
replacement costs are $9,700 for the 12,000 ft3/min unit and
$15,500 for the 35,000 ft3/min unit.4 Annualized packing and
mesh pad replacement costs include the replacement costs as well
as the disposal and transportation costs associated with the used
materials. The replacement costs of the packing for the packed-
bed scrubber were calculated based on the following equation:
Replacement costs, $/yr = [(N)(C)(V)(CRFp)]
where:
N = number of beds per unit
C = cost of packing, $/m3 ($/ft3)
V = volume of packing in each bed, m (ft )
CRFp = capital recovery factor of 0.163, based on an
interest rate of 10 percent and a depreciable life of
10 years for the packing
The replacement costs of the mesh pads were calculated using the
following equation:
Replacement costs, $/yr = [(N)(C)(CRFm)]
where:
N = number of mesh pads
C = cost of each mesh pad, $/pad
CRFm = capital recovery factor of 0.264, based on an
interest rate of 10 percent and a depreciable life of
5 years for the mesh pads
B-13
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The disposal and transportation costs for the used packing
and mesh pad materials were calculated as follows:
Disposal and transportation costs, $/yr =
t (N) (dc + tc) (CRF) ]
where :
N = number of 55 -gal drums, V/Vd, rounded to the next
higher whole number
V = volume of packing or mesh pad material disposed for
each control device assuming 50 percent compaction,
m3 (ft3)
Vd = volume of 55-gal drum, 0.21 m3 (7.35 ft3)
dc = disposal cost, $50.00 + 10 percent tax/drum5
tc = transportation cost, $40 . 00/drum5
CRFp = capital recovery factor of 0.163 for scrubber
packing, based on an interest rate of 10 percent and
a depreciable life of 10 years
CRFm = capital recovery factor of 0.264 for mesh pads, based
on an interest rate of 10 percent and a depreciable
life of 5 years
Indirect costs include overhead, property taxes, insurance,
and administration. The overhead cost was calculated based on
60 percent of the sum of the operator, supervisor, and
maintenance labor plus any material costs.3 Property taxes,
insurance, and administration were collectively assumed to be
4 percent of the total capital cost.3
Capital recovery costs associated with the packed-bed
scrubber/mesh -pad unit(s), which are the costs of capital spread
over the depreciable life of the control device, were calculated
using the following equation:
CRC = [TCC] [(i
where,
CRC = capital recovery cost, $/yr
B-14
-------
TCC = total capital cost of control device(s), $
i = annual interest rate, 10 percent
n = depreciable life, 20 yr
B.2.2. Model Plant Costs
This section presents the installed capital and annualized
costs of applying packed-bed scrubber/mesh-pad mist eliminator
systems to model small, medium, and large hard chromium plating
plants. Model plant costs were compiled for new and existing
plants. The capital costs for ventilation hoods and ductwork
were not included in the capital costs for control devices
because plants must typically install ventilation hoods and
ductwork to comply with occupational health standards that
regulate employee exposure to chromium emissions in the
workplace.
B.2.2.1 New Facility Costs
B.2.2.l.l. Model plant capital costs. Table B-13 presents
the purchased equipment, installation, startup, and total capital
costs of packed-bed scrubber/mesh-pad mist eliminator systems for
the hard chromium plating model plants. The capital cost
estimates were compiled from Table B-ll as described below.
Small model plant = Column A costs
Medium model plant = Column B costs
Large model plant = 2 (Column B costs)
B.2.2.1.2. Model plant annualized control costs. The
annualized costs for the model plants are presented in
Table B-14. The annualized cost estimates, with the exception of
the labor requirements, indirect costs, and chromic acid recovery
credits, were compiled from Table B-12 as described below.
Small model plant = Column A costs
Medium model plant = Column E^ costs
B-15
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Large model plant = 2 (Column B2 costs)
The operator, supervisor, and maintenance labor requirements
for each model plant were calculated based on the assumption that
the labor required to operate and maintain more than one control
device increased the labor requirement by only 30 percent for
each additional control device, instead of increasing the labor
requirement by 100 percent. For example, for the model new large
hard chromium plating plant, which requires a total of two
control devices, the operator and maintenance labor requirement
was calculated as follows:
Operator and maintenance labor, $/yr = 3,010 +
(0.3) (3,010) = $3,910 [instead of (2) (3,010) = $6,020]
The maintenance material cost, which is based on 100 percent
of the maintenance labor for each control device, was assumed to
increase 100 percent for each additional control device for the
model plants and can be computed from Table B-12.
The indirect costs for each model plant include overhead,
property taxes, insurance, and administration. The overhead cost
is based on 60 percent of the sum of the operator, supervisor,
and maintenance labor plus the material costs for each model
plant. The property taxes, insurance, and administration are
equal to 4 percent of the total capital cost for each model
plant. For example, for the model new large hard chromium
plating plant, the indirect costs were calculated as follows:
overhead taxes, ins., adm
Indirect costs, $/yr = 0.60[(1.3) ($3,010) + 2($1,800)] + [0.04 ($195,600)]
= $4,510 + $7,820 = $12,330
The chromic acid recovery credits are calculated based on
the estimated removal efficiency for the packed-bed
scrubber/mesh-pad mist eliminator system and 100 percent recovery
B-16
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of the chromic acid captured by the control device. The chromic
acid recovery credit is calculated using the following equation:
Chromic acid recovery credit, $/yr = [ER] [Eff] [1.923] [c]
where,
ER = uncontrolled hexavalent chromium emission rate per
plant, kg/yr (Ib/yr)
Eff = efficiency of control device, decimal percent
1.923 = ratio of chromic acid molecular weight (100) to
hexavalent chromium molecular weight (52)
c = cost of chromic acid (Cr03), $3.28/kg ($1.49/lb)8
The chromic acid recovery credits shown in Tables B-14
and B-15 are based on a control efficiency of 99.8 percent.
B.2.2.2 Existing Facility Costs. The retrofit costs for
each model plant include costs for ductwork modifications and for
removal and disposal of existing control devices. Actual
retrofit costs will vary and depend on .the particular facility,
its layout, and present control level. Based on site visit
information on the plant layout and location of the existing
control devices, the retrofit cost estimates presented here are
believed to be representative of expenditures that existing
facilities would incur.
B.2.2.2.1 Model plant retrofit capital costs. Based on
information from control device vendors of scrubbers and mist
eliminators (chevron-blade and mesh-pad), the average increase in
the total capital cost to retrofit an existing facility was
25 percent.13 Therefore, the estimated retrofit capital costs of
packed-bed scrubber/mesh-pad mist eliminator systems for the
model small, medium, and large plants are $72,600, $122,200, and
$244,500, respectively.
B.2.2.2.2 Model plant retrofit annualized costs. Total
annualized retrofit costs of packed-bed scrubber/mesh-pad mist
eliminator systems for each model hard chromium plating plant are
B-17
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shown in Table B-15. The annualized retrofit costs are the same
as the annualized costs of a new control system except for the
capital recovery costs and indirect costs, because these costs
are a function of the installed capital cost. Capital recovery
costs for a retrofit situation are higher than those for new
systems because the installed capital costs for retrofit control
systems are 25 percent higher than those for new systems.
Indirect costs include overhead, taxes, insurance, and
administration. Taxes, insurance, and administration are based
on 4 percent of the capital costs; thus, these costs are also
higher for retrofit than for new facilities.
B.3 FIBER-BED MIST ELIMINATOR
Cost data for fiber-bed mist eliminators were obtained from
two vendors. Table B-16 presents capital cost estimates provided
by these vendors. Estimates of total installed capital costs
were obtained for the two different sizes of fiber-bed mist
eliminators specified in the model plants from CECO Filters, Inc.
