EPA-450/3-76-014
May 1976
CAPITAL
AND OPERATING COSTS
OF SELECTED AIR POLLUTION
CONTROL SYSTEMS
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Waste Management
Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina 27711
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EPA-450/3-76-014
CAPITAL
AND OPERATING COSTS
OF SELECTED AIR POLLUTION
CONTROL SYSTEMS
by
M.L. Kinkley and R.B. Ncveril
CARD, Inc.
7449 North Natche/, A\enue
Nilcs, Illinois 60648
Contract No. 68-02-2072
EPA Project Officer: Frank Bunyard
Prepared for
ENVIRONMENTAL PROTECTION AGENCY
Office of Air and ^'aste Management
Office of Air Quality Planning and Standard;-
Research Triangle Park, North Carolina 27711
Mav 1976
-------
This report is issued by the Environmental Protection Agency to report
technical data of interest to a limited number of readers. Copies are
available free of charge to Federal employees, current contractors and
grantees, and nonprofit organizations - as supplies permit - from the
Air Pollution Technical Information Center, Environmental Protection
Agency, Research Triangle Park, North Carolina 27711; or, for a fee,
from the National Technical Information Service, 5285 Port Royal Road,
Springfield, Virginia 22161.
This report was furnished to the Environmental Protection Agency by
Card, Inc. Niles, Illinois 60648, in fulfillment of Contract No. 68-02-2072
The contents of this report are reproduced herein as received from
Card, Inc. The opinions, findings, and conclusions expressed are
those of the author and not necessarily those of the Environmental Protection
Agency. Mention of company or product names is not to be considered
as an endorsement by the Environmental Protection Agency.
Publication No. EPA-450/3-76-014
11
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TABLE OF CONTENTS
Section Page
LIST OF TABLES v
LIST OF FIGURES vi
1 INTRODUCTION 1-1
1.1 Purpose of Manual 1-1
1.2 Organization of Manual 1-2
2 DESCRIPTION OF CONTROL SYSTEMS 2-1
2.1 High Voltage Electrostatic Precipitator 2-1
Systems
2.1.1 General Description 2-1
2.1.2 Cost Factors 2-4
2.1.3 Auxiliary Equipment 2-5
2.2 Venturi Scrubber Systems 2-11
2.2.1 General Description 2-11
2.2.2 Cost Factors 2-13
2.2.3 Auxiliary Equipment 2-13
2.3 Fabric Filter Systems 2-16
2.3.1 General Description 2-16
2.3.2 Cost Factors 2-21
2.3.3 Auxiliary Equipment 2-21
2.4 Thermal and Catalytic Incinerator System 2-23
2.4.1 General Description 2-23
2.4.2 Cost Factors 2-25
2.4.3 Auxiliary Equipment 2-26
2.5 Adsorption Systems 2-26
2.5.1 General Description 2-26
2.5.2 Cost Factors 2-27
2.5.3 Auxiliary Equipment 2-28
2.6 Application to Industry 2-28
2.7 Factors Affecting Retrofit Costs 2-37
3 PROCEDURE FOR ESTIMATING COSTS 3-1
3.1 General 3-1
3.2 Cost Comparison Methodologies 3-3
3.3 Example Case Study 3-6
4 CONTROL EQUIPMENT COSTS AND SELECTED DESIGN DATA 4-1
4.1 Electrostatic Precipitators 4-1
4.2 Venturi Scrubbers 4-3
4.3 Fabric Filters 4-9
I 4.4 Thermal and Catalytic Incinerators 4-16
4.5 Adsorbers 4-20
4.6 Ductwork 4-24
4.6.1 Capture Hoods 4-24
4.6.2 Straight Duct 4-30
TM
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TABLE OF CONTENTS (continued)
Section
4.6.3 Elbow Duct, Tees, and Transitions
4.6.4 Expansion Joints
4.6.5 Refractory Materials
4.7 Dampers
4.8 Heat Exchangers
4.8.1 Spray Chambers & Quenchers
4.8.2 Radiant Coolers
4.8.3 Dilution Air Ports
4.9 Mechanical Collectors
4.10 Fans, Motors, and Starters
4.10.1 Backwardly Curved Fans
4.10.2 Radial Tip Fans
4.11 Stacks
4.12 Cooling Towers
4.13 Pumps
4.14 Dust Removal Equipment
4.15 Operation, Maintenance and Installation Costs
4-34
4-37
4-39
4-41
4-44
4-44
4-47
4-47
4-50
4-58
4-58
4-59
4-70
4-74
4-78
4-83
4-85
5 UPDATING COSTS TO FUTURE TIME PERIODS
5.1 General
5.2 Equipment Cost Updating Procedures
APPENDIX A COMPOUND INTEREST FACTORS
B EQUIPMENT COST INDEXES
C GUIDE TO REFERENCES FOR THE 27 INDUSTRIES
D GUIDE TO ASSOCIATIONS FOR THE 27 INDUSTRIES
E CONVERSION FACTORS TO SI EQUIVALENTS
5-1
5-1
5-5
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LIST OF TABLES
TABLE PAGE
NUMBER TITLE NUMBER
2-1 INDUSTRY POLLUTANT SOURCES AND TYPICAL
CONTROL DEVICES 2-29
2-2 DESIGN PARAMETERS FOR RESPECTIVE INDUSTRIES
FOR HIGH EFFICIENCY PERFORMANCE 2-35
2-3 EFFICIENCY OF CARBON ADSORPTION AND LEL'S
FOR COMMON POLLUTANTS 2-36
4-1 BAG PRICES ($/SQ.FT.) 4-15
4-2 APPROXIMATE GUIDE TO ESTIMATE GROSS
CLOTH AREA 4-15
4-3 REFRACTORY ESTIMATING COSTS 4-40
4-4 PRICING FACTORS FOR OTHER MOTOR TYPES 4-62
4-5 MOTOR AND STARTER PRICE EQUATIONS 4-62
4-6 MOTOR TYPE SELECTION 4-62
4-7 MOTOR RPM SELECTION GUIDE 4-62
4-8 FAN SIZING FACTORS: AIR DENSITY RATIOS 4-63
4-9 PRICE ADJUSTMENT FACTORS FOR
APPROACH AT 4-77
4-10 PRICE ADJUSTMENT FACTORS FOR WET
BULB TEMPERATURES 4.77
4-li DEFINITIONS FOR COOLING TOWER 4-77
4-12 MAINTENANCE AND INSTALLATION COST FACTORS
AND EQUIPMENT LIFE GUIDELINES 4-89
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LIST OF FIGURES
FIGURE PAGE
NUMBER TITLE NUMBER
2-1 CONTROL SYSTEM FLOW CIRCUIT 2-2
2-2 ELECTROSTATIC PRECIPITATOR CONTROL SYSTEMS 2-6
2-3 VENTURI SCRUBBER CONTROL SYSTEMS 2-14
2-4 FABRIC FILTER CONTROL SYSTEMS 2-22
3-1 FABRIC FILTER SYSTEM DESIGN 3-11
3-2 ELECTROSTATIC PRECIPITATOR SYSTEM DESIGN 3-15
3-3 VENTURI SCRUBBER SYSTEM DESIGN 3-18
4-1 DRY TYPE ELECTROSTATIC PRECIPITATOR
PRICES VS. PLATE AREA 4-2
4-2 1/8" THICK CARBONSTEEL FABRICATED
SCRUBBER PRICE VS. ACFM 4-4
4-3 METAL THICKNESS REQUIRED VS. ACFM AND
DESIGN PRESSURE 4-5
4-4 PRICE ADJUSTMENT FACTORS VS. PLATE
THICKNESS AND ACFM 4-6
4-5 SCRUBBER INTERNAL SURFACE AREA AND SEPARATOR
DIAMETER AND HEIGHT VS. WASTE INLET GAS 4-7
VOLUME
4-6 INTERNAL GAS COOLER BUBBLE TRAY COST VS.
SEPARATOR DIAMETER 4-8
4-7 INTERMITTANT, PRESSURE, MECHANICAL SHAKER
BAGHOUSE PRICES VS. NET CLOTH AREA 4-10
4-8 CONTINUOUS, SUCTION OR PRESSURE, PULSE JET
BAGHOUSE PRICES VS. NET CLOTH AREA 4-11
4-9 CONTINUOUS, PRESSURE, MECHANICAL SHAKER
BAGHOUSE PRICES VS. NET CLOTH AREA 4-12
4-10 CONTINUOUS, PRESSURE, REVERSE AIR BAGHOUSE
PRICES VS. NET CLOTH AREA 4-13
4-11 CUSTOM BAGHOUSE PRICES VS. NET CLOTH AREA 4-14
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LIST OF FIGURES
FIGURE PAGE
NUMBERS TITLE NUMBER
4-12 PRICES FOR THERMAL INCINERATORS WITHOUT
HEAT EXCHANGERS 4-17
4-13 PRICES FOR THERMAL INCINERATORS WITH HEAT
EXCHANGERS 4-18
4-14 CATALYTIC INCINERATOR PRICES 4-19
4-15 PRICES FOR PACKAGED STATIONARY BED CARBON
ADSORPTION UNITS W/STEAM REGENERATION 4-22
4-16 PRICES FOR CUSTOM CARBON ADSORPBTION UNITS 4-23
4-17 RECTANGULAR CAPTURE HOODS PLATE AREA
REQUIREMENTS VS. HOOD LENGTH AND L/W 4-26
4-18 CIRCULAR HOODS PLATE REQUIREMENTS VS
HOOD DIAMETER AND H/D 4-27
4-19 LABOR COST FOR FABRICATED 10 GA. CARBON
STEEL RECTANGULAR CAPTURE HOODS 4-28
4-20 LABOR COST FOR FABRICATED 10 GA. CARBON
STEEL CIRCULAR CAPTURE HOODS 4-29
4-21 CARBON STEEL STRAIGHT DUCT FABRICATION
PRICE PER LINEAR FOOT VS. DUCT DIAMETER
AND PLATE THICKNESS 4-31
4-22 STAINLESS STEEL STRAIGHT DUCT FABRICATION
PRICE PER LINEAR FOOT VS. DUCT DIAMETER
AND PLATE THICKNESS 4-32
4-23 WATER COOLED CARBON STEEL STRAIGHT DUCT
FABRICATION PRICE PER FOOT VS. DUCT
DIAMETER 4-33
4-24 CARBON STEEL ELBOW DUCT PRICE VS. DUCT
DIAMETER AND PLATE THICKNESS 4-35
4-25 STAINLESS STEEL ELBOW DUCT PRICE VS. DUCT
DIAMETER AND PLATE THICKNESS 4-36
4-26 EXPANSION JOINTS COSTS, VS. DUCT DIAMETER 4-38
Vll
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LIST OF FIGURES
FIGURE PAGE
NUMBERS TITLE NUMBER
4-27 CARBON STEEL RECTANGULAR DAMPER PRICES VS. AREA 4-42
4-28 CARBON STEEL CIRCULAR DAMPER PRICES VS.
DIAMETER 4.43
4-29 SPRAY CHAMBER COSTS VS. INLET GAS VOLUME 4.45
4-30 QUENCKER COSTS VS. INLET GAS VOLUME 4-46
4-31 FABRICATED 40 FOOT HIGH 'U' TUBE HEAT
EXCHANGER PRICES WITH HOPPERS AND
MANIFOLDS 4-48
4-32 PRICES FOR FABRICATED CARBON STEEL DILUTION
AIR PORT VS. DIAMETER AND PLATE THICKNESS 4-49
4-33 CAPACITY ESTIMATES FOR MECHANICAL
COLLECTORS 4-51
4-34 CRITICAL PARTICAL SIZE ESTIMATES FOR
MECHANICAL COLLECTORS 4-52
4-35 MECHANICAL COLLECTOR PRICES FOR CARBON
STEEL CONSTRUCTION VS. INLET AREA 4-53
4-36 MECHANICAL COLLECTOR PRICES FOR STAIN-
LESS STEEL CONSTRUCTION VS. INLET AREA 4-54
4-37 MECHANICAL COLLECTOR SUPPORT PRICES VS.
COLLECTOR INLET AREA 4-55
4-38 MECHANICAL COLLECTOR DUST HOPPER PRICES
FOR CARBON AND STAINLESS STEEL CONSTR-
UCTION VS. COLLECTOR INLET AREA 4-56
4-39 MECHANICAL COLLECTOR SCROLL OUTLET PRICES
FOR CARBON AND STAINLESS STEEL CONSTRUC-
TION VS. COLLECTOR INLET AREA 4-57
4-40 BACKWARDLY CURVED FAN PRICES VS. CLASS, CFM,
AND AP FOR ARRANGEMENT NO. 1 4-60
4-41 BHP, FAN RPM AND MOTOR AND STARTER PRICES VS.
AP AND CFM 4- 61
4-42 RADIAL FAN PRICES VS. CFM, AND AP FOR
ARRANGEMENT NO. 1 4-64
vm
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LIST OF FIGURES
FIGURE PAGE
NUMBERS TITLE NUMBER
4-43 FAN RPM AND MOTOR BMP FOR RADIAL FAN 4-65
4-44 FAN INLET AND OUTLET DAMPER PRICES AS A
FUNCTION OF CFM AND AP 4-66
4-45 V-BELT DRIVE PRICES 4-67
4-46 RADIAL TIP FAN PRICES. 4-68
4-47 STARTER AND MOTOR PRICES FOR VENTURI
SCRUBBER APPLICATIONS (HIGH PRESSURE,
HIGH BHP) 4-69
4-48 FABRICATED CARBON STEEL STACK PRICE VS.
STACK HEIGHT AND DIAMETER FOR 1/4 INCH
PLATE 4-71
4-49 FABRICATED CARBON STEEL STACK PRICE VS.
STACK HEIGHT AND DIAMETER FOR 5/16
AND 3/8 INCH PLATE 4-72
4-50 PRICES FOR TALL STEEL STACKS, INSULATED
AND LINED 4-73
4-51 PRICES FOR INSTALLED COOLING TOWERS FOR
UNITS OF CAPACITY 1 1000 TONS 4-75
4-52 PRICES FOR INSTALLED COOLING TOWER BASED
ON WET BULT TEMPERATURE = 82°F AND
APPROACH = 10°F 4-76
4-53 CAST IRON, BRONZE FITTED, VERTICAL TURBINE
WET SUMP PUMP PRICES FOR 3550 RPM 4-79
4-54 CAST IRON, BRONZE FITTED, VERTICAL TURBINE
WET SUMP PUMP PRICES FOR 1750 RPM 4-80
4-55 CAST IRON, BRONZE FITTED, VERTICAL TURBINE
WET SUMP PUMP PRICES FOR 1170 RPM 4-81
4-56 PUMP MOTOR HP VS. CAPACITY AND HEAD FOR
VERTICAL TURBINE PUMPS 4-82
4-57 PRICES FOR SCREW CONVEYORS VS. LENGTH
AND DIAMETER 4-84
IX
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LIST OF FIGURES
FIGURE PAGE
NUMBERS TITLE NUMBER
4-58 ELECTROSTATIC PRECIPITATOR OPERATING COSTS
VS. ACFM AND POWER CONSUMPTION 4-86
4-59 VENTURI SCRUBBER OPERATING COSTS VS. ACFM
AND AP 4-87
4-60 FABRIC FILTER OPERATING COSTS VS. ACFM AND AP 4-88
4-61 THERMAL INCINERATOR OPERATING AND MAINTENANCE
COST VS. ACFM AND HYDROCARBON CONCENTRATION 4-90
4-62 CATALYTIC INCINERATOR OPERATING AND MAINTENANCE
COST VS. ACFM AND HYDROCARBON CONCENTRATION 4-91
4-63 CARBON ADSORPTION UNIT OPERATING AND MAINTENANCE
COST VS. ACFM AND HYDROCARBON CONCENTRATION 4-92
5-1 CHEMICAL ENGINEERING PLANT COST INDEX 5-3
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Section 1
INTRODUCTION
1.1 PURPOSE OF MANUAL
One of the aims of the U. S. Environmental Protection Agency (EPA) is to
provide guidelines and technical assistance to state and local regulatory
agencies in the abatement of air pollution. The purpose of this manual is to
assist those agencies in estimating the cost of air pollution control
systems for the various manufacturers and processors who must comply with the
existing and future standards and codes. At present, literature is available
which gives generalized cost data for control systems based on industry averages;
however, this cost data has a wide range of magnitude due to the variety of
installations. In some cases, the cost of the control device itself may only
represent 25 percent of the total capital costs while in other cases, it may be
as high as 90 percent. These differences in costs can be attributed to the
cost of auxiliary equipment, method of controlling the source (direct exhaust
or canopy hood, etc.), physical location of control equipment with respect to
the source, local code requirements, characteristics of gas stream, plant
location, and many other influencing factors. In preparing this manual, the
main objective was to "break out" the individual component costs so that
realistic system cost estimates can be determined for any specific application
based on the peculiarities of the system.
In addition to capital costs, methods for estimating the operating and
maintenance costs are provided for each type of control system. A cost com-
parison methodology is also discussed whereby these recurring costs, together
with the capital or first costs, can be evaluated to determine the long term
advantages of one system over another.
1-1
-------
1.2 OafiANIZATION OF MANUAL
The cost estimating procedures and cost curves in this manual are provided
for those systems utilizing the following control devices:
1) High voltage electrostatic precipitators
2) Venturi scrubbers
3) Fabric filters
4) Thermal and catalytic incinerators
5) Adsorbers.
A description of the operation of these devices and the auxiliary equipment
required in a completely integrated pollution control system is contained in
Section 2. This description outlines the various design options available to
the engineer and the influence these options have on the total system cost.
A list of the design parameters for the various control devices is also cross-
referenced to the applicable industries and pollutant sources that use these
systems.
Section 3 describes the procedures used in estimating the costs of a
control system with an example of a typical application which can be controlled
by any one of three possible control devices. The selection of the most
economical system is determined by a life-cycle cost analysis of the three
possible systems. The methods and procedures, demonstrated in the example,
are applicable to all industries where the control of emissions is provided by
these five control systems.
1-2
-------
The basic cost curves for the control devices and auxiliary equipment
are contained in Section 4. These costs represent equipment, installation,
operating, and maintenance costs based on a reference date of December, 1975
and are estimated to be accurate to ± 20 percent, on a component basis, except
where noted. A method of extrapolating the costs to a future date is dis-
cussed in Section 5.
1-3
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Section 2
DESCRIPTION OF CONTROL SYSTEMS
The methods of gas cleaning used in industry today can be categorized by
the technique in which the gas or particulate is removed. These techniques
include: (1) electrostatic precipitation, (2) fabric filtration, (3) wet
scrubbing, (4) incineration, and (5) adsorption. The properties and character-
istics of the particular gas stream will generally dictate which technique of
gas cleaning is appropriate; however, in some cases, several techniques may be
suitable and the selection of one type in lieu of the others may be based on
efficiency and/or costs (both capital, maintenance, and operating).
Whichever technique is selected for a particular application, a certain
amount of auxiliary equipment must be utilized with the control device for
the efficient operation of the gas cleaning system. The arrangement of these
components with respect to the control device is shown in Figure 2-1. The
types of auxiliary equipment required will depend on the application; i.e.,
hot processes may require pre-coolers before the control device; the addition
of moisture may be required for proper operation of the control device, etc.
The following description of the five control systems is designed to provide
the user with the basic concept of the operation of the control device, the
parameters required to size and cost the control device, and the required
auxiliary equipment, with costs, necessary for proper operation of the gas
cleaning system.
2.1 HIGH VOLTAGE ELECTROSTATIC PRECIPITATOR SYSTEMS
2.1.1 General Description
Gas cleaning by electrostatic precipitation is particularly suited for
gas streams which can be easily ionized and which contain either liquid or
solid particulate matter. The method of removal consists of passing the
2-1
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CAPTURE
DEVICE
DUCTING
ANCILLARY
EQUIPMENT
I
Pumps, Cooling Towers,
Dampers And Controls
GAS
CONDITIONING
CONTROL
DEVICE
ro
i
Canopy Hoods,
Semi-Closed
Hoods,
Direct Ex-
haust
Water-Cooled
Refractory,
Carbon Steel,
Stainless Steel
U-Tube Cooler,
Quenchers,
Spray Chamber,
Mechanical
Collectors
FANS
STACK
Backward Curved,
Radial
In some applications the
fan may be ahead of the
control device.
DUST REMOVAL
&
TREATMENT
Thickners & Clarifiers,
Vacuum Filters,
Bins And Elevators,
Screw Conveyors
Figure 2-1 CONTROL SYSTEM FLOW CIRCUIT
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particle-laden gas through an electrostatic field produced by a high-voltage
electrode and a grounded collection surface. The gas is ionized by the high
voltage discharge and the particulate matter is charged by the interaction
of the gas ions. The particles migrate to the collecting surface which has
an opposite polarity and are neutralized. The adhesive properties of the
particles and the action of the electrical field keep the particles on the
collecting surface and inhibit re-entrainment. The particles are removed by
rappers or by other mechanical devices that vibrate the collector surface and
dislodge the particulate, which drops by gravity to hoppers. Usually this is
accomplished during normal operation, however, in cases where severe re-
entrainment is a problem, sections of the precipitator may be isolated during
rapping. The particulate matter is removed from the hoppers periodically by
either pneumatic or mechanical screw conveyors.
Electrostatic precipitators are used extensively on large volume applica-
tions where the fine dust and particulate is less than 10-20 microns in size
with a predominant portion in the sub-micron range. The precipitators can
achieve high efficiencies (in excess of 99%) depending on the resistivity of
the particulate matter and the characteristics of the gas stream. Wet or dry
particulate can be collected including highly corrosive materials if the units
are suitably constructed. Precipitators can be used at high temperatures (up
to 1000°F) but are normally operated at temperatures below 700°F. The static
pressure drop through the units is low, usually up to one-half inch W.G., for
units operating at normal gas velocities (2-8 feet per second). The initial
capital cost of electrostatic precipitators is high; however, operating
(utility) and maintenance costs are reasonably low. Safety precautions are
always required since the operating voltages are as high as 100,000 volts.