(CECO).11 CECO also provided information on operating parameters
(e.g., fan motor horsepower requirements, water consumption
rates, operator and maintenance hours, and the life expectancy of
the control device and fiber elements) that were used to
calculate annualized costs.11'1 The second vendor, Monsanto
Enviro-Chem (Monsanto), also provided cost data on fiber-bed mist
eliminators.15 However, because Monsanto only sells the fiber--
bed mist eliminators and is not involved in the installations,
incomplete cost information was obtained. Therefore, the cost
estimates provided here are based on CECO estimates only since
they were comparable to the capital cost estimates that were
provided by Monsanto.
B.3.1 Unit Costs
This section presents the installed capital and annualized
cost estimates for the two different sizes of fiber-bed mist
eliminators specified in the model plants.
B.3.1.1 Capital Costs. Table B-17 presents capital cost
estimates for the two different sizes of fiber-bed mist
B-18
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eliminators specified in the model plants. As indicated in
Table B-17, Unit A represents a design gas flow rate of
340 m3/min (12,000 ft3/min) and Unit B represents a design gas
flow rate of 990 m3/min (35,000 ft3/min). The capital costs for
fiber-bed mist eliminators include the purchase cost of the
control device and auxiliaries such as exhaust fans, motors,
inlet and outlet transitions, and stack; direct installation
costs for electrical panels and wiring, instrumentation and
controls, and piping; modification costs associated with the
modification of the existing ventilation system; indirect costs
for erection, engineering services, contractor fees, and
contingencies; and startup costs. Installation costs are based
on the assumption that no major structural modifications are
necessary. Modifications to the existing ventilation system will
be required because fiber-bed mist eliminators must be installed
on the ground beside the plating shop instead of on the roof due
to the height and weight of the units. The cost to modify the
existing ductwork is assumed to be 3 percent of the total
purchased equipment cost, which is based on the ductwork cost for
the original ventilation system. The purchased equipment cost
also includes taxes and freight costs, which are assumed to be
3 and 5 percent of the base equipment costs, respectively.3 The
startup cost is assumed to be l percent of the purchase equipment
cost.3
B.3.1.2 Annualized Costs. Table B-18 presents annualized
costs for fiber-bed mist eliminators. The annualized costs
include direct operating costs such as utilities; operator,
supervisor, and maintenance labor and materials; fiber element
replacement costs; indirect operating costs such as overhead,
property taxes, insurance and administration; and capital
recovery costs.
Utility costs include the costs of electricity and water
required to operate fiber-bed mist eliminators. The annual
electrical cost attributable to pollution control results from
the additional fan horsepower needed to overcome the pressure
B-19
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drop added to the ventilation system by the control device. The
incremental fan electrical costs were calculated using the
following equation:
0.746 kW
Electrical cost, $/yr = [( )(hp)(t)](c)
hp
where:
kW = kilowatt
hp = incremental horsepower of fan motor
t = operating time, hr/yr
c = electrical cost, $0.0461 per kWh6
For example, the fiber-bed mist eliminator that is sized for
an exhaust gas flow rate of 340 actual m3/min (12,000 actual
ft3/min) requires an additional 30 hp to operate the fan, and the
fiber-bed mist eliminator operates 2,000 hr/yr. Therefore, the
annual electrical cost to operate the fan is:
0.746 kW $0.0461
[ ] [30 hp] [2,000 hr/yr] [ ] = $2,060/yr
hp kWh
Water consumption costs are associated with the washdown of
the prefilter located before the mist eliminator and the fiber
elements in the fiber-bed mist eliminator. For purposes of this
analysis, it was assumed that water for washdown is recycled to
the process. Water costs are calculated using the following
equation:
Water cost, $/yr = [(N)(S)(FRFB)(tFB)+(FRpF)(60)(tpp)](C)
where:
N = No. of washdowns per 8-hr shifts
S = No. of 8-hr shifts per yr
FRFB = water flow rate for fiber-bed section, L/min
(gal/min)
tpB = duration of washdown, min
B-20
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FRpF = water flow rate for prefilter, L/min (gal/min)
tpp = operating time per year, hr/yr
C = water cost, $0.20/1,000 L ($0.77/1,000 gal)7
For example, for the fiber-bed mist eliminator used in the
example above, the fiber elements are washed down once every
8 hours at a water flow rate of 2.6 L/min (0.7 gal/min) for
60 minutes, and the prefilter is sprayed continuously with water
at a rate of 5.3 L/min (1.4 gal/min). The fiber-bed mist
eliminator operates 2,000 hr/yr. Therefore, the annual water
cost for this unit is:
[(1)(250) (0.7 gal/min) (60 min) + (1.4 gal/min) (60 min/h)
(2,000 h/yr)] ($0.77/gal) = $140/yr
The total annual cost of utilities for the mist eliminator
is equal to the sum of the electrical and water costs, which is
$2,200/yr.
The cost of replacement fiber material was included in the
annualized costs because the life expectancy of the fiber
material is less than the life expectancy of the control device.
The life expectancy of the fiber material is 5 years and the
replacement cost of each fiber element is $3,000. Annualized
fiber material replacement costs include the replacement cost of
the fiber material and the transportation and disposal costs
associated with the used fiber material. The replacement costs
of the fiber material were calculated based on the following
equation:
Replacement costs, $/yr = [(N)(C)](CRF)
where:
N = No. of fiber elements per unit11
C = cost of fiber material, $3,000/element11
CRF = capital recovery factor of 0.264, based on an
interest rate of 10 percent and a depreciable life of
5 years for the fiber elements
B-21
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The transportation and disposal costs for the fiber
material were calculated based on the following equation:
Disposal and transportation cost, $/yr = [(N)(dc) +
(N)(tc)] (CRF)
where:
N = No. of 55-gal drums, V/Vd, rounded up to the nearest
whole number
V = volume of fiber material disposed for each control
device compacted by 50 percent, m3 (ft3)
Vd = volume of 55-gal drum, 0.21 m3 (7.35 ft3)
dc = disposal cost, $50.00/drum (plus 10 percent tax)5
tc = transportation cost, $40.00/drum5
CRF = capital recovery factor of 0.264, based on an
interest rate of 10 percent and a depreciable life of
5 years for the fiber material
The annual cost of operating labor is based on the amount
of labor required to operate the control device plus supervision.
The operator labor is based on vendor estimates for labor hours
required per 2,000 hours of control device operation and a labor
rate of $8.37/hour.1 The supervision labor cost is assumed to be
15 percent of the operator labor cost.
The annual cost of maintenance labor for each control
device is based on vendor estimates per 2,000 hours of control
T O
device operation and a maintenance labor rate of $9.21/hour. '
The annual cost of materials is assumed to be 100 percent of the
maintenance labor cost.3
Indirect costs include overhead, property taxes, insurance,
and administration. The overhead cost was calculated based on
60 percent of the operator, supervisor, and maintenance labor
plus any material costs.3 Property taxes, insurance, and
administration were assumed to be 4 percent of the total capital
cost.3
B-22
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Capital recovery costs, which are the costs of capital
spread over the depreciable life of the control device, were
calculated using the following equation:3
CRC = [TCC] [ (i
where :
CRC = capital recovery costs, $/yr
TCC = total capital cost, $
i = annual interest rate, 10 percent
n = depreciable life of unit, 20 years
B.3.2 Model Plant Costs
This section presents estimates of installed capital and
annualized costs of applying fiber-bed mist eliminators to small,
medium, and large hard chromium plating plants. Model plant
costs were compiled for new and existing plants. The capital
costs for ventilation hoods and ductwork are not included in the
capital costs for control devices because plants must typically
install ventilation hoods and ductwork to comply with
occupational health standards that regulate employee exposure to
chromium emissions in the workplace.
B.3.2.1 New Facility Costs
B.3.2. l.l Model plant capital costs. Table B-19 presents
the purchased equipment, installation, modification, startup, and
total capital costs of fiber-bed mist eliminators for the hard
chromium plating model plants. The capital cost estimates for
the small and medium model plants are the same as the costs
presented in Columns A and B, respectively, of Table B-17. The
capital cost estimates for the large model plant are equal to two
times the cost presented in Column B of
Table B-17.
B . 3 . 2 . 1 . 2 . Model plant annualized control costs . The
annualized costs associated with the use of fiber-bed mist
eliminators for the hard chromium plating model plants are
presented in Table B-20. The annualized cost estimates, with the
exception of the labor requirements and indirect costs for the
B-23
-------
large model plant, were compiled from Table B-18 as follows:
(1) the annualized costs for the small and medium model plants
are the same as those presented in Columns A and B-j^ respectively;
and (2) the large model plant costs are equal to two times the
costs presented in Column B2.
The operator, supervisor, and maintenance labor
requirements for the large model plant were calculated based on
the assumption that the labor required to operate more than one
control device increased the labor requirement by only 30 percent
for each additional control device, instead of increasing the
labor requirement by 100 percent. Therefore, the labor cost for
the large model plant, which operates two control devices, was
calculated as follows:
Operator and maintenance labor, $/yr = (1.3) ($7,220) +
(1.3) ($2,650) = $12,800
The maintenance material cost, which is based on
100 percent of the maintenance labor for each control device, was
assumed to increase 100 percent for the additional control device
at the large model plant, and can be computed directly from
Table B-18 as described above.
The indirect costs for each model plant include overhead,
property taxes, insurance, and administration. The overhead cost
is based on 60 percent of the sum of the operator and maintenance
labor plus the material costs for each model plant. The property
taxes, insurance, and administration are equal to 4 percent of
the total capital cost for each model plant. Therefore, for the
large model plant, the indirect costs were calculated as follows:
B-24
-------
Indirect costs, $/yr = 0.6 [1.3(9,870) + 2 (2,650)]
+ 0.04 [2 (234,600)] = $10,880 + $18,800 = $29,600/yr
The chromic acid recovery credits are calculated based on
the estimated removal efficiency for fiber-bed mist eliminators
and 100 percent recovery of the chromic acid captured by the
control device. The chromic acid recovery credit is calculated
using the following equation:
Chromic acid recovery credit, $/yr = [ER] [EFF] (1.923] [c]
where:
ER = uncontrolled hexavalent chromium emission rate per
plant, kg/yr (Ib/yr)
EFF = efficiency of control device, 99.8 percent
1.923 = ratio of chromic acid molecular weight (100) to
hexavalent chromium molecular weight (52)
C = cost of chromic acid (Cr03), $3.28/kg ($1.59/lb)8
B.3.2.2 Existing Facilities Costs. The retrofit costs for
each model plant include costs for ductwork modifications and for
the removal and disposal of existing control devices. Actual
retrofit costs will vary and depend on the particular facility,
its layout, and present control level. Based on site visit
information on the plant layout and location of the existing
control devices, the retrofit cost estimates presented here are
believed to be representative of expenditures that existing
facilities would incur.
B.3.2.2.1 Model plant retrofit capital costs. Based on
information from control device vendors of scrubbers and mist
eliminators (chevron-blade and mesh-pad), the average increase in
the total capital cost to retrofit an existing facility was
25 percent.1-^ This corresponds to an 8 percent increase in the
total capital cost for fiber-bed mist eliminators. Therefore, a
10 percent increase in the total capital cost for fiber-bed mist
eliminators was used for calculating retrofit costs for the model
plants. The estimated retrofit capital costs of fiber-bed mist
B-25
-------
eliminators for the small, medium, and large model plants are
$129,400, $258,100, and $516,100, respectively.
B.3.2.2.2 Model plant retrofit annualized costs. Total
annualized retrofit costs of fiber-bed mist eliminators for each
hard chromium plating model plant are shown in Table B-21. The
annualized retrofit costs are the same as the annualized costs of
a new control system except for the capital recovery costs and
indirect costs because these costs are a function of the
installed capital cost. Capital recovery costs for a retrofit
situation are higher because the installed capital costs for
retrofit control systems are 10 percent higher than those for new
systems. Indirect costs include overhead, taxes, insurance, and
administration. Taxes, insurance, and administration are based
on 4 percent of the capital costs; thus, these costs are also
higher for retrofit than for new facilities.
B-26
-------
•12'-
-A—»-• B-
Control
Device
B
Duct Component
Specification
Gas flow rate, cfm
Duct diameter, in.
Duct length, ft
No. of 30 degree entries
No. of one step tapers
No. of 90 degree elbows
Duct
A
2.625
12
12
2
0
0
Section
B
5.250
18
27
3
2
1
Location
C
• 10.500
24
20
0
1
1
Figure B-l. Plan view and ductwork specifications for the small
hard chromium plating model plants.
B-27
-------
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B-29
-------
TABLE B-2. ANNUAL OPERATING COST FACTORS FOR MESH-PAD MIST
ELIMINATORS, PACKED-BED SCRUBBER/MESH-PAD MIST ELIMINATOR SYSTEMS,
AND FIBER-BED MIST ELIMINATORS
Cost categories
Cost factors
Direct operating costs
1. Operating labor
a. Operator*'^
b. Supervisor
2. Maintenance
a. Labor1'3
b. Materials4
3. Replacement parts, packing material
4. Replacement parts, mesh pads or fiber
material
5. Transportation and disposal of used packing
material and mesh pads^
6. Utilities
a. Electricity
b. Water7
Indirect operating costs
7. Overhead3
8. Property tax3
9. Insurance
10. Administration-^
11. Capital recovery'
Credits
o
Chromic acid recovery
$8.37/man-hr
15 percent of la
$9.21/hr
100 percent of 2a
16.3 percent of the total replacement cost4
26.4 percent of the total replacement cost"
$50/drum disposal (plus 10 percent tax)
$40/drum transportation
$0.0461/kWh
$0.7771,000 gal
60 percent of la + Ib -I- 2a + 2b
1 percent of capital cost
1 percent of capita] cost
2 percent of capital cost
11.7 percent of capital cost of packed-bed
scrubber/mesh-pad mist eliminator system0
$3.28/kg
aBased on an interest rate of 10 percent and a scrubber packing life of 10 years.
Based on an interest rate of 10 percent and a mesh-pad life of 5 years.
cBased on an interest rate of 10 percent and an equipment life of 20 years.
B-30
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Fiber-bed mist eliminator
mualized Costs
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B-31
-------
TABLE B-4. CAPITAL COST ESTIMATES PROVIDED BY VENDOR C FOR
MIST ELIMINATORS WITH MESH PADS IN SERIES
(SEPTEMBER 1990 DOLLARS)a
Airflow, n\3/min (ft3/min)
Cost
I.
2.
3.
4.
5.
6.
7.
component
Basic mist eliminator cost
Inlet and outlet transition
Fan and motor
Stack
Base equipment
Installation
Total capital cost
340 (12,000)
15,700
720
5,430
1,430
23,280
2,660
25,940
990 (35,000)
38,850
2,000
22,180
2,340
65,370
2,980
68,340
aAll costs were rounded to the nearest $10.
B-32
-------
TABLE B-5. CAPITAL COST ESTIMATES OF MIST ELIMINATORS WITH
MESH PADS IN SERIES (November 1988 Dollars)
Mesh-pad mist eliminator size
Control device parameters
Design gas flow rate, nr/min (fr/min)a
Pressure drop, kPa (in. w.c.)
Fan static pressure, kPa (in. w.c.)"
Fan motor size, hp (kW)c
Cost data
1 . Basic mesh-pad mist eliminator
2. Inlet and outlet transitions
3. Fan and motor
4. Stack
5. Base equipment"
6. Sales taxes and freight6
7. Total purchased equipment
8. Installation^
9. Startup"
10. Total capital cost1
A
340(12,000)
1.4(5.5)
1.4(5.5)
25 (18)
15,200
800
5,200
1.400
22,600
1.810
24,410
2,570
240
27,200
B
990 (35,000)
1.4(5.5)
1.4(5.5)
100 (73)
37,500
2,000
21,400
2.300
63,200
5.060
68,260
2,870
680
71,800
stream temperature is 27°C (80°F), gas stream moisture content is 2 percent, and altitude is 305 m
(1,000ft).