The overall size of electrostatic precipitators is comparable to fabric fil-
2-3
-------
ters (baghouses) and space requirements are an important factor in the layout
and design of the facilities.
2.1.2 Cost Factors
The cost of the basic electrostatic precipitator is a function of the
plate area which, in turn, is a function of the required efficiency. The re-
lationship of the plate area to efficiency can be shown by the Deutsch equation:
E.I-«[-"&]
where E = collection efficiency
w = drift velocity, fps
2
A = plate area, ft
Q = flow rate, cfm
The electrical characteristics of the dust, quantified by the drift
velocity, as shown in the Deutsch equation, have a large effect on the collect-
ion efficiency and plate area, and consequently, on the cost of the precip-
itator. The resistivity of the dust varies with the temperature and moisture
content of the gas, therefore, in some applications, auxiliary equipment may
be required to precondition the gas stream prior to entering the precipitator.
The addition of moisture in the gas stream together with low operating temp-
eratures will necessitate insulating the precipitator to prevent condensation
and subsequent corrosion problems. The cost of the basic precipitator is
therefore separated into insulated and non-insulated units. Special cost
factors can be incurred in the type of power supply such as automatic voltage
control, number of individual sections energized, type of rectifier, etc.,
and also, in special materials of construction and special plate design.
These factors are additive costs to the basic collector price and represent
custom features either required by the process or by the buyer's specifica-
tions. For most applications, the cost curves presented in this manual are
sufficient.
2-4
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2.1.3 Auxiliary Equipment
Figure 2-2 illustrates schematically the types of auxiliary equipment that
would be used in a gas cleaning system incorporating electrostatic precipitators.
These include the capture device, ductwork, mechanical collectors, coolers,
spray chambers, fans, dust removal, and stacks. The use of all or only some
of this auxiliary equipment will depend on the particular application and
pollutant source. In general, all systems will require a capture device, duct-
work, and a fan. The capture device can be either a round or rectangular hood
located near the pollutant source or it can be directly connected to the source
as, for instance, a kiln or furnace. These devices are usually refractory
lined, water-cooled, or simply fabricated from carbon steel depending on the
gas stream temperatures. Refractory or water-cooled capture devices are used
where wall temperatures exceed 800°F; carbon steel is used for lower tempera-
tures.
Ducting has several effects on the sizing and costing of a control system.
In addition to conveying the dust-laden stream to the control device, the duct-
work can act as a heat exchange means for cooling of hot gases. Also, it
always adds flow resistance or pressure losses that result in added horsepower
for the fan.
The four basic types of ducting can be classified as carbon steel, stain-
less steel, water cooled, and refractory. The differentiation between types
is not necessarily based on construction alone but rather on the capability
of each to transport gases at different temperatures. Water-cooled and refrac-
tory ducts can convey gases at any temperature, but are economically used at
gas temperatures above 1500°F. Stainless steel ducts are generally used with
gas temperatures between 1150°F and 1500°F or where the corresponding wall
temperature is below 1200°F. Carbon steel ducts are used at gas temperatures
2-5
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1N3
I
CTl
DIRECT EXHAUST
DUCTWORK
_fj \J \J V lf_
RADIANT COOLER
SPRAY COOLER
STACK
PRECIPITATOR
\
SCREW CONVEYOR
MECHANICAL COLLECTOR
CONTROL DEVICE AND TYPICAL AUXILIARY EQUIPMENT
Figure 2-2 ELECTROSTATIC PRECIPITATOR CONTROL SYSTEMS
-------
below 1150°F or where the wall temperature is less than 800°F. In the event
of corrosive gases, stainless steel ducts can be used at lower temperatures.
For cold processes, carbon steel ducts are used exclusively for non-
corrosive gases. In designing ducts, a savings in the size of the ducts
(increasing velocity) will eventually be compensated for in fan horsepower,
therefore, the design velocity of the gas stream is maintained at a suitable
conveying velocity for the type of dust. Typical velocities for industrial
dusts can be listed as follows:
DUST TYPE DUCT VELOCITY, fpm
1) Light Density - gases, smokes, zinc and 2000
aluminum oxide fumes, flour, and lint.
2) Medium/Light Density - grain, sawdust, 3000
plastic and rubber dusts.
3) Medium/Heavy Density - iron and steel 4000
furnace dusts, cement dusts, sandblast
and grinding dusts, and most heavy
industry dusts.
4) Heavy Density - metal turnings, lead 5000
and foundry shakeout dusts.
Since the type and configuration of the capture devices and ductwork are so
varied, the cost of these items must be estimated according to size, type and
materials of construction, and plate thicknesses. For ducting, the costs are
developed on a per lineal foot basis and for hoods the costs are based on the
surface area in square feet.
Mechanical collectors, such as cyclones, are used in some cases as pre-
cleaners to remove the bulk of the heavier dust particles. These devices
operate by separating the dust particles from the gas stream through the use
of centrifugal force. Construction is such that centrifugal force is exerted
on the gas stream through the use of a tangential inlet, producing a downward
vortex. The particles impinge on the sides of the cyclone and are removed
2-7
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from the bottom. The gas stream changes direction at the base of the cyclone
and exits in an upward vortex through an axial outlet at the top of the cyclone,
Cyclones are available as combinations of large single-cyclones or as units
having multiple tubes for higher efficiencies. For the purpose of precleaning,
cyclones can remove the majority of dust particles above 20 microns in size
to reduce the loading and wear on the control device. The size of a cyclone
is usually based on an inlet velocity of approximately 3600 fpm, and therefore
the cost of the cyclone is based on inlet area size. Other cost factors
include materials of construction, plate thickness, supports, and hoppers.
Dust removal from collectors (baghouses, precipitators, cyclones) can be
accomplished intermittently by manual means or continuously by screw conveyors.
For applications having light dust concentrations, the collected dust is stored
in the hoppers of the control device and periodically emptied through a valve
for disposal by truck or local transport. For heavy dust loading, screw
conveyors are generally used to continuously remove the dust as it is collected.
The cost of continuous removal equipment is based on the diameter of the screw
conveyor and its overall length.
Coolers and spray chambers are used with electrostatic precipitators for
systems handling hot gases to reduce the gas volume to the collector; or, in
the case of spray chambers, to add moisture to the gas stream to reduce the
resistivity and enhance the electrical characteristics of the dust. Dry-type
coolers used expressly for cooling the gas stream without adding water generally
consist of radiant "U-tubes" of 30 to 60 feet in height and between 12 and
36 inches in diameter. These tubes are manifolded together both in parallel
and in series to provide sufficient heat transfer surface to reduce the gas
temperature to a value compatible with efficient precipitator operation. The
number of required "U-tubes" in series depends on the inlet gas temperature
2-8
-------
and the required outlet gas temperature. The number of "U-tubes" in parallel
depends on the volume of gas being handled and the desired gas velocity per
tube. The cost of a cooler, therefore, can be estimated from the number of
modular U-tubes of a given diameter and height based on the desired tempera-
ture drop and flow rate for the particular application.
Wet-type coolers or spray chambers cool and humidify the'gas by the
addition of water sprays in the gas stream. For effective evaporation, a
cylindrical chamber is usually provided to reduce the gas stream velocity at
the point at which the water is injected and where evaporation occurs. The
diameter and length of the chamber is dependent on the maximum droplet size
of the sprays, and the relative temperature and velocity of the gas stream and
water droplets. Generally, gas stream velocities are maintained at approx-
imately 10 feet per second with inlet spray water pressures of approximately
100 psig. Increasing the water pressure results in reduced water droplet
size, faster evaporation, and consequently, smaller chambers. The cost of
spray coolers is based on the size and volume of the chamber, materials of
construction and the water flow rate.
Centrifugal fans, having either backward curved or radial tip blades,
are used almost exclusively to transport the dust-laden gases through the
system. The backward curved fan provides the highest efficiency, but because
of its inherent design, must be used downstream of the control device where
the gas stream is relatively dust-free. These fans are categorized into
Classes I through IV according to maximum impeller speeds and pressures. The
cost of the fan is based on its construction, class, volume, and pressure
delivered at standard conditions. The radial tip fan, sometimes referred to
as the industrial fan, operates at a lower efficiency, but is capable of hand-
ling dusty gas streams and can be used upstream of the control device. The
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impeller of this fan consists of flat radial paddles which can be modified to
include wear plates for abrasive dust applications. These fans can also be
operated at high temperatures. The cost of this type of fan is based on
materials of construction, total Volume, and pressure delivered at standard
conditions.
The cost of the motor and motor starter for centrifugal fans is related
to the fan speed, total system pressure, gas volume flow rate, and selected
motor housing. Fan speeds are chosen from a continuum, with aid of the fan
laws, to provide a desired head at a prescribed flow. Motor speeds are chosen
from a set of perhaps only five discrete choices (Table 4-7). Since belts
and pulleys are routinely used, fan speed and motor speed should be selected
as close to each other as possible. The motor housings should be chosen for
the particular environment in which it will be operating. Drip-proof motors
should be used in areas which are weather protected and relatively clean.
Totally enclosed motors should be used in dusty areas or areas exposed to
weather and severe splashing. Explosion-proof motors must be used in hazardous
atmospheres where explosive fumes are present.
Stacks are provided downstream of the fans for dispersion of the exhaust
gases above the immediate ground level and surrounding buildings. Minimum
stack exit velocities should be at least 1.5 times the expected wind velocity;
or for instance, in the case of 30 mph winds, the minimum exit velocity should
be 4000 fpm. Small stacks are usually fabricated of steel, which may be re-
fractory lined, and are normally limited to exit velocities of approximately
9000 fpm. Tall stacks, over 200 feet, can be designed with liners of steel or
masonry. The cost of stacks is based on diameter, material thickness and
type, height, and whether a liner is provided.
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2.2 VENTURI SCRUBBER SYSTEMS
2.2.1 General Description
Venturi type scrubbers are capable of providing high efficiency collec-
tion of sub-micron dusts which are not easily collected by other types of
scrubbers. Basically, the scrubber is constructed with a converging section
of the venturi to accelerate the gas stream to a maximum velocity at the throat
section where impaction with the scrubbing fluid or liquor occurs. Fine drop-
lets of the scrubbing liquor are atomized as a result of this interaction and
the relative velocities between the dust particles and droplets cause collision
and agglomeration as they proceed through the throat section. Further agglor-
meration occurs as the gas stream is decelerated in the diverging section of
the venturi, thus producing droplets with the entrapped dust of a size easily
removable by mechanical means.
The pressure drop through the venturi is a function of gas stream throat
velocity and scrubbing liquor flow rate, which in turn have been chosen for a
desired collection efficiency on a given dust. The smaller the dust particle
size, the higher the pressure drop required. As the pressure drop is increased,
finer droplets are atomized to interact with the dust particles through impinge-
ment and agglomeration, with the consequent increase in collection efficiency.
Increasing the pressure drop can be accomplished by either increasing the gas
stream throat velocity, increasing the scrubbing liquor flow rate or both.
Fundamentally, the relationship between pressure drop and collection efficiency
is the same for all types of venturi scrubbers irrespective of the size, shape
or general configuration of the scrubber. Venturi scrubbers are normally
operated at pressure drops of between 6 and 80 inches W.G. depending on the
characteristics of the dust, and at liquor flow rates of 3 to 20 gpm per 1000
ACFM. The collection efficiencies range from 99+% for one micron or larger
sized particles to 90 to 99% for particles below one micron size.
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A separator for removal of the agglomerates from the gas stream is pro-
vided downstream of the scrubber. These separators are usually of the cyclone
type where the gas stream and agglomerates are given a cyclonic motion which
forces the liquid and particles to impinge on the walls of the separator by
centrifugal force. The separator normally consists of a cylindrical tank with
a tangential inlet located at the lower side of the tank and an exhaust outlet
located at the top of the tank on the center!ine axis. A cone bottom with out-
let is provided to collect the liquid slurry. The collected particles settle
to the bottom of the cone and are removed to the water treatment facility while
the cleaner liquid above the sediment is removed and recycled to the scrubber.
For hot processes, a considerable amount of water is vaporized in the
scrubber and upstream equipment (e.g., quencher), which must be handled by the
fan. Although the gas volume is reduced, a large portion remains as water
vapor which results in higher horsepower requirements and in higher operating
costs. To alleviate this condition, a gas cooler can be incorporated into
the separator to cool and dehumidify the gas stream. Several types of gas
coolers are used for this purpose; one type employs spray banks of cooling
water followed by impingement baffles while a second type utilizes flooded
plates or trays with either perforated holes or bubble caps to permit passage
6f the gas stream through the bath of cooling water. Several plates or trays
can be used in sequential stages to provide the necessary cooling and contact
time.
In addition to its ability to remove sub-micron dusts, the venturi scrubber
with separator and gas cooler/contactor can also be used as a gas absorber.
These units have been used successfully in the removal of acid mists in the
chemical industry and the removal of S0~ and SO., in municipal power plant flue
£ 0
gases.
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2.2.2 Cost Factors
The cost of the scrubber and separator are based on the volumetric flow
rate, operating pressure, and materials of construction. The sizes of the
scrubber, separator, and elbow (vertically oriented) are determined from
the actual inlet gas volume in acfm and priced accordingly for a basic plate
thickness of 1/8 inch. Additional cost factors are provided for different
metal thicknesses, fiberglass or rubber liners, manual or automatic venturi
throat, and stainless steel construction. The plate thickness for the scrubber
and separator is a function of the maximum operating design pressure and shell
diameter; therefore, as the volume flow rate and/or pressure drop increase,
the metal wall thicknesses must also be increased to prevent buckling. In
addition, some allowances for corrosion or erosion are usually added to the
design conditions. Typical design parameters for a scrubber and separator
are based on a scrubber inlet gas velocity of 3500 fpm and a separator super-
ficial inlet velocity of 600 fpm. For a given flow rate, the internal surface
area for the scrubber, elbow and separator can be determined to establish the
additive cost of a rubber or fiberglass liner. Likewise, the diameter and
height of the separator will determine the volume available for an internal
gas cooler.
2.2.3 Auxiliary Equipment
The auxiliary equipment normally associated with venturi scrubber systems
is shown schematically in Figure 2-3. These include a capture device and duct-
work, a quencher, dust removal and treatment, fan, and a stack. The capture
device, ductwork, and stack are the same components used for electrostatic
precipitator systems and are discussed in Section 2.1.3. The quencher, used
for hot processes, is fundamentally the same as a spray chamber; however, it
is much simpler in operation, requires minimum controls, and usually has no
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HOOD
DIRECT EXHAUST
ro
i
DUCTWORK
QUENCHER
FAN
SEPARATOR/
COOLER
SCRUBBER
STACK
TO TREATMENT
CONTROL DEVICE AND TYPICAL AUXILIARY EQUIPMENT
Figure 2-3 VENTURI SCRUBBER CONTROL SYSTEMS
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sprays to plug. The objective of using a quencher is to reduce the gas stream
temperature to the saturation temperature and this is accomplished by flooding
the gas stream with cooling water. Since the quencher is operated with more
water than required to reach saturation temperature, outlet gas temperature
controllers are not necessary, nor are the banks of spray nozzles which are
normally operated by these controllers. Quenchers are usually fabricated from
corrosion resistant materials, or are refractory lined, and can be either hor-
izontally or vertically oriented. Costs are based on inlet gas volume and
materials of construction. Quenchers also act as a precleaner for larger sized
dust particles with the collected slurries being returned to the waste treat-
ment facility.
Waste removal and treatment facilities for both the scrubber and quencher
(if used) generally consist of a thickener and vacuum filter or centrifuge.
The overflow from the thickener is recycled to the scrubber and quencher while
the heavier solids are removed for dewatering by the filter or centrifuge. The
costs of thickeners, vacuum filters, and centrifuges are completely covered in
the following reports, also listed in Appendix C as source Nos. 119 and 128.
"Capital and Operating Costs of Pollution Control Equipment Modules",
Vol. I and Vol. II, EPA-R5-73-023 a and b, July, 1973. NTIS PB 224-535
& PB 224-536.
"Estimating Costs and Manpower Requirements for Conventional Wastewater
Treatment Facilities", EPA 17090 DAN 10/71. NTIS PB 211-132.
Radial tip fans are used almost exclusively in venturi scrubber control
systems because of their ability to operate at high pressures and temperatures
with abrasive gas streams. With scrubber systems, a certain amount of carry-
over of dust-laden water droplets can be expected which would be destructive
to other types of fans operating at the impeller tip velocities necessary
for 20-80 inches W.G. pressures. The radial tip fan can also be protected
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with wear plates and water sprays (for cleaning blades) for dirty or highly
abrasive gas streams. The cost of radial blade fans is a function of the
actual volume in cfm and the total pressure delivered based on incremental
pressure ranges of 20,40 and 60 inches W.G.. Construction can be either carbon
steel for general purposes or stainless steel for corrosive gases. Special
linings are also available for unique conditions.
2.3 FABRIC FILTER SYSTEMS
2.3.1 General Description
Gas cleaning by fabric filtration is suited for applications where dry
particulates are handled or where water in the process gases is in the vapor
stage. The basic filter collector or "baghouse" is capable of operating in
excess of 99% efficiency, although satisfactory operation of the system is
contingent upon the characteristics of the gas stream and the particulate matter
being removed. Basically, the unit consists of compartments containing rows
of filter bags or tubes. The particle-laden gas is ducted to each compartment
where the gas passes through the bags while the particles are retained on the
surface of the bags. The pressure drop across the filter medium increases as
the particulate collects on the fabric until a preset time limit is reached,
at which time a section is isolated and the entrapped material is dislodged
..and collected in hoppers located below the filtering area. Baghouses are
characterized by the methods used to clean the bags as well as the frequency
of bag cleaning. These methods are generally referred to as: 1) shaker type,
2) reverse air, and 3) pulse jet.
The shaker type method of cleaning consists of hanging the bags on an
oscillating framework driven by a motor with a timer. The baghouse is
separated into several compartments so that at periodic intervals, the gas
flow to a compartment is interrupted and the motors and connected frames in
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the compartment are activated with the subsequent shaking of the bags to re-
move the particulate. The shaker type mechanisms produce a violent action on
the bags and, in general, produce more wear on the bags than other types of
cleaning mechanisms. For this reason, shaker type cleaning is used in
conjunction with heavier and more durable fabric materials.
The reverse air method of cleaning the bags is accomplished by passing
air countercurrent to the direction of the gas flow in normal filtration when
the compartment is isolated for cleaning. The reverse air is supplied by a
separate fan or in some cases, the pressure differential across the bags can
be used to collapse the bags without the aid of a fan. This type of cleaning
is used with fragile bags (such as fiberglass) or lightweight bags and usually
results in longer life for the bag material.
Bag cleaning by pulse jet is accomplished by the use of compressed air
jets located at the top of the bags. Periodically, a blast of compressed air
is issued down the bag, rapidly expanding the bag to dislodge the particulate.
In some cases, this method of cleaning does not require the isolation of the
bags to be cleaned from the filtering process so that extra compartments
required for cleaning with the shaker and reverse air type baghouses are not
needed. In addition, the pulse jet baghouses can sustain higher filtering
velocities through the filter medium (higher air-to-cloth ratios) and there-
fore the overall size of the baghouse is reduced.
Baghouses are also categorized as to the type of service and frequency
of bag cleaning and are generally referred to as either intermittent or
continuous duty. Intermittent baghouses are cleaned after filtering is
completed; i.e.-, after the process stream is secured or shut down, usually
at the end of each day. These baghouses operate with low dust loadings since
they cannot be cleaned while on stream. Continuous baghouses operate indef-
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initely and cleaning of a portion of the filter occurs at periodic intervals
while the process gases are being filtered by the remaining filter area.
Continuous duty baghouses are more expensive than the intermittent type due
to the accessories required in the cleaning process and the additional filter
area required for continuous cleaning.
The location of the baghouse with respect to the fan in the gas stream is
also a factor in the capital costs. Suction type baghouses, located on the
suction side of the fan, must withstand high negative pressures and therefore
are more heavily constructed and reinforced than baghouses located downstream
of the fan (pressure baghouse). The negative pressure in the baghouse can
result in the infiltration of outside air which can result in condensation,
corrosion or even explosions if combustible gases are being handled. In
the case of toxic gases, this inward leakage can have an advantage over the
pressure type haghouse, where leakage is outward. The main advantage of the
suction baghouse is that the fan handling the process stream is located at
the clean gas side of the baghouse. This reduces the wear and abrasion on
the fan and permits the.use of more efficient fans (backwardly curved blade
design). However, since the exhaust gases from each compartment are combined
in the outlet manifold to the fan the location of compartments with leaking
bags is difficult to determine and adds to the cost of maintenance. The
outlet manifold from the baghouse is connected to the fans which are usually
located at ground level; therefore, a stack is normally required to vent the
gas from the fan.
Pressure-type baghouses are generally less expensive since the housing
must only withstand the differential pressure across -the baghouse. Maintenance
is also reduced since the compartments can be entered and leaking bags can be
observed with reasonable comfort while the compartment is in-service. With a
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pressure baghouse, the housing acts as the stack to contain the fumes with the
subsequent discharge at the roof of the structure. The main disadvantage of
the pressure-type baghouse is that the fan is exposed to the dirty gases where
abrasion and wear may become a problem.