Static pressures are based on the ventilation specifications in Figures 1 and 2 and the pressure drop across the
control device.
cVendor C provided motor sizes based on the static pressures and gas flow rates specified above.
dSum of 1 through 4.
eSales taxes and freight costs are 3 and 5 percent, respectively, of base equipment costs.
'Sum of 5 and 6.
^Includes all costs associated with installing instrumentation, electrical components, and piping, erection and
contingencies; and fee. Assumes that the installation requires no major structural modifications.
"One percent of total purchased equipment cost.
'Sum of 7, 8, and 9. Costs were rounded to nearest $100.
B-33
-------
TABLE B-6. ESTIMATED ANNUALIZED COSTS OF MIST ELIMINATORS
WITH MESH PADS IN SERIES
(November 1988 Dollars)
Control device parameters
Design gas flow rate, m /min (fr/min)
Operating hours, hr/yr
Incremental fan motor size, hp (kW)° c
Total water consumption per year, gal
Maintenance hours, hr/yr
Operator labor hours, hr/yr"
Life expectancy of unit, yrb
Life expectancy of pad material, yr
Cost datad
1. Utilities
2. Operator, supervisor, and maintenance
3. Maintenance materials
4. Mesh-pad replacement6
5. Indirect costs
6. Capital recovery
7. Total annualized costs^
Mesh -pad
A
340 (12,000)
2,000
15(11)
48,800
150
62.5
10
5
1,070
1,980
1,380
1,780
3,110
4,430
13,800
mist eliminator size
B,a
990 (35,000)
3,500
60(44)
85,470
262.5
62.5
10
5
7,290
3,020
2,420
4,790
6,130
11,700
35,400
R *
K1
990 (35,000)
6,000
60 (44)
146,280
450
62.5
10
5
12,490
4,740
4,140
4,790
8,200
11,700
46,100
aB. is based on a 990 m^/min (35,000 fr/min) unit operating 3.500 h/yr; I$2 is based on the same size unit
operating at 6,000 h/yr.
Value of parameter provided by vendor.
cThe incremental fan size is the additional horsepower required to operate the control device over the
horsepower required to operate the ventilation system.
^Annualized costs were calculated from the control device parameters provided by the vendor and the operating
hours specified above. All costs are rounded to the nearest $10.
Includes cost of mesh pad replacement and transportation and disposal of the used mesh pads with 50 percent
compaction.
^Includes overhead, property tax, insurance, and administration.
SSum of 1 through 6. Numbers may not add exactly due to independent rounding. Cost data were rounded to
nearest $100.
B-34
-------
TABLE B-7. ESTIMATED CAPITAL COSTS OF MESH-PAD MIST
ELIMINATOR UNITS FOR NEW AND EXISTING HARD CHROMIUM
PLATING MODEL PLANTSa (November 1988 Dollars)
Model plant size"
Small
Medium
Large
Cost data
Total purchased
equipment (TPE)
Installation
Startup (1 percent of
TPE)
Total capital cost
(new)c
Total capital costd
24,400
2,600
200
27,200
34,000
68,300
2,900
700
71,800
89,800
136,500
5,700
1.400
143,600
179,500
cost data were rounded to the nearest $100.
^Small model plant costs are based on a unit with a 340 rrr/min
(12,000 ft3/min) gas flow rate; medium model plant costs are
based on a unit with a 990 m3/min (35,000 ft3/min) gas flow
rate; large model plant costs are two times medium model plant
costs.
^Numbers may not add exactly due to independent rounding.
"Based on a 25 percent increase in total capital cost to retrofit
an existing facility.
B-35
-------
TABLE B-8. ESTIMATED ANNUALIZED COSTS OF MESH-PAD MIST
ELIMINATOR UNITS FOR NEW HARD CHROMIUM PLATING
MODEL PLANTSa (November 1988 Dollars)
Cos t_ data
Utilities
Operator and maintenance
labor0
Maintenance materials
Mesh-pad replacementd
Indirect costs6
Capital recovery
Annualized cost
Chromic acid recovery^
Net annualized cost^
Model
Small
1,100
2,000
1,400
1,800
3,100
4.400
13,800
(300)
13,500
plant size'3
Medium
7,300
3,000
2,400
4,800
6,100
11.700
35,400
(2.600)
32,800
Large
25,000
6,200
8,300
9,600
14,400
23.400
86,800
(10.100)
76,700
aAll costs were rounded to the nearest $100.
^Small model plant costs are based on a unit with a 340 nr/min
(12,000 ft3/min) gas flow rate; medium model plant costs are
based on a unit with a 990 m3/min (35,000 ft3/min) gas flow
rate; large model plant costs (with the exception of operator
and maintenance labor and indirect costs) are equal to two times
medium model plant costs.
clncludes operator, supervisor, and maintenance labor.
^Includes costs of mesh pad replacement and transportation and
disposal of old mesh pads with 50 percent compaction.
elncludes overhead, property taxes, insurance, and
administration.
fChromic acid recovery credit is based on a control efficiency of
99.8 percent.
^Numbers may not add exactly due to independent rounding.
B-36
-------
TABLE B-9. ESTIMATED ANNUALIZED COSTS OF MESH-PAD
MIST ELIMINATOR UNITS FOR EXISTING HARD CHROMIUM
PLATING MODEL PLANTSa (November 1988 Dollars)
Cost data
Utilities
Operator and maintenance
labor0
Maintenance materials
Mesh-pad replacement"
Indirect costs6
Capital recovery
Annualized cost
Chromic acid recovery
Net annualized cost^
Model
Small
1,100
2,000
1,400
1,800
3,400
5,500
15,200
(300)
14,900
plant size*3
Medium
7,300
3,000
2,400
4,800
6,900
14.600
39,000
(2,600)
36,400
Large
25,000
6,200
8,300
9,600
15,900
29.300
94,200
(10.100)
84,100
aAll costs were rounded to the nearest $100.
^Small model plant costs are based on a unit with a 340 nrVmin
(12,000 ft3/min) gas flow rate; medium model plant costs are
based on a unit with a 990 rrr/min (35,000 ft3/min) gas flow
rate; large model plant costs (with the exception of operator
and maintenance labor and indirect costs) are equal to two times
medium model plant costs.
clncludes operator, supervisor, and maintenance labor.
"Includes costs of mesh pad replacement and transportation and
disposal of old mesh pads with 50 percent compaction.
elncludes overhead, property taxes, insurance, and
administration.
fChromic acid recovery credit is based on a control efficiency of
99.8 percent.
^Numbers may not add exactly due to independent rounding.
B-37
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B-38
-------
TABLE B-ll. CAPITAL COST ESTIMATES OF PACKED-BED
SCRUBBER/MESH-PAD MIST ELIMINATOR SYSTEM
(VENDOR A) (November 1988 Dollars)
Control device parameters
Design gas flow rate, m /min (fr /min)a
Pressure drop, kPa (in. w.c.)
Fan static pressure, kPa (in. w.c.)"
Fan motor size, hp (kW)c
Amount of packing, nr (ft3)
Amount of mesh pad material, nr (fr)
Cost data
1 . Basic extended packed-bed scrubber
2. Inlet and outlet transitions
3. Fan and motor
4. Recirculation tank
5. Recirculation pump and motor
6. Stack
7. Base equipment6
8. Sales taxes and freight'
9. Total purchased equipment^
10. Installation11
11. Startup'
12. Total capital cost)
Packed-bed scrubber/mesh-pad
A
340 (12,000)
1.7(6.8)
2.2 (8.8)
30 (22)
2.3 (80)
1 . 1 (40)
27,140
770
10,140
770
1,540
1.350
41,710
3.340
45,050
12,550
450
58,100
unit size
B
990 (35,000)
1.7 (6.8)
2.8 (11.3)
100 (75)
6.7 (236)
3.3(118)
51,450
2,030
17,000
1,160
2,220
2.510
76,370
6.110
82,480
14,480
820
97,800
*Gas stream temperature is 27°C (80°F), gas stream moisture content is 2 percent, and altitude is 305 m (1,000 ft).
Static pressures are based on the ventilation specifications in Figures 1 and 2 and the pressure drop across the control
device.
cVendor A provided motor sizes based on the static pressures and gas flow rates specified above.
dAll costs are rounded to the nearest $10.
eSum of 1 through 6.
Sales taxes and freight costs are 3 and 5 percent, respectively, of base equipment costs.
SSum of 7 and 8.
Includes all costs associated with installing instrumentation, electrical components, and piping, erection and contingencies;
and fee. Assumes that the installation requires no major structural modifications.
'One percent of total purchased equipment cost.
JSum of 9, 10, and 11. Costs were rounded to nearest $100.
B-39
-------
TABLE B-12. ANNUALIZED COSTS OF PACKED-BED SCRUBBER/MESH-PAD
MIST ELIMINATOR SYSTEM (VENDOR A) (November 1988 Dollars)
Control device parameters
Design gas flow rate, m /min (ft /min)
Operating hours, hr/yr
Incremental fan motor sire, hp (kW)° c
Volume of remote recirculation tank, L
(gal)b
Recirculation pump motor, hp (kW)°
Maintenance hours, hr/yr
Operator labor hours, hr/yr°
Life expectancy of unit, yr
Life expectancy of packing material, yr
Life expectancy of mesh pads, yr
Cost datad
1. Utilities
2. Operator, supervisor, and maintenance
3. Maintenance materials
4. Packing material replacement6
5. Mesh pad replacement6
6. Indirect costs
7. Capital recovery
8. Total annualized costsS
Packed-bed
A
340 (12,000)
2,000
20 (15)
760 (200)
3 (2.2)
50
125
20
10
5
1,640
1,670
460
330
2,720
3,600
6,860
17,300
scrubber/mesh-pad unit
B,a
990 (35,000)
3,500
60(44)
1,890(500)
7.5 (5.6)
110
125
20
10
5
8,310
2,260
1,050
950
4,430
5,900
11,540
34.400
size
B/
990 (35,000)
6,000
60 (44)
1,890(500)
7.5 (5.6)
195
125
20
10
5
14,260
3,010
1,800
950
4,430
6,800
11,540
42,800
aB, is based on a 990 m^/min (35,000 ft^/min) unit operating 3,500 h/yr; E-^ is based on the same size unit
operating at 6,000 h/yr.
Value of parameter provided by Vendor A.
cThe incremental fan size is the additional horsepower required to operate the control device over the
horsepower required to operate the ventilation system.
^Annualized costs were calculated from the control device parameters provided by the vendor and the operating
hours specified above. All costs are rounded to the nearest $10.
deludes cost of replacement and transportation and disposal of the used packing and mesh pads with
50 percent compaction.
'Includes overhead, property tax, insurance, and administration.
SSum of 1 through 7. Numbers may not add exactly due to independent rounding. Cost data were rounded to
nearest $100.
B-40
-------
TABLE B-13. ESTIMATED CAPITAL COSTS OF PACKED-BED SCRUBBER
MESH-PAD MIST ELIMINATOR SYSTEMS FOR NEW AND EXISTING HARD
CHROMIUM PLATING MODEL PLANTS (VENDOR A)a
(November 1988 Dollars)
Model plant size*3
Small
Medium
Large
Cost data
Total purchased
equipment (TPE)
Installation
Startup (1 percent of
TPE)
Total capital cost
(new)c
Total retrofit
capital costd
45,100
12,600
500
58,100
72,600
82,500
14,500
800
97,800
122,200
165,000
29,000
1.600
195,600
244,500
aAll cost data were rounded to the nearest $100.
^Small model plant costs are based on a unit with a 340 m3/min
(12,000 ft3/min) gas flow rate; medium model plant costs are
based on a unit with a 990 m3/min (35,000 ft3/min) gas flow
rate; large model plant costs are two 'times medium model plant
costs.
GNumbers may not add exactly due to independent rounding.
^Based on a 25 percent increase in total capital cost to retrofit
an existing facility.
B-41
-------
TABLE B-14. ESTIMATED ANNUALIZED COSTS OF PACKED-BED
SCRUBBER/MESH-PAD MIST ELIMINATOR SYSTEMS FOR NEW
HARD CHROMIUM PLATING MODEL PLANTS (VENDOR A)a
(November 1988 Dollars)
Cost data
Utilities
Operator and maintenance
labor0
Maintenance materials
Packing material
replacement"
Mesh pad replacement
Indirect costs6
Capital recovery
Annualized cost^
Chromic acid recoveryf
Net annualized cost^
Model
Small
1,600
1,700
500
300
2,700
3,600
6.900
17,300
(300)
17,000
plant size"
Medium
8,300
2,300
1,100
1,000
4,400
6,000
11.500
34,400
(2.600)
31,800
Large
28,500
3,900
3,600
1,900
8,900
12,300
23.1.00
82,200
(10,100)
72,100
aAll cost data were rounded to the nearest $100.
bSmall model plant costs are based on a unit with a 340 m3/min
(12,000 ft3/min) gas flow rate; medium model plant costs are
based on a unit with a 990 m3/min (35,000 ft3/min) gas flow
rate; large model plant costs (with the exception of operator
and maintenance labor and indirect costs) are equal to two times
medium model plant costs.
clncludes operator, supervisor, and maintenance labor.
"^Replacement costs include the cost associated with purchasing
new material and transportation and disposal of old material
with 50 percent compaction.
elncludes overhead, property taxes, insurance, and
administration.
fChromic acid recovery credit is based on a control efficiency of
99.8 percent.
^Numbers may not add exactly due to independent rounding.
B-42
-------
TABLE B-15. ESTIMATED ANNUALIZED COSTS OF PACKED-BED
SCRUBBER/MESH-PAD MIST ELIMINATOR SYSTEMS FOR EXISTING
HARD CHROMIUM PLATING MODEL PLANTS (VENDOR A)a
(November 1988 Dollars)
Cost data
Utilities
Operator and maintenance
labor0
Maintenance materials
Packing material
replacement
Mesh pad replacement^
Indirect costs6
Capital recovery
Annualized cost^
Chromic acid recovery
Net annualized cost^
Model
Small
1,600
1,700
500
300
2,700
4,200
19,600
(300)
19,300
plant size"
Medium
8,300
2,300
1,100
1,000
4,400
6,900
14.400
38,300
(2.600)
35,700
Large
28,500
3,900
3,600
1,900
8,900
14,300
28.900
90,100
(10.100)
80,000
f-All cost data were rounded to the nearest $100.
bSmall model plant costs are based on a unit with a 340 m3/min
(12,000 ft3/min) gas flow rate; medium model plant costs are
based on a unit with a 990 rrr/min (35,000 ft3/min) gas flow
rate; large model plant costs (with the exception of operator
and maintenance labor and indirect costs) are equal to two times
medium model plant costs.
^Includes operator, supervisor, and maintenance labor.
Replacement costs include the cost associated with purchasing
new material and transportation and disposal of old material
with 50 percent compaction.
elncludes overhead, property taxes, insurance, and
administration.
fChromic acid recovery credit is based on a control efficiency of
99.8 percent.
^Numbers may not add exactly due to independent rounding.
B-43
-------
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B-44
-------
TABLE B-17.