The design and construction of baghouses are separated into two groups:
standard and custom. Standard baghouses are pre-designed and built as modules
which can be operated singly or combined to form units for larger capacity
applications. The custom or structural baghouse is designed specifically for
an application and is usually built to the specifications prescribed by the
customer. The cost of the custom baghouse is much higher than the standard
and is used almost exclusively in large capacity (large volume) applications.
The advantages of the custom baghouse are many and are usually directed to-
wards ease of maintenance, accessibility, and other customer preferences. In
standard baghouses, a complete set of bags are usually replaced in a compart-
ment at one time because of the difficulty in locating and replacing single
leaking bags, whereas, in custom baghouses, single bags are accessible and
can be replaced one at a time as the bags wear out.
The type of filter material used in baghouses is dependent on the
specific application in terms of chemical composition of the gas, operating
temperature, dust loading, and the physical and chemical characteristics of
the particulate. A variety of fabrics, either felted or woven, are available
and the selection of a specific material, weave, finish, or weight is based
primarily on past experience. The type of cloth will generally dictate the
type of cleaning mechanism to be used in the baghouse. Usually, felted fabrics
are used with pulse jet cleaning whereas woven fabrics are used with mechan-
ical shaker or reverse air cleaning. The type of yarn (filament, spun, or
staple), the yarn denier, and twist are also factors in the selection of
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suitable fabrics for a specific application. Because of the violent agita-
tion of mechanical shakers, spun or staple yarn fabrics of heavy weight are
usually used with this type of cleaning while filament yarn fabrics of
lighter weight are employed with reverse air cleaning. The type of material
will dictate the maximum operating gas temperature for the baghouse. Nominal
operating temperatures for various fabrics are listed below:
COTTON: 180°F
POLYPROPYLENE: 180°F
NYLON: 200°F
ACRYLIC: 275°F
POLYESTER: 275°F
NOMEX: 425°F
TEFLON: 500°F
FIBERGLASS: 550°F
The superficial face velocity of gas passing through the cloth affects
pressure drop and bag life. The fundamental filtering parameters are
based on this velocity which is equal to the total actual volumetric flow rate
in cubic feet per minute divided by the net cloth area in square feet. This
ratio is referred to as the air-to-cloth ratio and is the basis for sizing and
costing baghouses. High air-to-cloth ratios will reduce the size of the bag-
house (and subsequent cost) while low air-to-cloth ratios will require larger
units. The air-to-cloth ratio will also determine the type of cleaning
mechanism to be used in the baghouse. Shaker type and reverse air cleaning
can be used with air-to-cloth ratios of up to 4 to 1 while pulse jet cleaning
can be utilized with air-to-cloth ratios of up to 10 to 1 or higher in
special cases. The type of material selected as the cleaning fabric will also
dictate the range of air-to-cloth ratios to be used in a particular applica-
2-20
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tion; for Instance, polyester fabrics are normally used with ratios of up to
3 to 1, while fiberglass is usually limited to 2 to 1. These limiting ratios
are the normal "rule of thumb"; however, with light dust loading, these air-
to-cloth ratios can be exceeded in some cases.
2.3.2 Cost Factors
The cost reference for baghouses is based on the net cloth area. Net
cloth area is defined as the total filter area available for on-stream fil-
tration exclusive of the filter area in compartments which are isolated for
cleaning (in the case of intermittent filters, the net cloth area is actually
the gross cloth area). The net cloth area is determined by the air-to-cloth
ratio recommended for a particular application, which is principally based on
the type of fabric, type of dust, carrier gas composition, and the dust con-
centration. The cost options of the fabric filter are therefore based on the
following parameters as determined by the type of application.
1) Type of fabric and air-to-cloth ratio.
2) Intermittent or continuous duty.
3) Pressure or suction type construction.
4) Standard or custom design.
5) Type of cleaning mechanism.
6) Materials of construction.
2.3.3 Auxiliary Equipment
The typical auxiliary equipment associated with fabric filter systems is
shown schematically in Figure 2-4. This equipment includes the capture device,
ductwork, radiant coolers, spray chambers, dilution air ports, mechanical
collectors, dust removal equipment, fans, and stack. This equipment has been
discussed in Section 2.1.3 with the exception of dilution air ports.
Dilution air ports are provided to protect downstream components from
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r\ r\
HOOD
rv>
ro
DIRECT EXHAUST
U
RADIANT COOLER
STACK
DUST REMOVAL
MECHANICAL COLLECTOR
CONTROL DEVICE AND TYPICAL AUXILIARY EQUIPMENT
Figure 2-4 FABRIC FILTER CONTROL SYSTEMS
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"over-temperature" by diluting the hot gas stream with cooler ambient air.
Dilution air cooling requires the least amount of equipment compared to other
types of cooling; however, the downstream equipment such as the baghouse,. fans,
and ductwork are substantially increased in size (and cost) to compensate for
the additional air. The components for dilution cooling generally consist of
a duct tee, damper, and temperature controller. The damper is continually
modulated, inspiring ambient air to maintain the downstream gas temperature
at a pre-set level. The cost of the equipment for dilution cooling is based
on the duct diameter and represents the cost of ductwork, damper, sensor and
controller.
2.4 THERMAL AND CATALYTIC INCINERATOR SYSTEMS
2.4.1 General Description
Gas cleaning by thermal or catalytic incineration is readily adapted to
processes that emit combustible gases, vapors, aerosols, and particulates.
These systems are used extensively in removing odors and in reducing the opacity
of visible plumes from ovens, driers, stills, cookers and refuse incinerators.
The principle of operation consists of ducting the exhaust process gases to a
combustion chamber which employs either a catalyst bed or direct-fired burners
to combust the contaminant gases to carbon dioxide and water vapor. Direct-
fired gas burners are most commonly found because of their simplicity and
reliability; however, catalytic units do produce combustion at lower temper-
atures which can result in lower fuel costs. In direct-fired thermal inciner-
ators (afterburners), the contaminated gas stream is delivered to the refract-
(
ory lined burner area by either the process exhaust system or by a self contained
blower. The introduction of the gas stream at the burners insures turbulence
and complete mixing with the combustion products at the highest temperatures
possible. The gas stream and combustion products then enter the retention
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chamber at lower velocities to increase residence time and ensure complete
oxidation of the combustibles. To reduce fuel costs, recuperative heat ex-
changers can be provided downstream of the retention chamber to recover some
of heat from the exhaust gases by preheating the inlet contaminated gas
stream. A second method of recovering heat from the afterburner exhaust is
to recycle a portion of this gas to the inlet gas stream. The efficiency of
direct-fired afterburners depends on the type and concentration of contam-
inants in the inlet gases, the operating temperature, turbulence, the mixing
of gases in the afterburner, and the residence time. Heat exchangers, when
added, increase the thermal efficiency and reduce fuel costs at the expense of
higher initial costs.
Direct-fired thermal incinerators can be provided as packaged units for
small volume applications which include the basic chamber, fan, and controls.
Larger units are usually custom designed or are modifications of standard com-
ponents integrated into a complete unit. The amount of controls and instru-
mentation required for these systems will depend on the characteristics of
the process gas stream. Steady state processes require the least amount of
controls whereas, fluctuating gas streams would require modulating controllers
for the burners, recycle gas, etc.. Most units however, require a minimum
amount of controls such as safety pilots and flame failure shut-offs, high
temperature shut-offs (fan failure), and temperature monitors and recorders.
The fans used for these units usually are of the axial flow or low pressure
centrifugal type since pressure drops for the incinerator alone are low.
An alternative to the direct-fired thermal incinerator is the catalytic
incinerator which utilizes a catalyst bed to oxidize the contaminants to
carbon dioxide and water vapor. This reaction takes place at reduced temp-
eratures (650-1200°F) as compared to the direct-fired incinerator (850-1800 F)
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and, therefore, the fuel costs can be reduced. One of the limitations of the
catalytic incinerator, however, is its susceptibility to fouling and degrada-
tion by particulates or metal poisons such as zinc, lead, tin, etc. For this
reason, the gas streams containing organic vapors or solvents are better
suited for catalytic combustion while those containing fumes and smokes should
be controlled by the direct-fired incinerator.
The catalytic incinerator consists of the catalyst bed, preheat burners,
ductwork, fan, and controls. The preheat burners are required to raise the
temperature of the inlet gas stream to a level compatible with the oxidation
reaction temperature of the catalyst. To conserve on fuel costs, the preheat
burners can be regulated by controllers monitoring the exit gas temperature
of the catalyst bed. As the bed temperature increases from heat transferred
by the exothermic reaction, the amount of heat supplied by the preheat burners
can be reduced accordingly. This can result in a savings of approximately
40-60 percent in fuel costs as compared to the direct-fired incinerator. The
catalytic incinerator, however, has a higher maintenance cost than the direct-
fired incinerator due to the necessity of periodically cleaning the catalyst
bed and the eventual replacement of the bed. Catalytic incinerators are
available in packaged units for small volume applications and custom units
for larger applications. Heat exchangers are also available which will pro-
vide up to 50 percent heat recovery.
2.4.2 Cost Factors
The cost of thermal and catalytic incinerators is based on the actual
volume flow rate, and such design factors as whether the unit is a package
or custom design-, and whether a heat exchanger is used for heat recovery.
The basic cost of the incinerators includes the incinerator and base, fan,
motor, starter, integral ductwork, controls, instrumentation, and heat ex-
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changer (where applicable). For thermal incinerators, the cost of the units
also varies with the designed residence time. Longer residence times will
necessitate higher cost equipment due to the longer and larger retention
chambers.
2.4.3 Auxiliary Equipment
A minimum of auxiliary equipment is required for thermal and catalytic
incinerators since the units are normally self-contained. Usually some duct-
work, a fan, and a capture device are required to transport the process gas
stream from the source to the control device if the distance is appreciable.
A separate fan however is supplied with the incinerator to ensure proper
distribution and mixing of the gases in the incinerator. An exhaust stack is
also required to disperse the exhaust gases above the level of the surround-
ing buildings. The cost of these components is covered in Section 2.1.3.
2.5 ADSORPTION SYSTEMS
2.5.1 General Description
Gas cleaning by adsorption is used primarily in the removal of organic
liquids and vapors from process streams. The principles of adsorption and
the affinity of certain adsorbents for specific compounds are quite complex;
however, the process can be considered as the mechanical and chemical bonding
of a substance on the surface of an adsorbent. The control system using
this principle usually consists of at least two adsorbent beds with
one bed on stream adsorbing while the second bed is regenerating. Regenera-
tion is usually accomplished by heating the adsorbent to a high temperature to
drive off the adsorbed compounds. Continuous adsorbers have also been devised
where adsorption and regeneration take place in different positions of the
same bed, which is progressively displaced through the vessel. Some problems
that exist in adsorption systems are the result of solids in the process gas
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stream. Participate matter in the gas stream can be detrimental to adsorber
beds by blinding the adsorbent; therefore, efficient filters must be provided
at the inlet to the beds. Corrosion is also a factor in the maintenance of
the beds and equipment, and is usually related to the method of bed regenera-
tion. Activated carbon is the most widely used adsorbent in industry,
however, other adsorbents such as silica gel, bauxite, and alumina
are used for some specific processes. The regeneration of activated carbon
adsorption beds is normally accomplished by passing steam through the bed in
the opposite direction of the normal gas flow during adsorption. The flow rate,
temperature, and pressure of the steam required for regeneration is dependent
on the type and characteristics of the adsorbate and the quantity adsorbed.
After regeneration, the beds are normally cooled by passing clean air through
the carbon before being placed on stream. Fixed bed adsorbers usually consist
of at least two beds; one adsorbing while the other is regenerating. If the
time for regenerating and cooling is longer than the adsorption time, three
beds may be used; one adsorbing, one regenerating, and one cooling. The
operations involved with switching beds from the adsorption stage to the
regeneration stage can be either manual or automatic. Automatic systems cost
more due to the mechanisms and controls required. Carbon adsorbers are
supplied as either packaged units for small volume applications or custom
designed units for larger applications. The units, as supplied, consist of
the adsorber beds, activated carbon, fans or blowers, controls, and the steam
regenerator (excluding steam source).
2.5.2 Cost Factors
The cost of carbon adsorbers is based on the weight of activated carbon
required. The carbon requirements are determined by the gas flow rate, the
type and concentration of the pollutant, the carbon adsorption efficiency for
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that particular pollutant, and the specific time of adsorption/regneration.
Packaged units are priced according to the mode of operation; i.e., automatic
or manual while custom designed units for large volume applications are all
automatic.
2.5.3 Auxiliary Equipment
Since the adsorbers are usually supplied as self-contained units, the only
auxiliary equipment needed would be hoods and ductwork which are discussed in
Section 2.1.3.
2.6 APPLICATION TO INDUSTRY
Not all of the five control systems can be applied universally throughout
the various industries. For instance, adsorbers are only effective with gas-
eous pollutants while thermal and catalytic incinerators require combustible
particulates and vapors for proper operation. Particulate-laden gas streams
which are not combustible must be controlled by precipitators, scrubbers, or
baghouses. Precipitators and baghouses are used solely for particulate coll-
ection while scrubbers may be used for both particulates and gases (when
used as a contactor/absorber). The selection of a control system for a par-
ticular process, therefore, may be limited to only one or two types of control
devices. Tables 2-1 and 2-2 lists 27 industries with typical sources of pollu-
tants and itemizes the types of control devices with their design parameters that
are used to control these sources. Table 2-3 lists the types of solvents
and their lower explosive limit that might be expected in the exhaust gases
from such sources as spray booths, printing presses, etc.. These solvents
are usually recovered through the use of an activated carbon adsorber and,
therefore, the carbon adsorption efficiency for each solvent is also provided.
Appendix C provides a cross-reference of literature information applic-
able to each industry. Appendix D provides a list of associations related to
2-28
-------
Table 2-1 INDUSTRY POLLUTANT SOURCES AND TYPICAL CONTROL DEVICES
rv>
i
INDUSTRY
1) Brick
Manufacturing
2) Castable
Refractories
3) Clay Refrac-
tories
4) Coal -fired
Boilers
5) Conical
Incinerators
6) Cotton Ginning
7) Deti'i-'ic'iit
M.inu I uc luri iii|
SOURCE
1) Tunnel kiln
2) Crusher, mill
3) Dryer
4) Periodic kiln
1 ) Electric arc
2) Crusher, mill
3) Dryer
4) Mold and shakeout
1) Shuttle kiln
2) Calciner
3) Dryer
4) Crusher, mi 1 1
1 ) Steam generator
1 ) Incinerator
1 ) Incinerator
1 ) S|n\iy Dryer
COflTROL SYSTEM
1) Scrubber, baghouse
precipi tator
2) Baghouse, scrubber
3) Same as 1
4) Same as 1
1 ) Baghouse, scrubber
2) Same as 1
3) Same as 1
4) Same as 1
1) Baghouse, precipi-
tator, scrubber
2) Same as 1
3) Same as 1
4) Baghouse, precipi-
tator
1 ) Precipi tator,
Scrubber
1 ) Scrubber
1 ) Scrubber
1 ) Scrubbc>r, baghouse
CAPTURE DEVICE
1 ) Direct tap
2) Canopy hood
3) Same as 1
4) Same as 1
1 ) Direct tap
2) Canopy hood
3) Direct tap
4) Canopy hood
1 ) Direct tap
2) Same as 1
3) Same as 1
4) Canopy hood
1 ) Direct tap
1 ) Direct tap
1 ) Direct tap
' Direct tap
TYPICAL GAS FLO.,
DESIGN RATE
1 ) Combustion air-
fan capacity
2) 250 fpm hood face
3) Sank: as 1
4) Same as 1
1 ) Infilt. air
2) 250 fpm hood face
3) Fan capacity
4) Same as 2
1 ) Fan capacity
2) Same as 1
3) Same as 1
4) 250 fpm hood face
1 ) Induced draft fan
capacity
1 ) Combustion air
rate
1 ) Combustion ait-
rate
1 ) Fan capacity
TYPICAL GAS
TEMPERATURE
1) 200-600F
2) 70F mill
3) 250F
4) Same as 1
1) 3000-4000F
2) 70F
3) 300F
4) 150F
1) 150-800F kiln
2) Same as 1
3) 250F
4) 70F
1) 300F
1) 400-700F
1) 500-700F
1) 180-250F
-------
Table 2-1 INDUSTRY POLLUTANT SOURCES AND TYPICAL CONTROL DEVICES (cont'd)
ro
oo
o
INDUSTRY
8) Feed Mills
9) Ferroalloy
Plants
a) HC Fe Mn
b) 50';. Fe Si
c) HC Fe Cr
10) Glass
Manufacturing
11 ) Grey Iron
Foundries
SOURCE
1 ) Storage bins
2) Mills/grinders
3) Flash dryer
4) Conveyors
1 ) Submerged arc
furnace (open)
2) Submerged arc
furnace (closed)
3) Tap fume
1 ) Regenerative tank
furnace
2) Weight hoppers and
mixers
1 ) Cupola
2) Electric arc
furnace
3) Core oven
4) stakeout
CONTROL SYSTEM
1) Baghouse, scrubber
2) Same as 1
3) Same as 1
4) Same as 1
1) Scrubber, baghouse,
precipitator
2) Scrubber
3) Same col lector or
baghouse
1 ) Baghouse, scrubber
precipitator
2) Same as 1
1 ) Af terburner-
baghouse for
closed cap,
Afterburner-
precipitator for
closed cap,
scrubber
2) Baghouse, scrubber
precipitator
3) Afterburner
1) Bacjhousc
CAPTURE DEVICE
1 ) Direct tap
2) Canopy hood
3) Direct tap
4) Canopy hood
1 ) Ful 1 or canopy
hood
2) Direct tap
3) Canopy
1) Direct tap
2) Canopy
1 ) Direct tap
2) Direct tap,
full/side draft
hood
3) Direct tap
4) Full/side draft
hood
TYPICAL GAS FLOW
DESIGN RATE
1 ) 250 fpm canopy
hood face velocit
2) Same as 1
3) Air heater flow
rate (dryer)
4) Same as 1
1) 2500-5500 scfm/
mw wi ch scrubber
2) a) 220^
b) 180 y scfm/mw
c) 190 j
3) 200 fpm/ ft2
1 ) Fan capacity
2) 200 fpm/ ft2
1 ) Tuyere air
+ infi 1 . door air
+ afterburner
second air
2) 2000 fpm/ft2
hood
3) Fan capacity
4) 200-500 cfm/ft2
hood
TYPICAL GAS
TEMPERATURE
1) 70F
<2) 70F
3) 170-250F
4) 70F
1) 400-500F
open arc
2) 1 000-1 200F
closed arc
3) 150F hood
1) 600-850F
furnace
2) 100F mixers \
1) 1200-2200F
2) ~2500F direct
tap
~400F hood
3) 150F
) ~150F
-------
Table 2-1 INDUSTRY POLLUTANT SOURCES AND TYPICAL CONTROL DEVICES (cont'd)
'INDUSTRY
12) Iron & Steel
(Sintering)
13) Kraft Recovery
Furnaces
14) Lime Kilns
15) Municipal
Incinerator
16) Petroleum
Cat«.ily tic
Cracking
SOURCE
1 ) Sinter machine
a) Sinter bed
b) Ignition fee.
c) Wind boxes
2) a) Sinter crusher
b) Conveyors
c) Feeders
1 ) Recovery furnace
and direct contact
evaporator
1) Vertical kilns
2) Rotary sludge
kiln
1 ) Incinerator
1 ) Catalyst
regenerator
CONTROL SYSTEM
1) Precipi tator,
baghouse, scrubber
2) Baghouse, scrubber
1 ) Precipitator,
scrubber
1) Baghouse, scrubber,
precipi tator
2) Scrubber, precipi-
tate r
1 ) Scrubber, precipi-
tator, baghouse,
afterburner
1 ) Precipi tator,
(boi ler )-precipi-
tator, scrubber
CAPTURE DEVICE
1 ) Down draft hood
2) Canopy hood
1 ) Direct tap
1) Direct tap
2) Direct tap
1 ) Direct tap
1 ) Direct tap
a) High pressure
b) Low pressure
TYPICAL GAS FLOW
DESIGN RATE
1 ) Based on bed size
2) 250 fpm hood face
1 ) Primary and seconc
ary air supply
capacity
1 ) Combustion air
rate
2) Combustion air
rate
1 ) Combustion air far
capacity where
appl i cable
1 ) Regeneration air
rate + boiler
combustion air
TYPICAL GAS
TEMPERATURE
1) 150-400F
sinter machine
2) 70F conveyors
- 1) 350F
1) 200-1200F
2).200-1200F
1) 500-700F
1) HOOF regener-
ator,
500F from
boiler
r\>
i
co
-------
Table 2-1 INDUSTRY POLLUTANT SOURCES AND TYPICAL CONTROL DEVICES (cont'd)
CO
ro
INDUSTRY
17) Phosphate
Rock Crush-
ing
18) Polyvinyl
Chloride
Production
19) Pulp and
Paper
SOURCE
1 ) Crusher & screens
2) Conveyor
3) Elevators
4) Fluidized bed
calciner
1 ) Process equipment
vents
1 ) Fluidized bed
t'cac t or
CONTROL SYSTEM
1) Baghouse, scrubber,
pred pita tor
2) Same as 1
3) Same as 1
4) Same as 1
1 ) Adsorbers,
afterburners,
precipitators
1 ) Scrubber
CAPTURE DEVICE
1 ) Canopy hood
2) Same as 1
3) Same as 1
4) Same as 1
1 ) Direct tap
1 ) Direct tap
TYPICAL GAS FLOW
DESIGN RATE
1) 350 cfm/ft belt
width at speeds
~'200 fpm
500 cfm/ft belt
width at speeds
-x/200 fpm
2) 100 cfm/ft of
casing cross-
section (elevator
50 cfm/ft of
screen area
3) Combustion air rai
4) Blower race
1 ) Process gas
stream rate
1 ) Combustion air
rate
TYPICAL GAS
TEMPERATURE
1) 70F hoods
2) Same as 1
e 3) Same as 1
4) 600-1 500F
calciner
1) -15 to 130F
1) 600-1500F
nil
-------
Table 2-1 INDUSTRY POLLUTANT SOURCES AND TYPICAL CONTROL DEVICES (cont'd)
i
CO
co
INDUSTRY
20) Secondary
Aluminum
21 ) Secondary
Copper
Smelters
22) Sewage Sludge
Incinerators
23) Surface Coat-
ings- Spray
Booths
SOURCE
1 ) Reverbatory
furnace
2) El. induction
furnace
3) Crucible furnace
4) Chlorinating
station
5) Dross processing
6) Sweating furnace
1) Reverbatory
furnace
2) Crucible furnace
3) Cupola & blast
furnaces
4) Converters
5) El. induction
furnaces
1 ) Multiple hearth
incinerator
2) Fluidi.'ed bed
incinerator
1 ) Spray booth
CONTROL SYSTEM
1 ) Scrubber (low
energy) + baghouse.
precipi tator
2) Same as 1
3) Same as 1
4) Same as 1
5) Same as 1
6) Same as 1
1 ) Baghouse, scrubber
precipi tator
2) Same as 1
3) Same as 1
4) Same as 1
5) Same as 1
1 ) Scrubber
2) Same as 1
1 ) Adsorber
CAPTURE DEVICE
1 ) Canopy hood
(hearths), direct
tap
2) Same as 1
3) Same as 1
4) Same as 1
5) Same as 1
6) Same as 1
1) Direct tap, canopy
hood, full hood
2) Same as 1
3) Same as 1
4) Same as 1
5) Same as 1
1 ) Direct tap
2) Same as 1
1 ) Canopy hood
TYPICAL GAS FLOW
DESIGN RATE
1 ) Max. plume vol .