ESTIMATED CAPITAL COSTS FOR FIBER-BED
MIST ELIMINATORS
Fiber-bed mist eliminator size
Control device parameters
Design gas flow rate, nr /min (ft /min)a
Pressure drop, kPa (in. w.c.)
Fan static pressure, kPa (in. w.c.)*5
Fan motor size, hp (kW)c
Cost data
1. Basic fiber-bed mist eliminator
2. Inlet and outlet transitions
3. Fan and motor
4. Stack
5. Base equipment
6. Sales taxes and freight6
7. Total purchased equipment
8. Installation^
9. Modification11
10. Startup'
11. Total capital cost)
A
340 (12,000)
1.5-2.0(6-8)
2.0-2.5 (8-10)
40(30)
66,000
Included in 1
10,000
2.000
78,000
6.240
84,240
30,000
2,500
840
117,600
B
990 (35,000)
1.5-2.0(6-8)
2.6-3.1 (10.5-12.5)
125 (93)
141,000
Included in 1
15,000
3.000
159,000
12.720
171,720
56,000
5,200
1.720
234,600
''Gas stream temperature is 27°C (80°F), gas stream moisture content is 2 percent, and altitude is 305 m
(1,000 ft).
"Static pressures are based on the ventilation specifications hi Figures 1 and 2 and the pressure drop across the
control device.
CCECO Filters, Inc., provided motor sizes based on the static pressures and gas flow rates specified above.
dSum of 1 through 4.
eSales taxes and freight costs are 3 and 5 percent, respectively, of base equipment costs.
fSum of 5 and 6.
^Includes all costs associated with Installing instrumentation, electrical components, and piping, erection and
contingencies; and fee. Assumes that the installation requires no major structural modifications.
"Modification costs are the costs associated with modifying the existing ventilation system.
JOne percent of total purchased equipment cost.
JSum of 7, 8, 9, and 10. Costs were rounded to nearest $100.
B-45
-------
TABLE B-18. ANNUALIZED COSTS OF FIBER-BED MIST ELIMINATORS
Control device parameters
-3 0
Design gas flow rate, m/min (ft /nun)
Operating hours, hr/yr
Incremental fan motor size, hp (kW)b c
No. of fiber elements'3
Dimensions of fiber elements, (h,d,rt) m
(ft)b
Frequency of washdown, No. /8-hr
Duration of washdown, min"
Washdown water flowrate, L/min
(gal/min)b
Washdown of prefilter (continuous),
L/min (gal/min)
Maintenance hours, hr/yr
Operator labor hours, hr/yr'
Life expectancy of unit, yrb
Life expectancy of fiber elements, yr
Cost datad
1. Utilities
2. Operator and maintenance labor6
3. Maintenance materials
4. Fiber element replacement'
5. Indirect costsS
6. Capital recovery
7. Total annualized costs*1
Fiber-bed
A
340 (12,000)
2,000
30 (22)
4
6.1,0.61 0.05
(20.0, 2, 0.17)
1
60
2.6 (0.7)
5.3(1.4)
64
250
20
5
2,200
2,990
590
3,320
6,850
13,760
29,700
mist eliminator size
Ba
1
990 (35,000)
3,500
85 (63)
12
6.1,0.61,0.05
(20.0, 2, 0.17)
1
60
7.6 (2.0)
23.7 (6.25)
168
438
20
5
11,280
5,760
1,550
9,920
13,770
27,450
69,700
B,a
990 (35,000)
6,000
85 (63)
12
6.1,0.61 0.05
(20.0, 2, 0.17)
1
60
7.6 (2.0)
23.7 (6.25)
288
750
20
5
19,340
9,870
2,650
9,920
16,890
27,450
86,100
aB, is based on a 990 m^/min (35,000 ft^/min) unit operating 3,500 h/yr; 62 is based on the same size unit
operating at 6,000 h/yr.
Value of parameter provided by vendor.
cThe incremental fan size is the additional horsepower required to operate the control device over the
horsepower required to operate the ventilation system.
"Annualized costs were calculated from the control device parameters provided by the vendor and the operating
hours specified above. All costs are rounded to the nearest $10.
Includes operator, supervisor, and maintenance labor.
^Includes cost of fiber replacement and disposal and transportation of old fiber material with 50 percent
compaction.
^Includes overhead, property tax, insurance, and administration.
nSum of 1 through 6. Numbers may not add exactly due to independent rounding. Cost data were rounded to
nearest $100.
B-46
-------
TABLE B-19. CAPITAL COSTS OF FIBER-BED MIST ELIMINATORS FOR HARD
CHROMIUM PLATING MODEL PLANTS
Model plant size
Cost datad
Purchased equipment
Installation
Modification
Startup
Total capital cost6
Smalla
84,200
30,000
2,500
800
117, 600
Medium13
171,700
56,000
5,200
1.700
234,600
Largec
343,400
112,000
10,400
3.400
469,200
aSmall model plant costs are from Column A in Table B-21.
^Medium model plant costs are from Column B in Table B-21.
GLarge model plant costs are two times Column B in Table B-21.
°Costs were rounded to the nearest $100.
eNumbers may not add exactly due to independent rounding.
B-47
-------
TABLE B-20. ANNUALIZED COSTS FOR FIBER-BED MIST ELIMINATORS
FOR NEW HARD CHROMIUM PLATING MODEL PLANTS
Cost .._dat_ad
Utilities
Operator and maintenance
labor6
Maintenance materials
Fiber material
replacement f
Indirect costs^
Capital recovery
Annualized cost"
Chromic acid recovery1
Net annualized cost"
Small a
2,200
3,000
600
3,300
6,900
13.800
29,700
(300)
29,400
Model plant size
Medium13
11,300
5,800
1,600
9,900
13,800
27.500
69,700
(2.600)
67,100
Large0
38,700
12,800
5,300
19,800
29,600
54.900
161,200
(10.100)
151,100
aSmall model plant costs are equal to the costs presented in
Column A of Table B-22.
^Medium model plant costs are equal to the costs presented in
Column BT of Table B-22.
GLarge model plant costs (with the exception of operator and
maintenance labor and indirect costs) are equal to two times the
costs presented in Column B2 of Table B-22.
dAll costs were rounded to nearest $100.
elncludes operator, supervisor, and maintenance labor.
^Fiber material replacement costs include the cost associated
with purchasing new fiber material and transportation and
disposal of the old material with 50 percent compaction.
^Includes overhead, property taxes, insurance, and
administration.
^Numbers may not add exactly due to independent rounding.
^•Chromic acid recovery credit is based on a control efficiency of
99.8 percent.
B-48
-------
TABLE B-21. ANNUALIZED COSTS FOR FIBER-BED MIST ELIMINATORS
FOR EXISTING HARD CHROMIUM PLATING OPERATIONS
Cost dataa
Utilities
Operator and maintenance
laborb
Maintenance materials
Fiber material
replacement0
Indirect costs^
Capital recovery
Annualized cost6
Chromic acid recovery
Net annualized cost8
Small
2,200
3,000
600
3,300
7,300
15.100
31,600
(300;
31,300
Model plant size
Medium
11,300
5,800
1,600
9,900
14,700
30.200
73,400
1 (2.600)
70,800
Large
38,700
12,800
5,300
19,800
31,500
60.400
168,600
(10.100)
158,500
f-All costs were rounded to nearest $100.
^Includes operator, supervisor, and maintenance labor.
cFiber material replacement costs include the cost associated
with purchasing new fiber material and transportation and
disposal of the old material with 50 percent compaction.
^Includes overhead, property taxes, insurance, and
administration.
8Numbers may not add exactly due to independent rounding.
fChromic acid recovery credit is based on a control efficiency of
99.8 percent.
B-49
-------
B.4 REFERENCES FOR APPENDIX B
1. Supplement to Employment and Earnings, Bureau of Labor
Statistics. August 1988. p. 55.
2. Monthly Labor Review, Bureau of Labor Statistics, Volume 112,
Number 1. January 1989.
3. EAB Control Cost Manual (Third Edition), U. S. Environmental
Protection Agency, Research Triangle Park, North Carolina.
Publication No. EPA 450/5-87-001A. February 1987.
4. Cost Enclosure for Packed-Bed Scrubber/Mesh-Pad Mist
Eliminator Systems: Vendor A. Prepared for U. S.
Environmental Protection Agency, Research Triangle Park,
North Carolina. October 24, 1990.
5. Telecon. Caldwell, M. J., MRI, with Glovenor, S., Chemical
Waste Management. April 11, 1989. Information on
transportation and disposal of hexavalent chromium solid
waste.
6. Monthly Energy Review. Energy Information Administration.
Department of Energy. Washington, D.C. October 1988.
7. Telecon. Caldwell, M. J., MRI, with Kraft, G., American
Water Works Association. March 13, 1989. Information
concerning nationwide residential and commercial water rates
for January 1989.
8. Telecon. Barker, R., MRI, to Jones, R., Ashland Chemical
Corp. Raleigh, North Carolina. June 1, 1989. Information
concerning industrial grade chromic acid costs.
9. Cost enclosure from Vendor C, to R. Barker, Midwest Research
Institute. October 5, 1990.
10. Telecon. Barker, R., MRI, to Vendor A. November 20, 1990.
Information concerning estimated operator and maintenance
hours.
11. Cost Enclosure for Fiber-Bed Mist Eliminators: CECO Filters,
Inc. Prepared for U. S. Environmental Protection Agency,
Research Triangle Park, North Carolina. September 19, 1989.
pp. 2-3.
12. Telecon. Barker, R., MRI, with Kaulius, S., CECO Filters,
Inc. October 3, 1989. Information regarding cost data and
operating parameters for fiber-bed mist eliminators.
B-50
-------
13. Memo from Barker, R., MRI, to Smith, A., EPA. Summary of
Retrofit Capital and Annualized Cost Data for the Engineering
Control Devices for the Hard and Decorative Chromium Plating
and Chromic Acid Anodizing Model Plants. July 6, 1989.
pp. 1-2.
14. Cost Enclosure for Packed-Bed Scrubber/Mesh-Pad Mist
Eliminator Systems: Vendor C. Prepared for U. S.
Environmental Protection Agency, Research Triangle Park,
North Carolina. October 5, 1990.
15. Cost Enclosure for Fiber-Bed Mist Eliminators: Monsanto
Enviro-Chem. Prepared for U. S. Environmental Protection
Agency, Research Triangle Park, North Carolina.
September 20, 1989. pp. 1-2.
16. Holmes, T. L., and Chen, G. K. Design and Selection of
Spray/Mist Elimination Equipment. Chemical Engineering.
October 15, 1984. p. 86.
B-51
-------
APPENDIX C. SUMMARY OF MODEL PLANT CAPITAL AND ANNUALIZED
COSTS FOR THE NEW EMISSION CONTROL TECHNOLOGIES
Capital and annualized costs are presented here in tabular
form for packed-bed scrubbers and the new emission control
technologies for hard chromium plating model plants. Costs for
new and existing plants are included in the tables.
C-l
-------
TABLE C-l. CAPITAL COSTS OF SINGLE PACKED-BED SCRUBBERS FOR HARD
CHROMIUM ELECTROPLATING MODEL PLANTS (NOVEMBER 1988 DOLLARS)
Cost dataa
Purchased equipment
Installation
Startup
Total capital costb
Total retrofit capital costc
Model
Small
19,500
17,000
200
36,700
45,900
plant size
Medium
47,300
26,400
500
74,200
92,800
Large
94,600
52,900
900
148,400
185,500
aCosts were rounded to nearest $100.
^Numbers may not total exactly due to independent rounding.
GCapital cost estimate representative of an existing facility
cost.
C-2
-------
TABLE C-2. ANNUALIZED COSTS FOR SINGLE PACKED-BED SCRUBBERS FOR
NEW HARD CHROMIUM ELECTROPLATING MODEL PLANTS
(NOVEMBER 1988 DOLLARS)
Cost data5
Utilities
Operator and maintenance
laborb
Maintenance materials
Packing replacement0
Indirect costs'^
Capital recovery
Annualized cost
Chromic acid recovery8
Net annualized costf
Small
600
1,700
500
100
2,800
4.300
10,000
(300
9,700
Model plant
Medium
3,800
2,300
1,100
300
5,000
8.700
21,200
) (2,600)
18,600
size
Large
12,900
3,900
3,600
600
10,400
17,400
48,800
(10,000)
38,800
f-All costs were rounded to nearest $100.
Includes operator, supervisor, and maintenance labor.
cPacking replacement costs include the cost associated with
purchasing new packing material and transportation and disposal
of the old material with 50% compaction.
Includes overhead, property taxes, insurance, and
administration.
eChromic acid recovery credit is based on a control efficiency of
99 percent.
fNumbers may not total exactly due to independent rounding.
C-3
-------
TABLE C-3. ANNUALIZED COSTS FOR SINGLE PACKED-BED SCRUBBERS FOR
EXISTING HARD CHROMIUM ELECTROPLATING MODEL PLANTS
(NOVEMBER 1988 DOLLARS)
Model plant size
Cost dataa
Utilities
Operator and maintenance
laborb
Maintenance materials
Packing replacement
Indirect costs^
Capital recovery
Annualized cost
Chromic acid recovery6
Net annualized costf
Small
600
1,700
500
100
3,100
5.400
11,400
(300)
11,100
Medium
. 3,800
2,300
1,100
300
5,700
10.900
24,100
(2,600)
21,500
Large
12,900
3,900
3,600
600
11,900
21.700
54,600
(10,000)
44,600
aAll costs were rounded to nearest $100.
^Includes operator, supervisor, and maintenance labor.
GPacking replacement costs include the cost associated with
purchasing new packing material and transportation and disposal
of the old material with 50% compaction.
dlncludes overhead, property taxes, insurance, and
administration.
eChromic acid recovery credit is based on a control efficiency of
99 percent.
fNumbers may not total exactly due to independent rounding.
C-4
-------
TABLE C-4. CAPITAL COSTS OF MESH-PAD MIST ELIMINATORS WITH
MESH PADS IN SERIES FOR HARD CHROMIUM ELECTROPLATING
MODEL PLANTS (NOVEMBER 1988 DOLLARS)
Cost dataa
Purchased equipment
Installation
Startup
Total capital costb
Total retrofit capital costc
Model
Small
24,40.0
2,600
200
27,200
34,000
plant size
Medium
68,300
2,900
700
71,800
89,800
Large
136,500
5,700
1.400
143,600
179,500
aCosts were rounded to nearest $100.
^Numbers may not total exactly due to independent rounding.
GCapital cost estimate representative of an existing facility
cost.
C-5
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TABLE C-5. ANNUALIZED COSTS FOR MESH-PAD MIST ELIMINATORS WITH
MESH PADS IN SERIES FOR NEW HARD CHROMIUM ELECTROPLATING
MODEL PLANTS (NOVEMBER 1988 DOLLARS)
Model plant size
Cost dataa
Utilities
Operator and maintenance
laborb
Maintenance materials
Mesh pad replacement13
Indirect costs"
Capital recovery
Annualized cost6
Chromic acid recovery^
Net annual ized cost6
Small
1,100
2,000
1,400
1,800
3,100
4,400
13,800
(300)
13,500
Medium
7,300
3,000
2,400
4,800
6,100
11.700
35,400
(2,600)
32,800
Large
25,000
6,200
8,300
9,600
14,400
23.400
86,800
(10,100)
76,700
aAll costs were rounded to nearest $100.
^Includes operator, supervisor, and maintenance labor.