+ 20',: (hearths)
2) Infiltrated air
3) Same as 2
4) Same as 2
5) Same as 2
6) Same as 2
1) 200 fpm/ft2
canopy hood
2) Max. plume vol.
+ 2 OX
3) 1800 fpm infil-
trated air (full
hood)
4) Based on type
capture
5) Same as 4
1 ) Combustion air
blower capacity
2) Same as 1
i»
1) 150 fpm/ft2 hood,
100 fpm booth
face velocity
TYPICAL GAS
TEMPERATURE
1) 1600F fluxing,
600F holding
hearth
2) Based on type
capture
3) Same as 2
4) Same as 2
5) Same as 2
6) Same as 2
1) 2500F direct
tap
2) Based on type
capture
3) Same as 2
4) Same as 2
5) Same as 2
1) 600 to 1500F
2) Same as 1
1) 70F
-------
Table 2-1 INDUSTRY POLLUTANT SOURCES AND TYPICAL CONTROL DEVICES (cont'd)
INDUSTRY
24) Portland
Cement
25) Basic Oxygen
Furnaces
26) Electric Arc
Furnaces
27) Phosphate
Fertil izer
SOURCE
1 ) Rotary kiln
a) Wet
b) Dry
2) Crushers and
conveyors
3) 'Dryers
1 ) Basic oxygen
furnace
2) Charging hood
1 ) Arc furnace
2) Charging and
tapping
1 ) Digester vent air
2) Filters
3) Sumps
CONTROL SYSTEM
1) Precipitators,
baghouses
2) Baghouses
3) Precipitators,
baghouses
1 ) Precipitator,
scrubber, baghouse
2) Same as 1
1 ) Baghouse, scrubber,
precipitator
2) Same as 1
1 ) Scrubber, baghouse
2) Same as 1
3) Same as 1
CAPTURE DEVICE
1 ) Direct tap
2) Canopy hoods
3) Direct tap
1 ) Full -canopy hood
2) Canopy hood
1) Direct tap, full/
side draft hood
2) Canopy hood
1) Hood
2) Same as 1
3) Same as 1
TYPICAL GAS FLOW
DESIGN RATE
1 ) Combustion air
rate where
appl icable
2) 250 fpm hood face
"
3) Same as 1
1 ) Function of lance
rate and hood
design - up to
1 ,000,000 acfm
2) 300 fpm hood face
1 ) Function of lance
rate and hood
design - up to
200,000 acfm
2) 250 fpm hood face
1) Process stream
rate
2) Same as 1
3) Sank.1 as 1
TYPICAL GAS
TEMPERATURE
1) 150-850F kilns
2) 70F crushers
& conveyors
3) 200F dryers
1) 3500-4000F
2) 150-400F
1) 3500F Mirpct
tap)
2) 150F
(canopy)
1) 150F
2) Same as 1
3) Same as 1
I
GO
Is?
-------
Table 2-2. DESIGN PARAMETERS FOR RESPECTIVE
INDUSTRIES FOR HIGH EFFICIENCY PERFORMANCE
Industry
Basic oxygen furnaces
Brick manufacturing
Castable refractories
Clay refractories
Coal fired boilers
Conical incinerators
Cotton ginning
Detergent manufacturing
Electric arc furnaces
Feed mills
Ferroalloy plants
Glass manufacturing
Grey iron foundries
Iron and steel (sintering)
Kraft recovery furnaces
Lime kilns
Municipal incinerators
Petroleum catalytic cracking
Phosphate fertilizer
Phosphate rock crushing
Polyvinyl chloride production
Portland cement
Pulp and paper (fluidized bed reactor)
Secondary aluminum smelters
Secondary copper smelters
Sewage sludge incinerators
Surface coatings - spray booth
Fabric Filter
Air-to-Cloth Ratio
Reverse
Air
1.5-2.0
1.5-2.0
1.5-2.0
1.5-2.0
1.2-1.5
1.5-2.0
2.0
1.5
1.5-2.0
1.5-2.0
1.5-2.0
1.8-2.0
1.2-1.5
Pulse
Jet
6-8
9-10
8-10
8-10
5-6
6-8
10-15
9
7-8
7-8
8-9
8-9
5-10
7
7-10
6-8
6-8
Mechanical
Shaker
2.5-3.0
2.5-3.2
2.5-3.0
2.5-3.2
2.0-2.5
2.5-3.0
3.5-5.0
2.0
2.5-3.0
2.5-3.0
2.5-3.0
3.0-3.5
3.0-3.5
2.0-3.0
2.0
Venturi
Scrubber
In. of
Water
40-60
35
11
15
10-40
40-60-80
65
25-60
15-30
12-40
40
15-30
10-20
30
Precip-
itator
Drift Vel
Ft/ sec
.15-. 25
.22-. 35
.12-. 16
.14
.1-.12
.2-. 35
.2-. 3
.175-.25
.2-. 33
.125-. 175
.35
.2-. 3
.12-. 14
High Efficiency - A sufficiently low grain loading to expect a clear stack.
2-35
-------
Table 2-3 EFFICIENCY OF CARBON ADSORPTION AND LEL'S
FOR COMMON POLLUTANTS
Pollutant Lower explosive
limit
(percent by volume
in air)
Acetone
Benzene
n-Butyl acetate
n-Butyl alcohol
Carbon tetrachloride
Chloroform
Cyclohexane
Ethyl acetate
Ethyl alcohol
Heptane
Hexane
Isobutyl alcohol
Isopropyl acetate
Isopropyl alcohol
Methyl acetate
Methyl alcohol
Methyl ene chloride
Methyl ethyl ketone
Methyl isobutyl ketone
Perchlorethylene
Toluene
Trichlorethylene
Trichloro trifluoroethane
V M & P Naptha
Xylene
2.15
1.4
1.7
1.7
n
n
1.31
2.2
3.3
1
1.3
1.68
2.18
2.5
4.1
6.0
n
1.81
1.4
n
1.27
n
n
0.81
1.0
Carbon
adsorption
efficiency
(percent)
8
6
8
8
10
10
6
8
8
6
6
8
8
8
7
7
10
8
7
20
7
15
8
7
10
Efficiencies are based on 200 cfm of 100F solvent-laden air, with no other
impurities per hundred pounds of carbon per hour. Solvent recovery is
90-95%. Concentrations of solvent will alter efficiencies somewhat, but
for estimating purposes those figures are satisfactory for 25 ppm and
greater. See Section 4.5 for the use of this table. Source: Hoyt Manufac-
turing.
2-36
-------
the 27 industries. Additional information on these industries may be ob-
tained from these sources.
2.7 FACTORS AFFECTING RETROFIT COSTS
The cost of retrofitting an existing facility to include a pollution
control system will usually cost more than the installation in a new facility.
The increases in costs can be as high as 10 times the normal installation costs
depending on the degree of plant modifications. It is difficult to accurately
assess the increased costs for retrofitting without the plans and specifica-
tions of the particular plant and process being retrofitted. Some of the
factors that attribute to the additional costs, however, are discussed as
follows:
Plant age - Installation may require structural modifications to plant
and process alterations.
Available
space - May require extensive steel support construction and site
preparation. Existing equipment may require removal and
relocation. New equipment may require custom design to meet
space allocations.
Utilities - Electrical, water supply, and waste removal and disposal
facilities may require expansion.
Production
Shut-down- Loss of Production during retrofit must be included in
overall costs.
Labor - If retrofitting is accomplished during normal plant
operations, installation time and labor hours will be
increased. If installation occurs during off-hours,
overtime wages may be necessary.
Engineering-Increased engineering costs to integrate control system
into existing process.
2-37
-------
SECTION 3
PROCEDURE FOR ESTIMATING COSTS
3.1 GENERAL
The cost curves presented in Section 4 represent the equipment costs for
the various control devices and auxiliary equipment, together with the esti-
mated installation and annual operating and maintenance costs for systems
using these components. Installation costs for the equipment will depend
on such factors as: physical location of the equipment within the plant,
degree of assembly, availability of local erectors, wage rate and overtime
requirements, availability of utilities, equipment transportation and diff-
iculty of loading/unloading, and complexity of instrumentation and control.
Turnkey cost estimates by most suppliers also include engineering and con-
tingency costs. Engineering is generally estimated at 10 percent of the total
equipment and installation cost. This includes start-up and performance
testing besides the normal system design engineering. Contingencies are also
included in the cost estimates. These contingencies cover unexpected costs
due to inflation, union slow-downs and strikes, delays in receipt of materials,
start-up and guarantee testing problems, subcontractor price adjustments,
and other unforeseen problems. Contingency costs are generally estimated at
10 percent of the total costs. The capital costs for a control system are
therefore itemized as follows.
1) Equipment costs (control device + auxiliaries) = $
2) Tax and freight &7% of 1) * = $
3} Installation costs (Table 4-12) = $
*
Taxes range from 3-6%. Freight ranges from 1-5%. The 7% figure assumes
42 and 3% respectively.
3-1
-------
4) Subtotal (1 + 2 + 3) = $
5) Engineering @ 10% of 4) = $
6) Subtotal (4+5) = $
**
7) Contingencies @ 10% of 6) = $
8) Total capital costs (6 + 7) = $
For certain items, such as cooling towers, tall stacks, and refractory,
installed prices are given in Section 4. The cost of such equipment, then,
is not included in Line 1 above, rather these costs are added to Line 8 to
arrive at the total capital cost for the system.
Operating and maintenance curves in Section 4 are based on the average
costs for complete systems. Some costs may be higher or lower depending on
the type of maintenance, system efficiency, labor and material rates, the
number of hours operated per year, utility rates, and geographical location.
Some plants within the same geographical location will pay lower power or
utility rates than others due to the plant's total rate of consumption.
The use of the tables and curves in Section 4 to determine the capital,
operating, and maintenance costs of the five control systems is discussed in
Section 3.3 with a typical example of the procedures to be followed. Section
3.2 illustrates the use of life-cycle cost analysis. Appendix E provides
factors for converting English units of measurement to the International
System of Units (SI).
*
Engineering may range from 5-10%.
Contingencies may exceed 20% for retrofits, repairs, or alterations
3-2
-------
3.2 COST COMPARISON METHODOLOGIES
To adequately compare the costs of alternative air pollution control
systems, one needs a procedure for combining the aggregate effects of first
cost, operating cost, maintenance cost, and other costs or economic benefits
that may arise from owning and operating the system. The procedure to be
presented here is known as life-cycle cost analysis.
Life-cycle costing may involve either of two techniques: the Present
Worth method and the Uniform Annual Equivalent method. The Present Worth
(PW) technique provides a means of calculating a single lump sum that at the
present time would be equivalent to all present and future cash flows. If
the PW's for all alternatives are calculated, then the one alternative having
the lowest PW would be the most desirable from an owning and operating cost
standpoint. The Uniform Annual Equivalent (UAE) technique provides a means
of calculating an annual payment that would be equivalent to all present
and future cash flows. The alternative having the lowest UAE would be the
most desirable from an owning and operating cost standpoint. Both methods
are valid approaches to life-cycle costing; the use of the one or the other
depends on the user's individual preferences, and both will be described here.
The PW and UAE techniques incorporate the time value of money to cal-
culate the equivalent value at present time of some future cash flow. Money
has time value because a dollar now can be invested to yield more than a
dollar at some future date - just as a bank pays interest on a personal
savings account. The general formula for the PW of a future cash outlay, F,
taking place n periods from the present, given a discount rate, i, is:
Eq(3-l) ' PW = —E .
3-3
QMS.
-------
The PW of a uniform annual payment, A, is:
c /0 ox m, „ *-••* - Cn is the number of periods
Eqv3-2; PW = A ...
n
over which the annual payment
takes effect)
The UAE of a PW is:
Eq(3-3)
UAE = PW
Hence, for example:
$1,627.50 = $10,000
.1)
10 -i
These formulas are provided for the reader's reference. However, in
general practice one makes use of tables, which are given in Appendix A,
Compound Interest Factors. The use of these tables is now described. In
Equation 3-1 above, the compound interest factor is known as the single pay-
ment present worth factor and is typically denoted by (P/F, n) which reads
"present worth from future amount". The F symbolizes a single payment at
some future date, n periods from the present. In Equation 3-2, the compound
interest factor is known as the uniform series present worth factor and is
typically denoted by (P/A, n), which reads "present worth from an annuity".
The A symbolizes a uniform series of annual payments commencing at the end
of year one and stopping at the end of year n. In Equation 3-3, the compound
interest factor is known as the capital recovery factor, and is typically
denoted as (A/P, n), which reads "the annuity from the present amount",
which extends for n periods. Using the capital recovery factor, one can
compute the UAE from the PW. In the tables just mentioned, these factors
are provided. As an example of their use, consider the calculation of PW for
an initial payment of $3000, an annual payment of $1000 for 10 years, and a
lump sum payment of $1379 at the end of year 5:
PW= $3000 + 1000 (P/A, 10) + $1379 (P/F, 5)
-------
To clarify, the $3000 has no factor since it is already in the present;
the $1000 occurs each year for ten years (an annuity); in the fifth year
there is an additional single payment expense of $1379. Refering to Table
A-9, the factors are found to be* for a 10% discount rate:
PW= $3000 + $1000 (6.144) + $1379 (0.6209)
= $10,000.
Additionally, one can compute that the
UAE= PW (A/P,10)
= $10,000 (0.16275)
= $1627.5
There is yet one final topic that needs to be discussed and that is the
selection of the discount rate. In its most limited sense, interest is the
money paid for the use of borrowed capital. But in life-cycle cost analysis,
a broader view is required; interest is the cost of employing capital for air
pollution control. If in fact the capital needed for owning and operating
air pollution control equipment comes from direct loans, then the discount
rate used in the PW and UAE calculations is equal to the interest rate of the
loans. A similar statement can be made for bond issues. The discount rate
for government investments is the interest rate the treasury must pay to borrow
money. A more complicated situation arises however when the firm does not
borrow, but instead uses equity funds. In this case, the discount rate is the
cost of employing equity, which is the expected rate of return on investments
that the firm can make. Higher discount rates tend to favour lower first costs,
since the high rate of discounting considerably reduces the present worth of
future cash outlays. The selection of the discount rate should be given
serious thought, because the ranking of investment alternatives can vary
according to the level of the discount rate.
3-5
-------
Example of the use of life-cycle costing is given in Section 3.3. More
extended discussion of cost analysis may be found in the book, Principles of
Engineering Economy by Grant and Ireson, the Ronald Press Company, New York,
New York, 1970. The reader is encouraged to study this text, as there are
many important topics and caveats that could not be covered in this brief
space. Some special concerns include: proper handling of depreciation and
tax effects, equipment replacement, lease or buy decision, unequal equipment
lives, determining the discount rate, calculating utility costs, etc. How-
ever these subjects are'principally the internal concern of the purchaser of
abatement equipment.
3.3 EXAMPLE CASE STUDY
For purposes of illustration of the use of the manual, a case study on
rotary lime kiln air pollution control is presented here. Since this manual
provides very little guidance regarding the design of air pollution control
systems, it is essential that the user have prepared in advance an engineering
design for control of the pollutant source. Care should be taken in perfor-
ming the design because a poor design is likely to result in unrealistic
costs. There may be many system configurations that will satisfy the techni-
cal requirements, but only one or two will cost the least. In the example
presented here, the engineering design is intended to demonstrate the use of
the manual and is simplified in the interest of clarity and brevity. Hence
the design may not be optimal- The reader should however, concentrate on
understanding how the manual is used. Engineering design techniques may be
found in EPA Pub. AP-40, Air Pollution Engineering Manual, (see Appendix C,
.No. 88)
3-6
-------
Lime (CaO or CaO'MgO) is the product of the calcination of limestone
(CaCOs or CaCOs-MgCOa). Lime manufacturing involves several sources of
pollutants. The sources include:
a) Quarrying - stripping, drilling, blasting, loading, and hauling.
b) Stone processing - crushing, pulverizing, screening, and conveying.
c) Limestone calcining (kilns).
d) Lime hydration, drying, and bagging.
e) Fugitive dust-roads, stockpiles, transportation, etc.
This section is concerned solely with rotary lime kiln operations. Kilns
are basically of two types: vertical and rotary. Rotary kilns are used by
the majority (80-90%) of lime plants and they represent the largest single
source of pollutants in the lime industry. The pollutants are predominately
particulate matter. Broadly speaking, about 30% of the dust from rotary
kilns is less than lOy and the mean size is 30y. The exhaust temperature
from rotary kilns depends on the length of the kiln and other process variables.
Lime kiln exhaust gas is usually cleaned with venturi scrubbers or fabric
filters, although electrostatic precipitators may also be used. This case
study will show cost estimation for all three methods. The following condi-
tions are assumed:
• A typical 250 TPD rotary kiln to be controlled at 1000 ft elevation.
• Required control efficiency of 99+%.
0 Exhaust gas from kiln: 30,000 SCFM or 88,300 ACFM @ 1100F.
• Control device to be located 200' from source.
• Direct tap of exhaust from kiln.
• Duct-velocity = 4000 fpm to prevent fallout
t Surrounding terrain does not impose unusual constraints on system
design and stack height (501).
!13V JlNi'S,
-------
OUTLINE OF ENGINEERING CALCULATIONS
Case A - fabric filter
Establish overall engineering design as follows:
a. Use polyester (275F) or glass bags (550F).
b. A/C ratio = 2 for glass bags.
= 3 for polyester bags.
c. Suction baghouse:
- reverse air, insulated for glass bags
- mechanical shaker, insulated for polyester bags
d. Radiant coolers next to source.
e. Mechanical cyclone just prior to baghouse.
f. Dilution air port provided for temperature modulation.
g. By-pass damper omitted.
Figure 3-L.shows the system layout for a fabric filter operation. The
following discussion outlines how the design parameters are obtained for each
stage along the system.
Stage 1: Direct exhaust from kiln, determine carbon steel elbow duct size:
88300 ACFM = 22.1 Ft2
4000 fpm
Hence, 64" duct (22.3 ft2) may be used, giving:
88300 ACFM = 3950 fpm
22.3 ft2
Stage 2. a. Assume no temperature drop from kiln outlet to inlet of
radiant cooler. Estimate that about 600 F temperature is
required out of the cooler. Try initial 5000 fpm through two
18" U tubes in series. Thus need
88300 ACFM
1.767 ft2/tube X 5000 fpm
= 10 pairs of tubes in parallel
-------
Screw conveyor
DESIGN PARAMETERS
SCFM
TEMPERATURE
ACFM
DUCT DIAMETER
STATIC PRES. (" WG)
1
30,000
1100 F
88,300
64"
Kiln
Draft
2
30,000
600 F
60,000
50"
-2.1"
3
30,000
530 F
56,000
50"
-2.7"
4
30,000
500 F
54,300
50"
-8.7"
5
38,600b
100 Fb
40,800b
50"
-
6
30,000*
68,600b
500 Fj
275 FD
54,300?
95,100b
Neglect
-
7
30,000j
68,600b
500 F<>
275 Fb
54,300*
95,100b
Neglect
-14.7"
co
i
a - glass bag
b - polyester bag
Figure 3-1 FABRIC FILTER SYSTEM DESIGN
-------
From engineering calculations*for 40' high tubes, the temper
ature drop for two tubes in series is 500F. Thus exit temp-
erature is GOOF and gas volume is 60000 ACFM. Pressure drop
is 2.1" W.G. Estimated length of cooler is 30 feet.
b. Determine carbon steel duct diameter
60000 ACFM 1K f.2
- - ID Tt
4000 fpm
p
Hence 50" duct (13.6 ft ) may be used, giving:
. 4400 fpm
13.6 ft*
Stage 3. Cooling of gas will take place over 200-30 = 170 ft. of duct.
Using engineering calculations, it is found that 600F gas
through 170' of duct drops to about 530F- Therefore, the new
ACFM is:
60000 ACFM X 990_R = 5600Q ACFM
1060 R
Check duct velocity:
56000 AC™ = 4100 fpm
13.6 ft*
Hence duct size remains at 50" throughout. Two expansion joints
will be required, one 50", the other 64". Pressure drop through
duct is about 1/3" per 100 ft or .6" W.G.
Heat transfer calculation methods may be found in the EPA publication AP-40,
See Appendix C, reference 88.
-------
Stage 4. Select two mechanical collectors in parallel to handle 28000 ACFM
2
each. For 6" pressure loss, the inlet area is 8.5 ft and the
critical partical size is 24 microns. Temperature drop will be
about 30F, thus new gas volume is:
56000 ACFM X 960_R = 54j30Q ^
990 R
Stage 5. Dilution air port is provided for baghouse for modulation of gas
temperature. For glass bags, no dilution air will generally be
required. For polyester bags, dilution air is estimated as follows
(neglecting the difference in heat capacities):
(30,000 SCFM)(500F) + D (100F)=(30000+D)(275F)
D = 38,600 SCFM
Stage 6. Hence total gas volume is 68,600 SCFM or 95100 ACFM @ 275F for
polyester bags, and is 54300 ACFM @ 500F for glass bags.
The baghouse is sized as follows:
a. For glass bags:
ft2 net cloth area.
2.0 A/C
b. For polyester bags:
= 31700 ft2 net cloth area
3.0 A/C
Baghouses are nominally sized for 6" W.G. Neglect temperature drop
through the baghouse.
Stage 7. Total pressure drop across system is:
Radiant cooler - 2.1" W.G.
Ductwork .6"
Mechanical collector 6.0"
Baghouse 6.0"
14.7" W.G.
3-11
-------
Size fans for 54,300 ACFM and 95,100 ACFM for glass and polyester
bags respectively. Select 50' high stacks of 50" and 66" respect-
ively. Fifty feet of 9" diameter screw conveyor will be required.
Case B - Electrostatic Precipitator
Establish overall engineering design as follows:
a. Drift velocity = .25 fps.
b. Insulated precipitator
c. Inlet gas temperature of 700F for good resistivity
d. Spray chamber next to source
Figure 3-2 shows the system layout for an electrostatic precipitator
operation. The following discussion outlines how the design para-
meters are obtained for each stage along the system.
Stage 1. Same as for Case A, Fabric Filter.
Stage 2. Estimate spray chamber outlet temperature of 800F. Water required
is about 15 gpm. Chamber length is about 35 feet. New gas volume
will be:
88,300 ACFM X 1260_R = 713QO Acm
1560 R
Calculate duct diameter:
71,300 ACFM = 17 8 ft2
4000 fpm
2
Hence 55" duct (16.5 ft ) may be used, giving:
71.300 ACFM = 4300 fpm
16.5 fr
Stage 3. a. Cooling through duct will be about 110F (for 206-35=165 ft).
Hence final temperature is 690F and new gas volume is:
71300 ACFM X 1150 R = 6500Q ACFM
1260 R
010
-------
CO
(—«
CO
'2
V
Spray
chamber
N/
/ \_
A. ,
/> a * a it a
Screw conveyer
DESIGN PARAMETER
SCFM
TEMPERATURE
ACFM
DUCT DIAMETER
STATIC PRES. (" WG)
/
1
30,000
1100 F
88,300
64"
Kiln
Draft
2
30,000
800 F
71,300
55"
3
30,000
690 F
65,000
55"
-1.0"
4
30,000
690 F
65,000
Neglect
-1.5"
Figure 3-2 ELECTROSTATIC PRECIPITATOR SYSTEM DESIGN
-------
Check duct velocity:
65'00°
= 3940fpm(OK).
16.5 ft
Two expansion joints will be needed as for baghouses.
b. Size precipitator as follows:
A = -65,000 ACFM ln(l-.993)/(0.25 fps X 60 s/min)
A = 21500 ft2
Stage 4. Total pressure drop across system is:
Spray chamber and duct - 1.0" W.G.
Precipitator - .5" W.G.
Total 1.5" W.G.
Size fan for 65,000 ACFM. Select a 50' high stack 55" diameter.
Fifty feet of screw conveyor 9" in diameter will be required.
Calculate KW of system for operating cost:
15 gpnr pump has ^5 HP motor = 3.7 KW
Screw conveyor has %5 HP motor = 3.7 KW
Fan has -^10 HP motor = 7.5 KW
Precipitator requires 78.3 KW
Total 93.2 KW
or 1.43 KW per 1000 ACFM
Case C - Venturi Scrubber
Establish overall engineering design as follows:
a. Venturi scrubber pressure drop estimated at 15" W.G.
b. Carbon steel, unlined construction
c. Quencher next to source.
Figure 3-3 shows the system layout for a venturi scrubber operation,
The following discussion outlines how the design parameters are
obtained for each stage along the system.
Stage 1. Same as for Case A, Fabric Filter.
3-14
-------
Quencher \/
Water treatment
CO
»—>
en
DESIGN PARAMETER
SCFM
TEMPERATURE
CFM
DUCT DIAMETER
STATIC PRES. (" WG)
1
30,000
1100 F
88,300
64"
Kiln
Draft
2
40,200
220 F
52,000
48"
3
40,200
190 F
49,700
48"
-1"
4
30,000
100 F
48,200
Neglect
-16"
Figure 3-3 VENTURI SCRUBBER SYSTEM DESIGN
-------
Stage 2. a.-Qaeneher is sized at about 60 gpm and 30' 'long to coolrgas from
HOOF to 220F. New gas volume is:
gas: 88,300 ACFM X 680_R = ^W ACRM
1560 R
water vapor: 60 gpm X 8.33 Ib/gal X 680 R X 21.1 cu ft/lb
530 R
= 13500 ACFM
total: 38,500 + 13500 = 52,000 ACFM
b. Required duct size is:
.5^000 AC™ = 13.0 ft2
4,000 fpm
Hence a 48" (12.57 ft ) duct may be used giving:
52'000 AC™ = 4140 fpm
12.57 ft
Stage 3. Through 170 ft of duct the gas temperature drops to about 190F,
hence the new gas volume is:
52,000 ACFM X 650_R = ^gJQQ
680 R
Check duct velocity:
49'-700 AC™ = 3950 fpm (OK).
12.57 ftr
Stage 4. Scrubber is sized for 49,700 ACFM; and will be constructed of 3/16"
steel to allow for erosion. Estimated gas exit temperature is
170F- Fan is sized for:
49,700 ACFM X 630_R = 48j200 ACFM
650 R
Select a 48" stack.
3-16
-------
ESTIMATING PURCHASE PRICE OF CONTROL SYSTEMS
Case A - Fabric Filter
a. (1) 64" carbon steel elbow, V Thick (Figure 4-24) - $ 1,800
b. (20) branches of 18" carbon steel radiant cooler 40'
high (Figure 4-31) - 62,000
c. (170) feet of 50" carbon steel duct 3/16" thick
(Figure 4-21) - 9,700
d. (2) carbon steel, 10 Ga., mechanical collectors with
inlet area = 8.5 ft* - 18,200
Collector (Figure 4-35) - $4100
Support (Figure 4-37) - 2600
3/16" Hopper (Figure 4-38)- 800
Scroll (Figure 4-39) - 1600
Total Each $9100
e. (1) 3/16" transition to mechanical collector
(Figure 4-24) - 600
(2) expansion joints, one 50", one 64" (Figure 4-28)- 6.000
Sub-Total $ 98,300
Glass Bags
f. (1) 50" carbon steel dilution air port, 3/16" thick
(Figure 4-32) 5,000
2
g. (1) 27,150 ft net cloth area, continuous, reverse 140,400
air, insulated baghouse (Figure 4-10) -
h. Suction add-on (Figure 4-10) - 9,100
i. (1 set) 27,150 X 1.17 = 31,765 sq ft gross area
glass bags (Table 4-1) - 12,700
j. (1) 54,300 ACFM backwardly curved Class IV fan at
14.7MWG actual (29" standard) (Figure 4-40) - 5,600
k. (1) 1,800 RPM, 180 HP drip proof motor
(Figure 4-41) - $ 2,400
1. (1) Magnetic starter with circuit breaker
(Figure 4-41) - 1,400
m. -(1) 50" diameter, 50' high stack, 1/4"
thick (Figure 4-48) - 4,400
n. (50) feet of 9" screw conveyor (Figure 4-57) 3,400
Sub-Total $.184,400
3-17
-------
Polyester Bags
f. (1) 66" carbon steel dilution air port, 1/4"
thick (Figure 4-32) - $ 6,800
2
g. (1) 31,700 ft net cloth area, continuous,
mechanical shaker baghouse (Figure 4-9) - 100,900
h. Suction add-on (Figure 4-9) - 8,900
i. Insulation add-on (Figure 4-9) - 49,500
j. (1) set 31,700 X 1.17 = 37,089 sq ft gross
area Dacron bags (Table 4-1) - 11,100
k. (1) 95,100 ACFM backwardly curved Class IV fan
at 14.7" WG actual (29" standard) (Figure 4-40)- 9,000
1. (1) 1,800 RPM, 300 HP, drip-proof motor (Figure 4-41) 4,400
m. (1) magnetic starter with circuit breaker
(Figure 4-41) - 3,000
n. (1) 66" diameter, 50' high stack, 1/4" thick
(Figure 4-48) - 5,200
o. (50) feet of 9" screw conveyor (Figure 4-57)- 3,400
Sub-Total $202,200
Total capital and operating cost for the fabric filter system is summar-
ized below, see Table 4-12 for installation and maintenance cost and Figure
4-60 for operating costs:
Glass Bag Polyester Bag
Equipment $282,700 $300,500
Installation (75%) 212,000 225,400
Maintenance (2%} 4700/yr 6000/yr
Operating (8000 hrs) 14,400/yr 25,600/yr
Bags (life: 1.5; 2.0 yr) 8,500/yr 5,600/yr
3-18
-------
Case B - Electrostatic Precipitator
a. (1) 64" carbon steel elbow, 1/4" thick
(Figure 4-24) - $ 1»8QO
b. (1) spray chamber @ 88,300 ACFM (Figure 4-29)- 55.00U
c. (165) feet of 55" carbon steel duct 3/16" thick
(Figure 4-21) - 10,400
d. (2) expansion joints, one 55" and one 64"
(Figure 4-26) - 6,600
e. (1) 21,500 ft2 precipitator, insulated
(Figure 4-1) - 206,700
f. (1) 65,000 ACFM backwardly curved Class I fan
at 1.5" WG actual (3.4" standard) (Figure 4-40)- 7,500
g. (1) 600 RPM.45 BMP drip-proof motor (Figure 4-41)- 2,100
h. (1) magnetic starter with circuit breaker
(Figure 4-41)- 300
i. (1) 55" diameter, 50' high stack, 1/4" thick
(Figure 4-48) - 4,700
j. (50) feet of 9" screw conveyor (Figure 4-57)- 3,400
Total Equipment $29*8,500
Installation (75%) 223,900
Maintenance (2%) 4,400/yr
Operation (8000 Hrs) 14,400/yr
(See Figure 4-58)
Case C - Venturi Scrubber
a. (1) 64" carbon steel elbow, 1/4" thick
(Figure 4-24) - $ 1,800
b. (1) quencher @ 88,300 ACFM (Figure 4-30) - 25,000
c. (1) quencher pump for 60 gpm (Figure 4-53) - 700
d. (170) feet of 48" carbon steel duct, 3/16" thick
(Figure 4-21) - 9,300
e. (2) expansion joints, one 48" and one 64"
(Figure 4-26) - 6,000
f. (1) 49,700 ACFM scrubber, 3/16" thick (Figure 4-2)- 22,000
3-19
-------
g. (1) 48,EDO ACFM radial-tip fan at 16" WG actual
(20" standard) (Figure 4-42) - $ 8,000
h. (1) 900 RPM, 225 HP drip-proof motor (Figure 4-41)- 6,000
i. (1) magnetic starter with circuit breaker
(Figure 4-41) - 2j000
j. (1) 48" diameter, 50' high stack, 1/4" thick
(Figure 4-48) - 4,400
Total Equipment $ 85,200
Installation (140%) 119,300
Maintenance (13%) ll,10Q/yr
Operation (8000 Hrs) 36,000/yr
(See Figure 4-59)
COST COMPARISON
Initial capital investments for the three alternative systems will be:
Equipment
Tax & Freight @ 7%
Installation
Sub Total
Engineering @ 10%
Sub Total
Contingencies @ 10%
Sub Total $622,500 $657,400 $254,700
The calculation of Present Worth (PW) for a 10% discount rate is given
below. The effect of income taxes on PW is not considered, although in
practice one should consider tax effects, depending on tax advantages avail-
able to the firm.
Case A - Fabric Filter
Estimate equipment life of 20 years and glass bag life of 1.5 years.
The calculation of Present Worth (PW) for a 10% discount factor is shown
3-20
Fabric
Filter
$282,700
19,800
212,000
$514,500
51,400
$565,900
56,600
Electrostatic
Preci pita tor
$298,500
20,900
"223,900
$543,300
54,300
$597,600
59,800
Venturi
Scrubber
$85,200
6,000
119,300
$210,500
21,000
$231,500
23,200
-------
below. Annual bag cost is figured at $12,700/1.5 = $8500
PW = $622,500 + $4,700 (P/A,20) + $14,400 (P/A,20) + $8500 (P/A,20)
= $622,500 + $27,600 X 8.514
= $857,500 ± $171,000-.
Case B - Electrostatic Precipitator
Estimate equipment life of 20 years.
PW = $657,400 + $4400 (P/A,20) + $14,400 (P/A,20)
= $657,400 + $18,800 (8.514)
= $817,500 ± $163,000.
Case C - Venturi Scrubber
Estimate equipment life of 10 years.
PW = $254,700 + $11,000 (P/A, 20) + $36,000 (P/A, 20) + $254,700 (P/F.10)
= $254,700 + $47,000 (8.514) + $254,700 (0.3855)
= $753,000 ± $151,000.
Because the equipment costs are accurate to ±20%, the overall installed
equipment cost is also subject to the same accuracy. Hence the cost of the
scrubber system could range from $602,000 to $904,000, but a nominal estimate
would be $753,000. The range for the precipitator system is $654,000 to
$980,000 and the range for the fabric filter system is $686,000 to $1,028,000.
The user of this manual should not determine what is the most economical
system from these figures-rather the conclusion to be drawn is that a control
system would cost something between the ranges indicated above. However, the
designs presented here are not necessarily optimal, so this analysis should
not be viewed as realistic from a design and cost standpoint, rather the
reader should 'concentrate on understanding the use of the manual.
3-21
-------
SECTION 4
CONTROL EQUIPMENT COSTS AND SELECTED DESIGN DATA
4.1 ELECTROSTATIC PRECIPITATORS
Prices for dry type (mechanical rapper or vibrator) precipitators are
contained in Figure 4-1. These prices may also be used for rapper type, wet
bottom precipitators. Prices are a function of net plate area, which can be
calculated using the Deutsch equation:
(1) n - 1 - e t-wA/C»
or
(2) A = -Q In (l-n)/w
where n is efficiency
w is drift velocity, f/s
2
A is net plate area, ft
Q is flow rate, cfs
exp is e, the Naperian log base
For example, for gray iron foundries the drift velocity, w, is typically
0.12 f/s. If 99% cleaning efficiency is required on a flow rate of 10,000
cfm into the precipitator, the net plate area is calculated as follows:
A = (-10000 cfm* In (K99))/(0.12 f/s* 60 s/m)
= 6396 ft2
For the required plate area read the price for either the insulated or
uninsulated precipitators, depending on design requirements.
4-1
-------
DATA VALID FOR DECEMBER 1975
oe
o
UJ
CfL
a.
A, NET PLATE AREA, SO.FT.
Figure 4-1 DRY TYPE ELECTROSTATIC PRECIPITATOR PURCHASE PRICES VS. PLATE AREA
4-2
-------
4.2 VD1TURI SCRUBBERS
Prices for venturi scrubbers are contained in Figures 4-2 through 4-6.
To price a scrubber using these curves, use the following steps.
A. Determine the gas volume entering the venturi section and read the price
for a 1/8" thick carbon steel scrubber from Figure 4-2. For example, at
100,000 ACFM the price is approximately $34,000.
B. Determine the pressure drop across the scrubber required to obtain the
desired efficiency (see Table 2-2) and find the required metal thickness
for the design inlet volume from Figure 4-3. For 100,000 ACFM and 30",
the required metal thickness is V plate (always round up to the next
standard plate thickness).
C. From Figure 4-4, find the price adjustment factor for the design inlet
volume and the material thickness found in Step B. For 100,000 ACFM and
V plate, the factor is approximately 1.6. Thus, the carbon steel
scrubber price is now $34,000 X 1.6 = $54,400.
D. If stainless steel construction, rubber or fiberglas lining, or variable
venturi section is to be included, refer to Figure 4-2 and adjust price
accordingly. For 304 stainless steel construction, the adjusted price
would be $54,400 X 1.8 = $97,920. If rubber linings are required, refer
to Figure 4-5 to determine total square footage.
E. If an internal gas cooler is to be used, determine the number of trays
that can be fit into the separator (from separator height, Figure 4-5),
and determine the diameter of each tray (from separator diameter, Figure
4-5). Read price for one tray from Figure 4-6. For 100,000 ACFM the
separator diameter is approximately 13.5 ft. Thus the price for one tray
is about $13,000.
NOTE: Radial tip fans are commonly used with scrubbers.
4-3
-------
DATA VALID FOR DECEMBER 1975
55,000i
50,000
40,000
30JDOO-
20,000
10,000
5,000
NOTE:
1. Prices are for 1/8" Carbon Steel Scrubbers
2. Includes: Venturi, Elbow, Separator, Pumps
and controls, Flange-to-Flange
3. Do not use price equation for above
200,000 ACFM
Price Adjustments
G.
Item
Other metal thickness
316 Stainless Steel
304 Stainless Steel
3/16" Rubber Liner
Manual Variable
Venturi
Automatic Variable
Venturi
Fiberglas Lined
Factor
See Figure 4-4
x 2.5
x 1.8
L 1 I I
$3000
$5500
Add 15% of price
for 1/8" Carbon
Steel Scrubber
to total price
I
20 40
60
80
100
120
140
160
180 200
V, WASTE INLET GAS VOLUME, 1000 ACFM
Figure 4-2 1/8" THICK CARBON STEEL FABRICATED SCRUBBER PRICE VS. VOLUME
4-4
-------
1,000
o
CM
X
LU
UJ
OL
a.
o
I—I
10
UJ
Q
100
10
NOTE: 1. Safety Factor = 2
2. No Corrosion/Erosion
Allowance
1 I
10
100
200
V, WASTE INLET GAS, 1000 ACFM
Figure 4-3 METAL THICKNESS REQUIRED VS. VOLUME AND DESIGN PRESSURE
4-5
-------
DATA VALID FOR DECEMBER 1975
o
o
I/)
=>
•~3i
O
et
LU
CJ
l—(
oc
o.
V, WASTE INLET GAS, 1000 ACFM
Figure 4-4 PRICE ADJUSTMENT FACTORS VS. PLATE THICKNESS AND VOLUME
4-6
-------
4,000
3,000
cr
o
-------
DATA VALID FOR DECEMBER 1975
soyooo
-
40,000
30,000
20,000
Q£
LU
Q_
LU
O
i—I
0_
Q.
10,000
10
15
20
25
D, SEPARATOR DIAMETER, FT,
Figure 4-6 INTERNAL GAS COOLER BUBBLE TRAY COST VS. SEPARATOR DIAMETER
4-8
-------
4.3 FABRIC FILTERS
Prices for mechanical shaker, pulse-jet, reverse-air, and custom fabric
filters (baghouses) are contained in Figures 4-7 through 4-11. Prices are
based on net cloth area, which is calculated by dividing the gas volume
entering the baghouse by the required air-to-cloth (A/C) ratio (see Table 2-1),
For example, to handle 100,000 ACFM at an A/C =2.0 requires 50,000 ft net
2
cloth area. The price for a reverse-air, pressure-type baghouse at 50,000 ft
is $152,000. For stainless steel construction, insulation, and suction-type
design, the total price without bags would be:
Baghouse $152,000
SS 78,000
Insulation 80,000
Suction 16,000
Total $326,000
The prices^.for bags may be determined from Tables 4-1 and 4-2. From
Table 4-2 obtain factor to calculate gross cloth area (at 50,000 ft2 the
factor is 1.11) and from Table 4-1 obtain the price per square foot for the
appropriate cloth and baghouse type. The price of glass bags for the example
is thus:
50,000 ft2 X 1.11 X $.40/ft2 = $22,200
Baohouse prices are flange-to-flahge, including basic baghouse without
bags, 10 foot support clearance, and inlet and exhaust manifolds. Pressure
baghouses are designed for 12" W.G. and suction baghouses are designed for
20" W.G. Custom baghouse prices are more a function of specific requirements,
than of pressure or suction construction. Hence prices for custom units do
not differentiate between pressure or suction. All baghouses are assumed to
be factory assembled.
4-9
-------
DATA VALID FOR DECEMBER 1975
35
I
1—>
o
JP>
1
P
o
o
o
IX
10
678 9 10 11 12 13 14 15 16 17 18 19 - 20
NET CLOTH AREA, 1000 SQ. FT.
Figure 4-7 INTERMITTENT, PRESSURE, MECHANICAL SHAKER BAGHOUSE PRICES VS. NET CLOTH AREA
-------
DATA VALID FOR DECEMBER 1975
-faO-
o
o
o
o
I—H
GC.
O.
40
30
20
10
0 1
5 6 7 . .8 9 10 11 12 13 14 15 16 17 18 _]9 20
NET CLOTH AREA, 1000 SQ. FT.