GMesh pad replacement costs include the cost associated with
purchasing new mesh pad material and transportation and disposal
of the old material with 50% compaction.
^Includes overhead, property taxes, insurance, and
administration.
6Numbers may not total exactly due to independent rounding.
fChromic acid recovery credit is based on a control efficiency of
99.8 percent.
C-6
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TABLE C-6. ANNUALIZED COSTS FOR MESH-PAD MIST ELIMINATORS WITH
MESH PADS IN SERIES FOR EXISTING HARD CHROMIUM ELECTROPLATING
MODEL PLANTS (NOVEMBER 1988 DOLLARS)
Model plant
Cost dataa
Utilities
Operator and maintenance
laborb
Maintenance materials
Mesh pad replacement0
Indirect costs
Capital recovery
Annualized cost6
Chromic acid recovery^
Net annualized cost6
Small
1,100
2,000
1,400
1,800
3,400
5.500
15,200
(300)
14,900
Medium
7,300
3,000
2,400
4,800
6,900
14.600
39,000
(2,600
36,400
size
Large
25,000
6,200
8,300
9,600
15,900
29.300
94,200
) (10,100)
84,100
aAll costs were rounded to nearest $100.
"includes operator, supervisor, and maintenance labor.
cMesh pad replacement costs include the cost associated with
purchasing new mesh pad material and transportation and disposal
of the old material with 50% compaction.
^Includes overhead, property taxes, insurance, and
administration.
6Numbers may not total exactly due to independent rounding.
^Chromic acid recovery credit is based on a control efficiency of
99.8 percent.
C-7
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TABLE C-7. CAPITAL COSTS OF PACKED-BED SCRUBBER/MESH-PAD MIST
ELIMINATOR SYSTEMS FOR HARD CHROMIUM ELECTROPLATING
MODEL PLANTS (NOVEMBER 1988 DOLLARS)
Cost dataa
Purchased equipment
Installation
Startup
Total capital costb
Total retrofit capital costc
Model
Small
45,100
12,600
500
58,100
72,600
plant
Medium
82,500
14,500
800
97,800
122,200
size
Large
165,000
29,000
1.600
195,600
244,500
aCosts were rounded to nearest $100.
^Numbers may not total exactly due to independent rounding.
GCapital cost estimate representative of an existing facility
cost.
C-8
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TABLE C-8. ANNUALIZED COSTS FOR PACKED-BED SCRUBBER/MESH-PAD
MIST ELIMINATOR SYSTEMS FOR NEW HARD CHROMIUM ELECTROPLATING
MODEL PLANTS (NOVEMBER 1988 DOLLARS)
Cost dataa
Utilities
Operator and maintenance
labor13
Maintenance materials
Packing material replacement0
Mesh pad replacement0
Indirect costs^
Capital recovery
Annualized cost6
Chromic acid recovery^
Net annualized cost6
Small
1,600
1,700
500
300
2,700
3,600
6.900
17,300
(300
17,000
Model plant size
Medium
8,300
2,300
1,100
1,000
4,400
6,000
11,500
34,400
) (2,600) i
31,800
Large
28,500
3,900
3,600
1,900
8,900
12,300
23.100
82,200
(10,100)
72,100
f-All costs were rounded to nearest $100.
^Includes operator, supervisor, and maintenance labor.
°Replacement costs include the cost associated with
purchasing new material and transportation and disposal of the
old material with 50% compaction.
^Includes overhead, property taxes, insurance, and
administration.
6Numbers may not total exactly due to independent rounding.
Chromic acid recovery credit is based on a control efficiency of
99.8 percent.
C-9
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TABLE C-9. ANNUALIZED COSTS FOR PACKED-BED SCRUBBER/MESH-PAD
MIST ELIMINATOR SYSTEMS FOR EXISTING HARD CHROMIUM
ELECTROPLATING MODEL PLANTS (NOVEMBER 1988 DOLLARS)
Model plant
Cost dataa
Utilities
Operator and maintenance
laborb
Maintenance materials
Packing material replacement0
Mesh pad replacement0
Indirect costs0*
Capital recovery
Annualized cost6
Chromic acid recovery^
Net annualized cost6
Small
1,600
1,700
500
300
2,700
4,200
8.600
19,600
(300)
19,300
Medium
8,300
2,300
1,100
1,000
4,400
6,900
14,400
38,300
(2,600
35,700
size
Large
28,500
3,900
3,600
1,900
8,900
14,300
28.900
90,100
) (10,100)
80,000
aAll costs were rounded to nearest $100.
"Includes operator, supervisor, and maintenance labor.
Replacement costs include the cost associated with
purchasing new material and transportation and disposal of the
old material with 50% compaction.
^Includes overhead, property taxes, insurance, and
administration.
6Numbers may not total exactly due to independent rounding.
fChromic acid recovery credit is based on a control efficiency of
99.8 percent.
C-10
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TABLE C-10. CAPITAL COSTS OF FIBER-BED MIST ELIMINATORS FOR HARD
CHROMIUM ELECTROPLATING MODEL PLANTS (NOVEMBER 1988 DOLLARS)
Cost dataa
Purchased equipment
Installation
Modification
Startup
Total capital cost*3
Total retrofit capital costc
Model
Small
82,000
29,200
2,400
800
114,600
126,100
plant size
Medium
167,300
54,600
5,100
1.700
228,600
251,500
Large
334,600
109,100
10,100
3.300
457,100
502,800
aCosts were rounded to nearest $100.
^Numbers may not total exactly due to independent rounding.
GCapital cost estimate representative of an existing facility
cost.
C-ll
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TABLE C-ll. ANNUALIZED COSTS FOR FIBER-BED MIST ELIMINATORS FOR
NEW HARD CHROMIUM ELECTROPLATING MODEL PLANTS
(NOVEMBER 1988 DOLLARS)
Model plant
Cost dataa
Utilities
Operator and maintenance
labor13
Maintenance materials
Fiber material replacement0
Indirect costs"
Capital recovery
Annualized cost6
Chromic acid recovery
Net annualized cost6
Small
2,200
3,000
600
3,300
6,700
13,400
29,200
(300)
28,900
Medium
11,300
5,800
1,600
9,900
13,500
26.700
68,800
(2,600)
66,200
size
Large
38,700
12,800
5,300
19,800
29,200
53.500
159,300
(10,100)
149,200
costs were rounded to nearest $100.
^Includes operator, supervisor, and maintenance labor.
cFiber material replacement costs include the cost associated
with purchasing new fiber material and transportation and
disposal of the old material with 50% compaction.
dlncludes overhead, property taxes, insurance, and
administration.
6Numbers may not total exactly due to independent rounding.
fChromic acid recovery credit is based on a control efficiency of
99.8 percent.
C-12
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TABLE C-12. ANNUALIZED COSTS FOR FIBER-BED MIST ELIMINATORS FOR
EXISTING HARD CHROMIUM ELECTROPLATING MODEL PLANTS
(NOVEMBER 1988 DOLLARS)
Cost dataa
Utilities
Operator and maintenance
labor10
Maintenance materials
Fiber material replacement0
Indirect costs
Capital recovery
Annualized cost6
Chromic acid recovery^
Net annualized cost6
Small
2,200
3,000
600
3,300
7,200
14.800
31,000
(300
30,700
Model plant
Medium
11,300
5,800
1,600
9,900
14,400
29.400
72,400
) (2,600)
69,800
size
Large
38,700
12,800
5,300
19,800
31,000
58.800
166,400
(10,100)
156,300
costs were rounded to nearest $100.
^Includes operator, supervisor, and maintenance labor.
GFiber material replacement costs include the cost associated
with purchasing new fiber material and transportation and
disposal of the old material with 50% compaction.
Includes overhead, property taxes, insurance, and
administration.
6Numbers may not total exactly due to independent rounding.
^Chromic acid recovery credit is based on a control efficiency of
99.8 percent.
C-13
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