Figure 4-8 CONTINUOUS, SUCTION OR PRESSURE, PULSE JET BAGHOUSE PRICES VS. NET CLOTH AREA
-------
DATA VALID FOR DECEMBER 1975
10 15 20 25
65 70
Ifil
30 35 40 45 50 55 60
NET CLOTH AREA, 1000 SQ.FT.
Figure 4.9 CONTINUOUS, PRESSURE, MECHANICAL SHAKER BAGHOUSE PRICES VS. NET CLOTH AREA
-------
DATA VALID FOR DECEMBER 1975
GO
10
20
70
80
30 40 50 60
NET CLOTH AREA, 1000 SQ. FT.
Figure 4-10 CONTINUOUS, PRESSURE, REVERSE AIR BAGHOUSE PRICES VS. NET CLOTH AREA
-------
I
1—»
-p>
I
5j
Jp)
1400
DATA VALID FOR DECEMBER 1975
50
100
350
400
150 200 250 300
NET FABRIC AREA, 1000 SQ.FT.
Figure 4-11 CUSTOM PRESSURE OR SUCTION BAGHOUSE PRICES VS. NET CLOTH AREA
450
500
-------
DATA VALID FOR DECEMBER 1975 1WU1C " "™ ™"~
CLASS
Standard
^lif§;;
Custom
TYPE
Mechanical shaker, < 20000ft
Mechanical shaker, >20000ft
Pulse jet*
Reverse air
,. * "
Mechanical shaker
Reverse air
DACRON
.35
.30
.55
.30
.20
.20
ORLON
.60
.55
.90
.55
.30
.30
NYLON
.70
.65
.65
.40
.40
NOMEX
1.10
1.00
1.25
1.00
.60
.60
GLASS
.45
.40
.40
.25
.25
POLYPROPYLENE
.60
.50
.65
.50
\ ;
.30
.30
COTTON
.40
.35
v^.i^Jty
.35
, \*s
,' *s
\ -. •• '••ftAX-si
.35
.35
* For heavy felt, multiply price by 1.5
Table 4-2
APPROXIMATE GUIDE TO ESTIMATE
GROSS CLOTH AREA
en
NET CLOTH AREA
(Sq.ft.)
1 -
4001 -
12001 -
24001 - -
36001 -
48001 -
60001 -
72001 -
84001 -
96001 -
108001 -
132001 -
180001 ON
4000
12000
24000
36000
48000
60000
72000
84000
96000
1 08000
132000
180000
UP
GROSS CLOTH AREA
(Sq.ft..)
Multiply by 2
1.5
1.25
1.17
1.125
1.11
1.10
1 . 09
1.08
1 . 07
1.06
1 . 05
1 . 04
-------
4.4 THERMAL AND CATALYTIC INCINERATORS
Prices for thermal incinerators including refractory linings, are contained
in Figures 4-12 and 4-13. Catalytic incinerator prices are found in Figure
4-14. Residence times for thermal incinerators are determined from application
requirements for efficiency. The price of a thermal incinerator without heat
exchanger for a gas volume of 30,000 ACFM and 0.3 second residence time is
$34,000. With a heat exchanger, the price is not as sensitive to residence
times, and the price would be $80,000. The price of a custom catalytic unit
with heat exchange would be $88,000 at 30,000 ACFM. Gas volumes are measured
at operating temperature in the firing chamber.
4-16
-------
.DATA VALID FOR DECEMBER 1975
I
I—1
^J
INCINERATOR CAPACITY, 1000 ACFM
Figure 4-12 PRICES FOR THERMAL INCINERATORS WITHOUT HEAT EXCHANGERS
J>
-------
DATA VALID FOR DECEMBER 1975
oo
180
200
Jf1'
INCINERATOR CAPACITY, 1000 ACFM
Figure 4-13 PRICES FOR THERMAL INCINERATORS WITH HEAT EXCHANGERS
-------
f,
lis)
•140 DATA VALID FOR DECEMBER 1975
130
120
110
100
» 90
o
o
o
^ 80
LU
<_>
£ 70
o:
o
S 60
LU
Z
»—t
S 50
Q-
40
30
20
10
0
--•K i-
PA( KAGE I
P 4 12
\
NITS :
0.90 /(
0
10
I
30
CUSTOM
;P= 28
UNITJ
2.0/
P1
WITH
TfiM
't
40
50
60
70
80
90
TOO
A, INCINERATOR CAPACITY, 1000 ACFM
Figure 4-14 CATALYTIC INCINERATOR PRICES
-------
4.5 Adsorbers
Prices for carbon adsorbers are presented in Figures 4-15 and 4-16, as a
function of the total number of pounds of carbon in the unit. The total (gross)
number of pounds is determined by the adsorption rate and the regeneration rate
of the carbon for the emission being controlled. To calculate the net pounds of
carbon required for adsorption, first refer to Table 2-3 for a listing of carbon
adsorption efficiencies for various solvents. These efficiencies represent the
ratio of pounds of solvent collected per 100 pounds of carbon, per hour, under
conditions of 100F and 200 cfm. Select the efficiency for the solvent to be
controlled (for mixtures of solvents, see the reference noted below). Next de-
termine the-rate of solvent emission in pounds per hour. For example, suppose a
source produces 35 Ib/hr of toluene; since the efficiency for toluene is 7%,
then 100 Ib of carbon can adsorb 7 Ib of toluene per hour. Therefore a total
of
35 Ib x 17°i|j>b = 500 Ib of carbon
are required per hour- The air flow rate is figured at 200 cfm per 100 Ib of
carbon for efficient treatment, so a total of 1000 cfm is required in this case.
*
Next determine the steam regeneration rate for the solvent being collected,
and calculate the number of beds and gross pounds of carbon required. If the
regeneration rate (including cooling) equals the collection rate, two beds will
be required, thus the gross weight of carbon must be twice the net weight. If
the regeneration rate is one-half the collection rate, three beds will be needed,
thus the gross weight of carbon must be 3.0 times the net weight.
See Appendix C, Source No. 88, EPA AP-40
Air Pollution Engineering Manual, p 189 - 198
4-20
-------
For tte example above, saturated steam at 15 psig and 250F is sufficient to
regenerate the carbon. Since the flow rate of steam through the carbon is typically
1/5 to 1/10 the gas velocity, one can figure 20-40 cfm of steam through a 100-lb
bed. Under the conditions stated, a cubic foot of steam weighs 0.07235 Ib, hence a
total of 1.5 - 3.0 Ib of steam would pass through each minute. From Figure 124,
page 193, of reference 88, the pounds of steam required to recover a pound of toluene
is plotted over time. The point on the curve that satisfies the following identity
gives the time required for regeneration of 100 Ib of carbon:
(# of Ib of steam/lb of toluene)x(7 Ib toluene) = (2 Ib steam/min)x(# of min)
For this application, an approximate rate of steam usage of 13 Ib steam/lb
toluene gives a regeneration time of about 45 minutes. Cooling of the bed may be
accomplished in various ways, but for this example, assume 200 cfm of 100F outside
air per 100 Ib of carbon. The bed is at 250F (steam temperature) and is to be cooled
to 115F, the equilibrium temperature of the working bed. With these conditions, a
rough estimate of cooling time would be 30 minutes. Therefore, the total regeneration
and cooling time is 75 minutes, for 7 Ib of toluene in 100 Ib of carbon.
One can then figure that two beds will be required, each having a total cycle
time of 150 minutes. Each bed will contain:
(75 min regeneration/60 min adsorption)x(35 Ib adsorbed/hr)x(100 Ib-hr
irbon/7 Ib adsorbed) = 625 Ib carbon.
The total system thus requires 1250 Ib of carbon, and from Figure 4-15, the
price of an automatic unit is found to be $12,000 +_ 20%.
In Figure 4-15, typical commercial applications include dry cleaning plants
and metal cleaning operations, whereas industrial applications include lithography
and petrochemical applications. Industrial requirements include heavier materials
for high steam or vacuum pressure designs, and more elaborate controls to assure
safety against explosions and to prevent hydrocarbon breakthrough.
-------
DATA VALID FOR DECEMBER 1975
70r-r
1000
Figure 4-15
2000
3000
4000
5000
6000
7000
8000
9000
10,000
C, POUNDS OF CARBON, LB
PRICES FOR PACKAGED STATIONARY BED CARBON ADSORPTION UNITS W/STEAM REGENERATION
-------
DATA VALID FOR DECEMBER 1975
•*»
ro
to
O1
20
40
60 80 100 120
C, POUNDS OF CARBON, 1000 LB
Figure 4-16 PRICES FOR CUSTOM CARBON ADSORBTION UNITS
160
180
200
-------
4.6 DUCTWORK
4.6.1 Capture Hoods
Figures 4-17 through 4-20 contain data for estimating capture hood costs.
Figure 4-17 gives plate area requirements for rectangular capture hoods
and Figure 4-19 gives the corresponding labor costs for 10 Ga. carbon steel
construction. Determine the length-to-width ratio (L/W) and the length for
a given application, and read the plate area required and the labor cost.
For example, if the hood is 20 ft long by 5 ft wide, the L/W = 4, the fabri-
o
cation labor cost is $4000, and the plate required is 250 ft .
Figure 4-18 gives plate area requirements for circular capture hoods and
Figure 4-20 gives the labor costs for 10 Ga. carbon steel construction.
Determine the angle of slope, e, of the hood cone (or the height-to-diameter
ratio) and the diameter of the hood, and read the plate area required and the
labor cost. For example, if the hood is 20 ft in diameter and 9 = 50°, the
H/D = .6, the fabrication labor cost is $1900, and the plate required is
550 ft2.
To determine the total fabricated price, the plate weight must be cal-
culated, including 20% additional for structural supports. The density of
10 Ga. carbon steel is 5.625 lb/ft2. The density of %" plate is about
10.30 lb/ft2.
Since 10 Ga. (.1382") is usually sufficient for hoods, the total mass
of the hoods and structurals in the two examples is:
250 ft2 X 5.625 lb/ft2 X 1.2 = ~ 1690 Ib
550 ft2 X 5.625 lb/ft2 X 1.2 = - 3700 Ib
To determine angle of slope, see Appendix C, ref. 129, Fan Engineering,
especially figure 57, p 114.
4 ~
-------
The material cost, cut to size, is estimate as follows:
CIRCULAR HOODS
^ 3/16"
AF + $.108/1b
^ 1/4"
AF + $.194/1b
CARBON
STEEL RECTANGULAR HOODS LG + $.208/lb| LG + $.194/1b
where A is total plate area, not including structurals,
L is length of hood,
F is a pricing factor, and
G is a pricing factor.
F FACTOR
G FACTOR
DIAMETER
5
10
15
20
30
40
50
70
F
$.90/ft2
.60
.50
.45
.40
.40
.35
.35
L/W
1
2
4
8
G
$12/ft
8
4
2
Using these formulas, the material cost is calculated to be:
550 ft2 X $.45/ft^ + $.208/1 b X 3700 Ib = $1000
20 ft X $4/ft + $.208/1b X 1690 Ib = $430
Hence the total price for the two examples is:
35° Rectangular Hood, 20' X 5': $400 + $430 = $830
50° Circular Hood, 20' diam: $1900 + $1000 = $2900
If skirts or booth walls are needed, figure material cost at $.208/1b.
The weight of the wall will be the plate area times the material density,
plus 20% additional for structurals. For labor cost, figure cost at $.30/lb.
If refractory linings are desired, refer to Section 4.6.5.
4-25
-------
30JOOO,
10,000
1,000
cr
CO
.
UJ
cr:
•=c
Q-
Q
LU
100
10
Slope of Hood =35°
L = Length
W = Width
Curves Include 10% Scrap
Skirt Not Included
For Water Cooled Hoods
Use Double The Plate Area
CURVE EQUATIONS
A = -.5 + 0.306 L'
0
10 15 20
30
40
50
60
L, LENGTH DIMENSION, FT.
Figure 4-17 RECTANGULAR CAPTURE KOODS PLATE AREA REQUIREMENTS
VS. HOOD LENGTH AND L/W
4-26
-------
TiOOOOO
DATA VALID FOR DECEMBER 1975
15
20
45
25 30 35 40
HOOD DIAMETER, D, FT.
Figure 4-18 CIRCULAR HOODS PLATE REQUIREMENTS
50
55
60
65
70
4-27
-------
10000 DATA VALID FOR DECEMBER 1975
CO
o
ce.
o
ca
o
o
o
a:
a.
<
o
cc:
O
CO
o;
10
0
10
20
80
90
30 40 50 60 70
L, HOOD LENGTH DIMENSION, FT.
Figure 4-19 LABOR COST FOR FABRICATED 10 GA. CARBON STEEL RECTANGULAR CAPTURE HOODS
4-28
-------
100000
DATA VALID FOR DECEMBER 1975
0
20
70
80
JO 40 50 60
D, HOOD DIAMETER, FT.
figure 4-20 LABOR COST FOR FABRICATED 10 GA. CARBON STEEL CIRCULAR CAPTURE HOODS
90 100
4-29
-------
4.6.2 Straight Duct
Figure 4-21 gives the price for fabricated carbon steel duct in $ per
foot as a function of duct diameter and material thickness. A 48" duct,
V thick costs $73/ft. Hence 100 ft costs $7300. Figure 4-22 gives prices
for stainless steel construction and Figure 4-23 gives prices for water
cooled carbon steel duct.
For refractory lined duct, refer to Section 4.6.5.
"
-------
DATA VALID FOR DECEMBER 1975
700 , • , -•
I
CO
include flanges ev|ery 40
)' ll) 20 3b 40 50 60 76 80
0 120 ' 130 HO " 150 T60" "
170 180 190 200
D, DUCT DIAMETER, INCHES
Figure 4-21 CARBON STEEL STRAIGHT DUCT FABRICATION PRICE PER LINEAR FOOT VS. DUCT DIAMETER AND PLATE THICKNESS
Jf"
-------
DATA VALID FOR DECEMBER 1975
i
CO
fSJ
nclude flamies every 40
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
A"
D, DUCT DIAMETER, INCHES
Figure 4-22STAINLESS STEEL STRAIGHT DUCT FABRICATION PRICE PER LINEAR FOOT VS. DUCT DIAMETER AND PLATE THICKNESS
-------
o
o
DATA VALID FOR DECEMBER 1975
•tuu
eg
JS
z
1—4
_J
o:
UJ
^ 300
t\
UJ
1— 1
Q-
0
i 200
o
^ UJ
t o
£ s
1
ul
i 10°
[J
£
z
o
CO
.1 ,.
SNOT
• ; :
- - • - r
2.
3.
-. ... ; -
!
. 1.
i
? A ' -F QQ
-TT ' 1 CiC
" | 3 OfliO
1 Ul I 1 M *"
3late
itrfng
i • * (•*
bldtf^
- . j_
!
- . 4- .i 4-
I : i
• I i
| i
! '
• i
. I
I
' ' t
i
£
:6r»s
i
iih
|4
tr-
ain
•H^n
,* V 1 1 3 v* i
"
-
,..!
. 1 44 -
-1-4-
'
jf
\:
.
•
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T
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i
i
i
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I.
"kV
Fm
JC-1
Ij
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m
e
•^ i
:ioja
ncftje
' '
• ~i
.1.
"U4~T
! I !
„
r
J
-n
T
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—
«*•
-
L
Ft*
I
\\ i ^
JUIL
irigle
HJ-&
1 ~~" '•
1
J_
_:_
._
"1
i
j
i
-J^
i
i
<
,
i
S
L
.'
'Wejr
: M '
^ [I/
1 —
-|-f~
--+ -
•!-
XLf r
; '
^
." i j"
1 — -
*
at
in
! '
i ! i
1 . . J.
.r~. ',-L
-
-T-r •;-
-M
-r v'\^
._-]_ -I-4--I
i ' '
i i i
• • •
-
-M-l
..i. i .-
,^
r i
i
;
!
-
,**
• i |
•
.
,
'I ,
-
' _^P-*^
j • 1
1 • -
- 1- !
±i
i i
; i
i
1 ! 1
I
: r
ill:
i ; 1 :
1
i • i
"&::
j_i . ...
- |j;.j
r i
-r i • •
*^
liH
: ( j
.
::
.
....
U*
-
-
-
i
^r-
i
-
*>
C_J
60
70
30 40 50
D, DUCT DIAMETER, INCHES
Figure 4-23 WATER COOLED CARBON STEEL STRAIGHT DUCT FABRICATION PRICE PER FOOT VS, DUCT DIAMETER
80
-------
4.6.3 €1bow Duct, Tees, and Transitions
Figures 4-24 and 4-25 contain prices for carbon steel and stainless steel
elbow duct, respectively. Prices are a function of duct diameter and material
thickness.
For tees, the price will be 1/3 the corresponding price of an elbow hav-
ing the same diameter and thickness. For transitions, the price will be ^
the corresponding elbow price (use large diameter for sizing).
For refractory lined elbows refer to Section 4.6.5.
4-34
Ofrsil
-------
1 QOOOfl DRTA VALID FOR DECEMBER 1975
1000Q.
cc
Q.
o
CO
o
CO
s
1009.
100
D, DUCT DIAMETER, INCHES
Figure 4-24 CARBON STEEL ELBOW DUCT PRICE VS. DUCT DIAMETER AND PLATE THICKNESS
4-35
-------
10000th
9.
DATA VALID FOR DECEMBER 1975
10000
CSL
CL.
O
Q
o
CO
LU
UJ
0
20
40
60
80
120 140 160 180
200
D, DUCT DIAMETER, INCHES
Figure 4-25 STAINLESS STEEL ELBOW DUCT PRICE VS. DUCT DIAMETER AND PLATE THICKNESS
4-36
-------
4.6.4 Expansion Joints
Figure 4-26 contains prices for expansion joints as a function of duct
diameter.
4-37
-------
i
CO
00
7000
6000
5000
I/O
o
o
o
I—I
OO
4000
j j... ^___.
< 3000
Q-
X
2000
1000
4
i._.
-t--
•t
10
50
60
70
80
90
DUCT DIAMETER, INCHES
-26 CARBON STEEL EXPANSION JOINT COSTS VERSUS DUCT DIAMETER
--i-.-J
100
-------
4.6.5 Refractory Materials
Table 4-3 contains pricing data for refractory materials. Refractory
may be applied to capture hoods, straight duct, elbows, tees, transitions,
spray chambers, thermal and catalytic incinerators (for replacement), and
stacks. To estimate the cost, determine the surface area to be lined, the
thickness of the lining, and the type of refractory to be used. Compute the
cubic feet of refractory required and multiply by the price.
4-39
-------
Table 4-3
REFRACTORY ESTIMATING COSTS, DATA VALID FOR DECEMBER 1975
TYPE
Insulating Firebrick, 2300 °F
High Duty Firebrick, 3100 °F
Super Duty Firebrick, 3200 °F
Insulating Castable, 2000 °F
General Purpose Castable, 2200 °F
Dense Castable, 3000 °F
Plastic, 3000 °F
Ceramic Fibre Matt, 2300 °F
Ceramic Fibre Board, 1800 °F
High Alumina, 3500 °F
APPLICATION/FORM
Brick
Brick
Brick
Cast in Forms,
Trowelled, or Gunned
M
ii
Rammed w/Pneumatic
Hammer
Like Mineral Wool
Rigid Board
Brick
DENSITY
(Lb/cu. ft.)
50
135
145
50
120
140
140
N/A
N/A
180
PURCHASE PRICE
• ($/cu. ft.)
N/A
N/A
$6
$5
N/A
$20
$11
N/A
N/A
N/A
INSTALLED COST
($/cu. ft.)
N/A
N/A
$75
$25
N/A
$65
N/A
$20
N/A
N/A
-p»
I
N/A = Not Available
Ref: Appendix C, Source No. 37,"Afterburner Systems Study"
Chapter 7, pp 100-110.
,
10)
-------
4.7 DAMPERS
Prices for rectangular and circular dampers, with and without automatic
temperature regulated controls, are contained in Figures 4-27 and 4-28,
respectively. Rectangular dampers are priced as a function of cross-sectional
area for a length-to-width ratio of 1.3. Circular dampers are priced as a
function of damper diameter. These prices are for dampers only - the type
that may be used inside a duct or at inlets and outlets of control equipment
components.
4-41
-------
ro
14
13
12
11
10
v>
O
o
2 9
1/1
LU
y s
ce
a.
<
a
5 6
e>
I 5
<_j
LU
o;
4
DATA VALID FOR DECEMBER 1975
Mffr
" lTX3 TC
1.
2.
3,
Dqmpcjrs
Fdr staiiftklss
mijltiply
Price with
temperature
price
4»l^xv |l f^i ttij^v ^\<-i -^x/rifl
tJTtC* T| UUVCr CO t-JrUc
cofjstructjlon
ste(el
taj 3..0
contrcls is
regulated
a nominal estimate)
dafflflersj.
for
I -
34567
DAMPER CROSS-SECTIONAL AREA, 1000 SQ.IN.
Figure 4-27 CARBON STEEL RECTANGULAR DAMPER PRICES VS. AREA FOR L/W-1.3
10
-------
DATA VALID FOR DECEMBER 1975
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140
DAMPER DIAMETER, INCHES
Figure 4-28 CARBON STEEL CIRCULAR DAMPER PRICES VS. DIAMETER
4-43
-------
4.8 HEAT EXCHANGERS
4.8.1 Spray Chambers and Quenchers
Figure 4-29 contains prices for spray chambers and Figure 4-30 gives
prices for quenchers, both versus inlet gas volume.
4-44
-------
90
-p.
en
o
o
o
1/5
O
o
UJ
CO
i
0_
80
70
60
50
40
301-
dder, j gfgiti ijigst~
cofttriVs
20
50 100 150
INLET GAS VOLUME - ACFM
Figure 4-29 SPRAY CHAMBER COSTS VERSUS INLET GAS VOLUME
200
250
-------
-p>
I
o
o
o
CO
I—
o
OL
UJ
^n.
o
20
10
50
INLET VOLUME - 1000'S ACFM
Figure 4-30 QUENCHER COSTS VERSUS INLET GAS VOLUME
-------
4.8.2 Kadiant Coolers
Figure 4-31 contains prices for 'U' tube radiant coolers as a function of
the number of branches ('U1 tubes), the diameter of the tube, and the height
of the tube. Refer to Appendix C, Source No. 88, for design of 'U1 tubes.
4.8.3 Dilution Air Ports
Figure 4-32 contains prices for dilution air ports as a function of port
diameter and plate thickness.
4-47
-------
DOTA VALID FOR DECEMBER 1975
for st^inlesp stee! construction
tot^l price by p.3
0 2
FIGURE
10 12 14 16
NUMBER OF BRANCHES
18
20
22
24 26
28
4-31 FABRICATED 40 FOOT HIGH 'U1 TUBE HEAT EXCHANGER PRICES WITH HOPPERS
AND MANIFOLDS
-------
DATA VALID FOR DECEMBER 1975
o
o
o
o
I—I
D-
O
O.
OC
t— (
-------
4.9 MECHANICAL COLLECTORS
Figure 4-33 provides a means of estimating the volume capacity of mech-
anical collectors as a function of inlet cross-sectional area. Figure 4-34
provides a means of estimating the critical particle size for collectors vs.
inlet area. Critical particle size is defined as the largest sized particle
not separated from the gas stream.
Figures 4-35 through 4-39 contain pricing data for mechanical collectors
and components as a function of inlet area.
For example, suppose 50,000 cfm is to be passed through a mechanical
collector prior to entering a baghouse. A pair of 25,000 cfm capacity collec-
tors with a pressure drop of 4" AP and an inlet area of 9% sq. ft. would be
satisfactory for the purpose. The critical particle size is found to be
28 microns. For 10 Ga. carbon steel construction, the price of the collector
would be about $4500. The cost of additional components would be:
support: $2700
hopper: 780
scroll: 1400
$4880
The total price is thus $4880 + $4500 = $9380. In general, price of
collectors varies directly with inlet area since the mass of the unit in-
creases with increasing area. However, these curves give prices for only
single-unit collectors, not multiple units.
05>;
-------
_:__:__ 1
i
3456789 10
A, COLLECTOR INLET AREA, SQ. FT.
Figure 4-33 CAPACITY ESTIMATES FOR MECHANICAL COLLECTORS
11 12 13 14
/I..C1
-------
: j j
0 1
2 3 4 5 6 7 8 9 10 11 12 13
A, COLLECTOR INLET AREA, SQ. FT.
Figure 4-34 CRITICAL PARTIAL SIZE ESTIMATES FOR MECHANICAL COLLECTORS
14
-------
MEA VALID FOR DECEMBER 1975
8,000
o:
Q_
CtL
O
UJ
o
o
8
10 II 12 13 14
A, COLLECTOR INLET AREA., FT'
Figure 4-35 MECHANICAL COLLECTOR PRICES FOR CARBON STEEL CONSTRUCTION VS. INLET AREA
4-53
-------
DATA VALID FOR DECEMBER 1975
23,000,—
20,000
15,000
CC
0.
o
o
O
O
10,000
5,000
0
_L
I
12 13 14 15
23456789
A, COLLECTOR INLET AREA, FT.'
Figure 4-36 MECHANICAL COLLECTOR PRICES FOR STAINLESS STEEL CONSTRUCTION VS. INLET AREA
10 II
2
-------
DATA VALID FOR DECEMBER 1975
3,000
LU
o
Q_
0.
13
OO
2,000
1,000
400
EQUATIONS
Segment
1
2
3
Equation
P = 500 + 130 A
P = 900 + 125 A
P = 1700 + 105 A
8
10 II 12 13 14
A, COLLECTOR INLET AREA, FT'
Figure 4-37 MECHANICAL COLLECTOR SUPPORT PRICES VS. COLLECTOR INLET AREA
4-55
-------
DATA VALID FOR DECEMBER 1975
4,000
LlJ
o
Q.
OC
LU
Q.
O.
O
23456789
A, COLLECTOR INLET AREA, FT2
10 II 12 13 14
Figure 4-38 MECHANICAL COLLECTUK DUST HOPPER PRICES FuK CAKbON AND STAINLESS STEEL
CONSTRUCTION VS. COLLECTOR INLET AREA
4-56
-------
DATA VALID FOR DECEMBER 1975
LU
o
o:
a.
o
in
Q.
6,000
Curve Equations
P 450+542A-11.4A2
P = 406+379A-10.6A2
P 309+270A-8.0A2
P 272+188A-3.6A2
P 255+145A-2.7A2
Stainless
Stainless
Stainless
Carbon
Carbon
Carbon
3/16"
10 Ga
14 Ga
3/16"
10 Ga
236+126A-2.0A2
10 II 12 13 14
A, COLLECTOR INLET AREA, FT
Figure 4-39 MECHANICAL COLLECTOR SCROLL OUTLET PRICES FOR CARBON AND STAINLESS STEEL
CONSTRUCTION VS. COLLECTOR INLET AREA
4*57
-------
4.10 FANS, MOTORS, AND STARTERS
4.10.1 Backwardly Curved Fans
Backwardly curved fans are priced as a function of the actual air flow
rate, pressure drop at standard conditions, and class, as given in Figure 4-40.
If, for example, a Class HI fan is to operate at sea level with gas temperature
of 70 F and is to handle a gas volume of 20,000 CFM at 10" of water, the price
would be $3400.
However, in many cases a fan would not be operated at standard conditions,
and adjustments must be made through the use of Table 4-8 to properly cost
the fan. For example, if actual conditions are:
a. gas temperature = 300F
b. altitude = 1000 ft.
c. actual cfm = 50000
d. actual AP = 10" static pressure
then the fan is priced as follows:
1. obtain fan sizing factor from Table 4-8 for 300F at 1000 ft = .672
2. actual 10" static pressure/.672 = 15" at standard conditions
3. enter Figure 4-40 with 50,000 cfm and 15", read price of $6800
for Class IV fan. Since this is a high heat application, the
estimated price is $6400 X 1.03 = $7000.
The prices for the motor and the starter are obtained from Figure 4-41.
Enter the chart on the right with the gas flow rate and the static pressure
at standard conditions. For 10" S.P- and 20,000 cfm, find the point with
those coordinates and draw lines parallel to the "FAN RPM" guidelines and
the "BHP" guidelines. Read the fan rpm on the scale to the right, read the
bhp on the scale to the left. Then read the price for the type of starter
needed and for the drip-proof motor at the selected rpm. A guide to
determining motor rpm is given in Table 4-7. For the example, the fan rpm
is found to be about 1600 and the motor bhp is 44. According to Table 4-7,
the motor rpm should be 1800, hence the corresponding price is about $600.
4-58
-------
If a magnetic starter is selected, the price is about $350. Prices for motor
types other than drip-proof may be estimated using Table 4-4. A totally en-
closed motor for this example would cost $600 X 1.5 = $900. The selection of
a motor type may be made from Table 4-6.
For conditions other than standard, the following steps must be taken
to establish the motor and starter price. Again consider the 300F application
from before.
1. Find the bhp from Figure 4-41 using 50000 cfm and 15" S.P- = 180 bhp
2. Correct the bhp by multiplying by the fan sizing factor:
180 bhp X 0.672 = 121 bhp, actual.
3. Find motor and starter prices at 121 bhp. The fan rpm does not
require adjustment.
An inlet or outlet damper is usually required on fans, and prices for
such are presented in Figure 4-44. Note that the static pressure is measured
for standard conditions, as in Figures 4-40 and 4-41.
V-belt drives may be selected for some applications. Figure 4-45
concains prices for V-belt drives as a function of motor bhp and fan rpm.
For direct drives, estimate price at 5% of the motor price.
4.10.2 Radial Tip Fans
The method of estimating prices for radial tip fans is the same as for
backwardly curved fans. Prices for raHial tip fans operating under 20"
S.P. are given in Figure 4-42. Figure 4-43 provides the data for determining
the fan rpm and motor bhp for radial tip fans. Refer to Figure 4-41 and
Table 4-4 to obtain the motor and starter prices once the bhp has been
determined.
For radial tip fan applications involving greater that 20" S.P., Figures
4-46 and 4-47 should be used to estimate the fan and motor prices respectively.
The static pressure must be converted to standard conditions as before, using
Table 4-8.
4-59
-------
DATA VALID FOR DECEMBER 1975
i
cr>
o
1100000
1000000
100000
10000
S
6
7
6
5
1000
3 4 5678910
"20
AP, in H20
(AT STANDARD CONDITIONS)
Fan
Class
I
" II
III
IV
*Performance Range
(inches of water)
Performance Range*
Single Width
5" @ 2300 fpm to 2-1/2" @ 3200 fpm
8-1/2" I? 3000 fom to 4-1/4" G> 4175 fom
13-1/2" P 3780 fpm to 6-3/4" 0 5260 fpm
Above Class III specifications
designations are indicated by static pressure
at fan outlet velocity(feet per minute).
For high temperature
environment add 3%
( >250°F. <600°F)
For stainless steel
construction multiply
price by 2.5 .
Figure 4-40 BACKWARDLY CURVED FAN PRICES VERSUS CLASS, CFM, AND AP
FOR ARRANGEMENT NO. 1
-------
I
(ft
IS
I
TO I
1"
ft''
DATA VALID FOR DECEMBER 1975
2,000| i i i i i—i r 1 rr
1,000 :
CL.
O
10
DRIP-PROOF MOTOR OR STARTER PRICE, $
NOTE: Prices are for drip-proof motors only, for
other types of motors, see Tables 4-4 and 4-6.
Motors are purchased in standard sizes, but
for estimating purposes, curve prices are OK.
10
2 3 4 56 8 10 20
AP, H20 (AT STANDARD CONDITIONS)
Figure 4-41 BHP, FAN RPM AND MOTOR AND STARTER PRICES VS. AP AND CFM.
-------
Table 4-4
PRICING FACTORS FOR OTHER MOTOR TYPES *
Table 4-5
MOTOR AND STARTER PRICE EQUATIONS
HORSEPOWER
I20
> 20
TOTALLY ENCLOSED
FAN COOLED
1.3
1.5
EXPLOSION PROOF
1.6
1.7
RPM
Mag.
Exp.
3600\
1800/
1200
900
600
Starter
Prf. Str.
EQUATION
P =
P =
P =
P =
P =
P =
60+11.9 BHP + 0.00845BHP2
68+18.0 BHP
100+35.0 BHP-0.07 BHP2
204+52.6 BHP-0.083 BHP2
150+2.5 BHP+.04 BHP2 -
.00005 BHP3
270+8.5 BHP+.008 BHP2
I
(Ti
ro
Table 4-6
MOTOR TYPE SELECTION
Drip-proof:
In non-hazardous, reasonably clean
surroundings free of any abrasive
or conducting dust and chemical
fumes. Moderate amounts of moisture
or dust and falling particles or
liquids can be tolerated.
Totally Enclosed Non-Ventilated or
Fan Cool id":
In non-hazardous atmospheres con-
taining abrasive or conducting dusts,
high concentrations of chemical or
oil vapors and/or where hosing down
or severe splashing is encountered.
Totally Enclosed Explosion Proof:
Use in hazardous atmospheres containing:
Class I, Group D, acetone, acrylonitrile,
alcohol, ammonia, benzine, benzol, butane
ethylene dichloride, gasoline, hexane,
lacquer solvent vapors, naptha, natural
gas, propane, propylene, styrene, vinyl
acetate, vinyl chloride or xylenes;
Class II, Group G, flour, starch or
grain dust;
Class II, Group F, carbon black, coal
or coke dust;
Class II, Group E, metal dust including
magnesium and aluminum or their com-
mercial alloys.
Table 4-7
MOTOR RPM SELECTION 'GUIDE
MOTOR RPM
3600
1800
1200
900
600
FAN RPM RANGE
2400 - 4000
1400 - 2400
1000 - 1400
700 - 1000
< 700
-------
Table 4-8 FAN iu^ING FACTORS: AIR DENSITY RATIOS
Unity Basis = Standard A1r Density of .075 lb/ft3
At sea level (29.92 1n. Hg barometric pressure) this 1s equivalent to dry air at 70°F,
Air
Temp.
°F
70
100
150
200
250
300
350
400
450
500
550
600
650
700
Altitude in Feet Above Sea Level
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
15000
20000
Barometric Pressure in Inches of Mercury
29.92
1.000
.946
.869
.803
.747
.697
.654
.616
.582
.552
.525
.500
.,477
.457
28.86
.964
.912
.838
.774
.720
.672
.631
.594
.561
.532
.506
.482
.460
.441
27.82
.930
.880
.808
.747
.694
.648
.608
.573
.542
.513
.488
.465
.444
.425
26.82
.896
.848
.770
.720
.669
.624
.586
.552
.522
.495
.470
.448
.427
.410
25.84
.864
.818
.751
.694
.645
.604
.565
.532
.503
.477
.454
.432
.412
.395
24.90
.832
.787
.723
.668
.622
.580
.544
.513
.484
.459
.437
.416
.397
.380
23.98
.801
.758
.696
.643
.598
.558
.524
.493
.466
.442
.421
.400
.382
.366
23.09
.772
.730
.671
.620
.576
.538
.505
.476
.449
.426
.405
.386
.368
.353
22.22
.743
.703
.646
.596
.555
.518
.486
.458
.433
.410
.390
.372
.354
.340
21.39
.714
.676
.620
.573
.533
.498
.467
.440
.416
.394
.375
.352
.341
.326
20.58
.688
.651
.598
.552
.514
.480
.450
.424
.401
.380
.361
.344
.328
.315
16.89
.564
.534
.490
.453
.421
.393
.369
.347
.328
.311
.296
.282
.269
.258
13.75
.460
.435
.400
.369
.344
.321
.301
.283
.268
.254
.242
.230
.219
.210
SOURCE: AMCA STANDARD #402-66
AIR MOVING AND CONDITIONING ASSOCIATION, INC.
205 West Touhy Avenue
Park Ridge, Illinois 60068
-------
o:
DATA VALID FOR DECEMBER 1975
1OOOOJ
10000
250°F, <600°F )
For Stainless Steel
Construction multiply
Price by 2.5 .
U4
t-H
Q-
Z
<
Figure 4-42 RADIAL FAN PRICES VERSUS SCFM, AND AP FOR ARRANGEMENT NO. 1
-------
MOTOR
BHP
IOOO—i
500-
—100
200
:__L_1 i_._J. . 100
234 6 8 10 20
AP, IN H20
Figure 4-43 FAN RPM AND MOTOR BHP FOR RADIAL FANS
4-65
-------
lOOQOOoq
7691
10000
iooooq -
100Q
AP, IN H20
(AT STANDARD
CONDITIONS)
10 20
Figure 4-44 FAN INLET AND OUTLET DAMPER PRICES AS A FUNCTION OF CFM AND
oc
D-
o:
LU
a.
-------
I
en
DATA VALID FOR DECEMBER 1975
1500
„ 1400
Q
Od
<
3 1300,
° 1200
CO
o
Q
ID
1100
1000
OL
Q.
cr:
Q
LL)
CO
I
NOT€: 1. Select V-Bel!t closest td
fan RPM
™1
2.. Qo not "Ix.trflpol.alte" prlices. _ j
for belts abiove 15|0 HP. lapplicatiord
20
40
60
80 100 120
MOTOR HORSEPOWER, HP
140
160
180
200
Figure 4-45 V-BELT DRIVE PRICES
-------
•(=<»•
O
o
O
LU
o
I—I
Cti
CL.
70
DATA '-VALID FOR DECEMBER 1975
60
50
40
30
20
10
1.
2.
TP= Fan Pressure measured
at standard conditions
For stainless steel con-
struction and rubber lined
housing, multiply price by
2.5.
30
50
100
150
AIR FLOW RATE, 1,000 CFM
Figure 4-46 RADIAL TIP FAN PRICES
4-68
-------
o
o
o
<_)
1—I
Q.
75 -
!
70 :
65 ,
i
60 '
55
50 '
45
40 :
35 .
30
25 :
20
DATA VALID FOR DECEMBER 1975
NOfE: 1. Accuracy of this curve is ± 50K. Prices will
vary as function of:
a) Motor RPM
b) Frame size
c) Voltage
d) Motor enclosure
e) Type of starter
2. FTP = Fan Total pressure at Standard Cond1[tion5
10
5
20
60
140
160
80 100 120
AIR FLOW RATE, 1000 CFM
Figure 4-47 STARTER AND MOTOR PRICES FOR VENTURI SCRUBBER APPLICATIONS (HIGH PRESSURE, HIGH BHP)
180
200
-------
4.11 STACKS
Prices for stacks are given in Figures 4-48, 4-49 and 4-50. Figures
4-48 and 4-49 are for carbon steel, unlined, uninstalled stacks under 100'
Figure 4-50 contains installed prices for tall stacks over 200' with and
without liners and insulation.
4-70
-------
DATA VALID FOR DECEMBER 1975
CQ
7,000
6,000 —
5,000 —
4,000 —
NOTE: 1. Plate Thickness: 1/4 Inch
2. Includes: Flange, Stack,
Cables, Clamps, &. Surface
Coating
3. Cables are Stainless Steel
Qty: 4
Weight of 1/4" Stack
Diameter Weight (Ibs)
3,000 —
2,000-
1,000 —
H, STACK HEIGHT, FT
Figure 4-48 FABRICATED CARBON STEEL STACK PRICE VS. STACK HEIGHT AND
DIAMETER FOR 1/4 INCH PLATE
4-71
-------
DATA VALID FOR DECEMBER 1975
9,000
8,000
7,000
6,000
LLJ!
O
Q'
LUi
a:\
5,000
4,000 —
3,000
2,000
NOTE: 1. Includes: Flange, Stack, Cables,
Clamps & Surface Coating
2. Cables are Stainless Steel, Qty: 4
Weight of Stack
Diameter Thickness Weight
42
48
54
54
60
60
5/16
5/16
5/16
3/8
5/16
3/8
400
475
550
670
600
700
142H
162H
182H
218H
202H
242H
10
20
30
40
50
60
70
80
90
H, STACK HEIGHT, FT
Figure 4-49 FABRICATED CARBON STEEL STACK PRICE VS. STACK HEIGHT'AND
DIAMETER FOR 5/16 AND 3/8 INCH PLATE
4-72
-------
DATA VALID FOR DECEMBER 1975
300 400
HEIGHT, FT
Figure 4-50 PRICES FOR TALL STEEL STACKS, INSULATED AND LINED
4-73
-------
4.12 CODLING TOWERS
Two figures are given for pricing installed cooling towers. Figure 4-51
applies for capacities less than 1000 tons. Figure 4-52 applies for capacities
over 1000 tons (1 ton = 12000 BTU/HR). The use of Figure 4-52 requires expl-
anation.
Figure 4-52 provides prices for installed cooling towers as a function
of the range and the water flow rate at a wet bulb (W.B.) temperature of 82F
and an approach of 10F. See Table 4-11 for definitions of terminology. If
the W.B. is other than 82F, Table 4-10 provides factors for adjusting the
price. If the approach is other than 10F, Table 4-9 provides similar factors.
For example, suppose a cooling tower is to operate under conditions of
72F W.B. and a 20F approach (leaving water temperature = 92F). If the flow
rate is 50,000 gpm and the range is 60F, then the price before adjustments is
$540,000. The adjustment factor for 72F W.B. is 1.38 and the factor for a
20F approach is .5. The installed cooling tower price is thus:
(540,000 - 30,000) (0.5) (1.38) + 30,000 = $381,900
The fan motor horsepower is estimated as follows:
P
HP = 1t..- > where P is the price of the tower.
J. OUvJ
The pump motor horsepower is estimated as follows:
HP = gpm X 0.12.
The basin area is estimated as follows:
P 9
Basin Area = ___ ft .
150
Basin costs have not been provided since they are so highly dependant on
the individual application. The basin may be used in conjunction with other
processes, which involves a proration of costs, and the basin may be constructed
in many types of soils and terrain, which can dramatically alter the first cost.
Basin costs should be estimated on an application basis through a basin con-
tractor.
4-74
-------
.£»
cn
140
130
120.
110
100 !
8 90
o 80 ;
*—4
OL
Q.
S5 70 .
o
i—
£ 60 !
8 i
0 50 i
O '
< 40 I
Z !
t-H t
30 !
I
20 i
10 •
0 '
0
DATA VALID FOR DECEMBER 1975
N^TE; 1- «RICk.lfla
PUMPB, MOT
2. PRICE DOESi NOT I
KH.IN6I TOHERJ. -FANS
INSTALLATION.
i BASINl COST.
i
i
Hooo $i= 0.9! + o.ojhi'T
; . \ |
_ I
700
100 200 300 400 500 600 700 800
T, COOLING TOWER CAPACITY, TONS
Figure 4-51 PRICES FOR INSTALLED COOLING TOWERS FOR UNITS OF CAPACITY - 1000 TONS
900
1000
-------
700
DATA VALID FOR DECEMBER 1975
600
o
o
o
cc.
UJ
I
C3
O
O
O
200
TOO
10
20
30
70
40 50 60
G, INLET FLOW RATE, 1000 GPM
Figure 4-52 PRICES FOR INSTALLED COOLING TOWER BASED ON WET-BULB TEMPERATURE = 82°F AND APPROACH = 10°F
-------
Table 4-9
Table 4-10
PRICE ADJUSTMENT FACTORS *
FOR APPROACH AT
PRICE ADJUSTMENT FACTORS *
FOR WET BULB TEMPERATURES
APPROACH, A°F
6
8
10
12
16
20
24
FACTOR, F!
1.60
1.20
1.00
.85
.65
.50
.40
WET BULB,°F
68
70
72
74
76
78
80
82
FACTOR, F?
1.54
1.46
1.38
1.30
1.22
1.15
1.07
1.00
NEW PRICE = (P-30000) F^+SOOOO
WHERE P IS THE PRICE FROM Figure 4-52
Table 4-11
DEFINITIONS FOR COOLING TOWER
Approach: The difference between the average temp-
erature of the circulating water leaving the device,
and the average wet-bulb temperature of the entering
air.
Range (cooling range): The difference between the
average temperature of the water entering the device,
and the average temperature of the water leaving it.
Jemperature, dewpoint: the temperature at which the
condensation of water vapor in a space begins for a
given state of humidity and pressure as the tempera-
ture of the vapor is reduced. The temperature corr-
esponding to saturation (100 percent relative humid-
ity) for a given absolute humidity at constant
pressure.
Temperature, dry-bulb: the temperature of a gas or
mixture of gases indicated by an accurate thermometer
after correction for radiation.
Temperature, wet-bulb: thermodynamic wet-bulb
temperature is the temperature at which liquid or
solid water, by evaporating into air, can bring the
air to saturation adiabatically at the same temper-
ature. Wet-bulb temperature (without qualification)
is the temperature indicated by a wet-bulb psychro-
meter constructed and used according to specifications.
4-77
-------
4.13 PUMPS
Figures 4-53, 4-54 and 4-55 contain prices for 3550 RPM, 1750 RPM, and
1170 RPM cast iron, bronze fitted, vertical turbine wet sump pumps. These
pumps can be used for scrubbers, cooling towers, water cooled duct, water sup
ply, and the like. Prices are a function of pump head in feet and pump cap-
acity in gpm. Figure 4-56 provides a means of estimating pump motor horse-
power for a given pump head and capacity. Motor prices may then be estimated
using Figure 4-41.
4-78
-------
1200
DATA VALID FOR DECEMBER 1975
T
1100 -
1000
GO
LU
O
CL.
Q_
O
o:
O
IT)
Lf>
ro
900
600
500
I
1. CURVES JASED pN HATER
"
7.
3. PUMPS AtPLICAfeLE FOfe
SCRUBBEPS, CODLING frOWERSi,
j i
I
50
100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050
PUMP CAPACITY, GPM
Figure 4-53 CAST IRON, BRONZE FITTED, VERTICAL TURBINE WET SUMP PUMP PRICES FOR 3550 RPM
-------
4000
DATA VALID FOR DECEMBER 1975
r ; - •
oo
o
*&
•s
oo
LU
I—I
a:
o_
s:
CL.
co
OL
(_5
t—i
Qi
O
IT)
3500 —
3000|
2500
2000
15001
1000:
500
0 300 600 900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200 4500 4800 5100 5400 5700 6000
PUMP CAPACITY, GPM
Figure 4-b4 CAST IRON, BRONZE FITTED, VERTICAL TURBINE WET SUMP PUMP PRICES FOR 1750 RPM
-------
I
CO
8000
7000
eooo;
O.
CL_
5000
40001
30001
a.
a:
20001
1000
0
DATA VALID FOR DECEMBER 1975
NOTE: 1. CURVES BA$ED ONjWATER
t. MOT^R WOT
1000
3. PUMPS APPlilCABU
2000
Figure 4-55
: FOR $CRUBB|RS,
WATERiSUPPL
E-Te-..
3000
4000
6000
7000
8000
9000
10000
PUMP CAPACITY, GPM
CAST IRON, BRONZE FITTED, VERTICAL TURBINE WET SUMP PUMP PRICES FOR 11/0 RPM
-------
1000ft
0
30
60
90
240 270
120 150 170 210
PUMP HEAD, FT
Figure 4-56 PUMP MOTOR HP VS. CAPACITY AND HEAD FOR VERTICAL TURBINE PUMPS
300
4-82
-------
4.14 DUST REMOVAL EQUIPMENT
Figure 4-57 contains prices for screw conveyors as a function of conveyor
length and diameter.
4-83
-------
i
Co
7000 - -
DATA VALID FOR DECEMBER 1975
6000
5000!
LU
o
cc
(X
cc:
o
O
o
3000
2000
1000
NOTE: 1. Prices include trough, screw, drive,
fltttngs, and motor.
2. HeaVy duty construction.
10
20
30
70
40 ' 50 60
LENGHT OF CONVEYOR, FT.
Figure 4-57 PRICES FOR SCREW CONVEYORS VS. LENGTH AND DIAMETER
-------
4.15 OPERATION, MAINTENANCE, AND INSTALLATION COSTS
Figure 4-58 contains operating costs for electrostatic precipitator
systems (from capture hood to stack exhaust) as a function of inlet gas vol-
ume to the precipitator and system power level in kilowatts per 1000 ACFM
(1 HP = .746 KW). To estimate system power level, total the following:
• KW of fans
t KW of pumps
• KW of precipitator
Figure 4-59 gives operating costs for venturi scrubber systems (from
capture hood to stack exhaust) as a function of inlet gas volume to the
scrubber and actual static pressure at the fan.
Figure 4-60 provides operating costs for fabric filter systems (from
capture hood to stack exhaust) as a function of inlet gas volume to the bag-
house and actual static pressure at the fan. These prices do not include bag
replacement, which must be estimated separately.
Table 4-12 gives installation costs for the five types of control systems,
and maintenance costs for precipitators, scrubbers, and baghouses, expressed
as a percent of purchased equipment cost. Equipment lives are also given.
Fig:, e 4-61 contains operating and maintenance costs for thermal
incinerators with and without heat exchangers versus hydrocarbon concentra-
tion and inlet gas volume. The gas volume is measured before entering the
heat exchanger for those units employing them. Figure 4-62 contains operat-
ing and maintenance costs for catalytic incinerators with and without heat
exchangers versus inlet gas volume and hydrocarbon concentration.
Figure 4-63 gives operating and maintenance costs for carbon adsorbers
versus inlet gas volume and hydrocarbon concentration.
-------
DATA VALID FOR DECEMBER 1975
can.
o
a:
ui
OL.
O
O
CD
a.
o
o::
O"
CL.
i—<
o
a:
a.
CO
o
a:
C_> :- -pi-
SYSTEM CAPACITY, ACFM
Figure 4-58 ELECTROSTATIC PRECIPITATOR OPERATING COSTS VS. VOLUME
AND POWER CONSUMPTION
-------
loop,
DATA VALID FOR DECEMBER 1975
SCRUBBER CAPACITY, ACFM
Figure 4-59 VENTURI SCRUBBER OPERATING COSTS VS. VOLUME AND PRESSURE DROP
4-87
-------
VALID FOR DECEMBER 1
fg^
r~,
i
FT
d:
L—
-j-
tit
-i-t
II
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H-;
&
**
cfiSr
ill
iltm
Eii
Jkiki
n at
tj^isiE
Fan
i: ji "faMr* "vf"'
j_ £ |jf |cy~'' fc^^i
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s
Of
LLJ
Q-
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O
o
LU
O.
O
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UJ
OL
CO
-~7^
10
15"
^11
—I."
d^
/
-|-
z
^y^\
-.f
H-
i i
Z
...J:
rf- hzi-h-tr "~r'i"
2--J--4-I |—+-h-l-:
!._L..L.^.-.|...4_U^_
ir-
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10'
10^ 10J
SYSTEM CAPACITY, ACFM
Figure 4-60 FABRIC FILTER OPERATING COSTS VS. VOLUME AND PRESSURE DROP
4-88
10'
-------
Table 4-12. MAINTENANCE AND INSTALLATION COST FACTORS,
AND EQUIPMENT LIFE GUIDELINES
NOTE: Estimate maintenance and installation costs as percent of total equip-
ment purchase price. Also note that a low installation percentage
does not imply low maintenance or a short equipment life. These guide-
lines are estimates of the range of values that have been experienced
in the industry. The choice of one over another depends on the appli-
cation.
Table 4-12a
Maintenance
Electrostatic preci pita tors
Venturi scrubbers
Fabric filters
Table 4-12b
Bag life
;X;^;:;Xx:;:;:::::;::X;X;Xv:v:::::::;:x:v::::Xv:;X:X:::::::::::::::::x::;::
Table 4-12c
Installation
Electrostatic preci pita tors
Venturi scrubbers
Fabric filters
Incinerators (wo/HE)
Incinerators (w/HE)
Adsorbers
Table 4-12d
Equipment Life
Electrostatic precipitators
Venturi scrubbers
Fabric filters
Thermal incinerators
Catalytic incinerators
Adsorbers
Low
1%
8%
1%
Low
4 mos.
Low
50%
70%
40%
30%
25%
30%
Short
5 yr.
5 yr.
5 yr.
5 yr.
5 yr.
5 yr.
Average
2%
13%
2%
Average
1.5 yrs.
Average
75%
140%
75%
50%
45%
50%
Average
20 yr.
10 yr.
20 yr.
10 yr.
10 yr.
10 yr.
High
4%
18%
5%
High
5 yrs.
High
120%
220%
120%
70%
65%
70%
Long
40 yr.
20 yr.
40 yr.
20 yr.
20 yr.
20 yr.
Very high
10%
40%
7%
Very high
10 yrs.
Very high
200%
350%
170%
90%
90%
90%
-------
DATA VALID FOR DECEMBER 1975
100 •
PPM
W/HE
LU
Q.
to
o
10
LU
Q_
o
LU
sr
>—i
o
2.
3,
Curves- based on PPM
concentration of hydrocarbon
such as toluene, ketone,
"and napthas.
Cost include all labor and
utility costs from collection
point to stack exhaust.
Costs with «md-without heat
'Included.
.1
10'
INCINERATOR INLET VOLUME, ACFM
Figure 4-61 THERMAL INCINERATOR OPERATING AND MAINTENANCE COST
VS. VOLUME AND HYDROCARBON CONCENTRATION
4-90
-------
100
DATA VALID FOR DECEMBER 1975
OL
ZD
o
£ 10
CL.
CO
O
CS
D-
O
o:
o
£ 1,
i—<
O
I—I
I—
<_>
1. ^urves-baiscd on
idO ppm
WO/HE
1500^ ppm
WO/HE
100 ppm
W/HE
150O ppm
W/ttE
of hydrocarbons such *2tS""
lcetonesr> ttnci naptlrasv " ~T
vOS uS 1 fiG tliQw * cr*r i rwQOr . Aii|Q—
1 ity j:qsts frpin cd 1 lectifoir^
3.
4.
po^nt toistack exhaus
catet;1ys1
Co$t& with and withoi
excha"ng!e^s Included.
t.
rep1jac€ment.
t heat
10
3x10
Figure 4-62
INCINERATOR INLET VOLUME, ACFM
CATALYTIC INCINERATOR OPERATING AND MAINTENANCE COST
VS. VOLUME AND HYDROCARBON CONCENTRATION
4-91
-------
DATA VALID FOR DECEMBER 1975
DC
Z3
O
a.
o
CO
Qi
O
1. Curves;based on concentration
oif jtoluene in PPM.
2. Costs include all labor and
utility costs from collection
point: to stack exhaust.
3. Costs include adsorber
replacement.
Figure 4-63
10
icr
ADSORBER INLET VOLUME, ACFM
CARBON ADSORPTION UNIT OPERATING AND MAINTENANCE
COST VS. VOLUME AND HYDROCARBON CONCENTRATION
4-92
-------
SECTION 5
UPDATING COSTS TO FUTURE TIME PERIODS
5.1 GENERAL
The methods for updating the costs given in this manual are contained in
this section. A separate procedure is described for each equipment type or
cost item-these procedures have been used to adjust old cost data to December
1975 levels, when necessary, and these procedures are recommended for updating
the costs for future time periods. They have been kept as simple as possible.
No attempt is made to predict future costs, since this is beyond the scope of
this manual. In general, the methods involve use of the Chemical Engineering
(CE) plant cost indexes and U.S. Department of Labor, Bureau of Labor
Statistics (BLS) wholesale price indexes. Selected index accounts are con-
tained in Appendix B.
These two sets of indexes were selected for applicability, consistency,
specificity, and availability. The CE index includes such process industries
as (among others):
a. chemicals and petrochemicals
b. fertilizers and agricultural chemicals
c. lime and cement
d. man-made fibers
e. paints, varnishes, pigments, and allied products
f. petroleum refining
g. soap glycerin and related products
h. wood, pulp, paper, and board
i. plastics
These industries are representative of the industries under the attention
of this manual. The CE indexes are based on 1957-1959 = 100 and are adjusted
-------
for labor productivity changes-not found in other cost indexes. There is
complete back-up information available regarding the make-up of the indexes,
hence it is possible to modify the indexes to suit particular needs (see
Arnold, T. H. and Chilton, C. H., New Index Shows Plant Cost Trends, Chemical
Engineering, Feb. 18, 1963, pp. 143-149. Also refer to Appendix C, Source Nos.
130 & 131).
Table B-l gives the CE indexes as far back as 1957- Figure 5-1 shows
how the overall CE plant index has changed since its inception. The following
are descriptions of the indexes regularly published by Chemical Engineering.
A. ENGINEERING & SUPERVISION
Engineering and Supervision is 10% of the total plant index.
It includes the following:
33% Engineers
47% Draftsmen
20% Clerical
B. BUILDINGS
Buildings is 7% of the total plant index and is based on a
special BLS construction index in which the ratio of materials
to labor is 53:47.
C. ERECTION & INSTALLATION LABOR
Erection and Installation Labor is 22% of the total plant
index. This is the average hourly earning as determined by
the BLS for the contract construction industry.
D. EQUIPMENT, MACHINERY, SUPPORTS
Equipment, Machinery and Supports consists of 61% of the total
plant index. This index consists of:
1. Fabricated Equipment-37%
Such as: a. boilers, furnaces, and heaters
b. columns and towers
c. heat exchangers
d. condensers and reboilers
e. process drums
f. reactors
g. pressure vessels and tanks
h. storage tanks and spheres
i. evaporators
5-2
-------
en
i
Co
2001
195|
190!
185j
180!
175i
170|
165;
160|
2 155'
o i
S 150|
§ 145
S 140J
| 135!
^ 130!
125;
120,
115!
110
105
100
95
90'
57
58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77
YEAR
Figure 5-1 CHEMICAL ENGINEERING PLANT COST INDEX
-------
2. Process Machinery-14%
"Off the shelf" items such as:
a. centrifuges
b. filters
c. mixing and agitating equipment
d. rotary kilns and dryers
e. conveyors and bucket elevators
f. high-pressure vacuum or refrigeration
producing equipment
g. extruders
h. crushing and grinding equipment
i. thickeners and settlers
j. fans and blowers
3. Pipe, Valves, and Fittings-20%
4. Process Instruments and Controls-7%
5. Pumps and Compressors-7%
6. Electrical Equipment and Materials-5%
Such as: a. electric motors
b. transformers
c. switch gear
d. wire and cable
7. Structurals, Supports, Insulation, and Paint-10%
Such as: a. structural, steel
b. foundation materials
c. insulation
d. lumber
e. paint
Cost elements not included in the CE indexes include:
a. site clearing and preparation
b. insurance and taxes during construction
c. company overhead allocated to the project
d. contractor's overhead
For purposes of this manual, the CE indexes have been used whenever there
is no specifically applicable BLS wholesale price index. The BLS indexes used
are given in Tables B-2 thru B-20; the specific commodities and associated
BLS code number and year of reference are listed below:
Code No. Base Year=100 Commodity Table No.
0312 1967 Cotton Broadwoven Goods B-2
0334 1967 Manmade Fiber Broadwoven Goods B-3
05310101 1967 Natural Gas B-21
0543 Dec/1970 Industrial Power B-22
-------
Code No.
Base Year=100
Commodity Table No.
Rubber and Plastic Products B-4
A-36, Carbon Steel Plates B-5
Stainless Steel Plate B-6
Carbon Steel Sheet B-7
Stainless Steel Sheet B-8
Pumps, Compressors, and B-9
Equipment
V-Belt Sheaves B-10
Fans and Blowers, Except B-ll
Portable
10 HP, AC Motors B-12
250 HP, AC Motors B-13
50 HP, AC Motors B-14
75 HP, 440 volt, AC Starters B-15
Refractories B-16
Fire Clay Brick, Super Duty B-17
High Alumina Brick, 70 Pet. B-18
Castable Refractories B-19
Insulation Materials B-20
5.2 EQUIPMENT COST UPDATING PROCEDURES
Using these indexes, the procedures for updating the purchase costs of
each equipment type will now be discussed.
Electrostatic Precipitators
Use CE Fabricated Equipment index. For precipitators with insulation,
use the following composite index on the additional cost only:
h (BLS #1392 factor) -t- % (CE Fabricated Equipment factor).
Venturi Scrubbers
Use CE Fabricated Equipment index. For rubber liners use BLS #07 on
the liner cost only.
07
10130246
10130247
10130262
10130264
1141
11450133
1147
11730112
11730113
11730119
11750781
135
13520111
13520131
13520151
1392
1967
1967
1967
1967
1967
1967
1967
1967
1967
1967
1967
1967
1967
1967
1967
Dec/1974
1967
5-5
-------
Fabric Filters
Use CE Fabricated Equipment index. For filters with insulation, use same
procedure as for precipitators with insulation. For stainless steel con-
struction, use BLS #10130264 on the additional cost. For filter media
use BLS #0312 or #0334.
Thermal and Catalytic Incinerators
Use CE Fabricated Equipment index for custom units. Use CE Process
Equipment index for package units.
Adsorbers
Same as for thermal and catalytic incinerators.
Ductwork
Use CE Fabricated Equipment index. For refractories, however, use the
appropriate BLS index; the base index is #135.
Dampers
Use CE Fabricated Equipment index. For automatic dampers, use CE
Process Instruments and Controls on that portion of price attributable
to automatic control.
Heat Exchangers
Use CE Fabricated Equipment index.
Mechanical Collectors
Use CE Process Machinery index.
Fans, Motors, and Starters
For fans use BLS #1147. For motors use the appropriate BLS index; the
base index is #1173. For starters use BLS #11750781. For V-belts use
BLS #11450133.
Stacks
Use CE Fabricated Equipment index.
Cooling Tower
Use CE Fabricated Equipment index.
Pumps
Use BLS #1141 index.
5-6
-------
Dust Removal Equipment
for screw conveyors, use the CE Fabricated Equipment index. For water
treatment equipment, use the appropriate CE or BIS index, depending on
the equipment component.
Operating Cost
For precipitators, scrubbers and baghouses use the following composite
factor:
.1 (Table B-23, Labor Cost) + .9 (BLS #0543, Industrial Power)
For incinerators and adsorbers use the following composite factor:
.1 (Table B-23, Labor Cost) + .1 (CE Equipment, Machinery, Supports)
+ .8 (BLS #05310101, Natural Gas)
5-7
-------
APPENDIX A
COMPOUND INTEREST FACTORS
-------
Table A-l 1% COMPOUND INTEREST FACTORS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
40
45
50
Single Payment
Present
Worth
Factor
P/F
0.9901
0.9803
0.9706
0.9610
0.9515
0.9420
0.9327
0.9235
0.9143
0.9053
0.8963
0.8874
0.8787
0.8700
0.8613
0.8528
0.8444
0.8360
0.8277
0.8195
0.8114
0.8034
0.7954
0.7876
0.7798
0.7720
0.7644
0.7568
0.7493
0.7419
0.7346
0.7273
0.7201
0.7130
0.7059
0.6717
0.6391
0.6080
Uniform Series
Capital
Recovery
Factor
A/P
1.01000
0.50751
0.34002
0.25628
0.20604
0.17255
0.14863
0.13069
0.11674
0.10558
0.09645
0.08885
0.08241
0.07690
0.07212
0.06794
0.06426
0.06098
0.05805
0.05542
0.05303
0.05086
0.04889
0.04707
0.04541
0.04387
0.04245
0.04112
0.03990
0.03875
0.03768
0.03667
0.03573
0.03484
0.03400
0.03046
0.02771
0.02551
Present
Worth
Factor
P/A
0.990
1.970
2.941
3.902
4.853
5.795
6.728
7.652
8.566
9.471
10.368
11.255
12.134
13.004
13.865
14.718
15.562
16.398
17.226
18.046
18.857
19.660
20.456
21.243
22.023
22.795
23.560
24.316
25.066
25.808
26.542
27.270
27.990
28.703
29.409
32.835
36.095
39.196
A-l
-------
Table A-2 2% COMPOUND INTEREST FACTORS
Single Payment
Uniform Series
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
40
45
50
Present
Worth
Factor
P/F
0.9804
0.9612
0.9423
0.9238
0.9057
0.8880
0-.8706
0.8535
0.8368
0.8203
0.8043
0.7885
0.7730
0.7579
0.7430
0.7284
0.7142
0.7002
0.6864
0.6730
0.6598
0.6468
0.6342
0.6217
0.6095
0.5976
0.5859
0.5744
0.5631
0.5521
0.5412
0.5306
0.5202
0.5100
0.5000
0.4529
0.4102
0.3715
Capital
Recovery
Factor
A/P
1.02000
0.51505
0.34675
0.26262
0.21216
0.17853
0.15451
0.13651
0.12252
0.11133
0.10218
0.09456
0.08812
0.08260
0.07783
0.07365
0.06997
0.06670
0.06378
0.06116
0.05878
0.05663
0.05467
0.05287
0.05122
0.04970
0.04829
0.04699
0.04578
0.04465
0.04360
0.04261
0.04169
0.04082
0.04000
0.03656
0.03391
0.03182
Present
Worth
Factor
P/A
0.980
1.942
2.884
3.808
4.713
5.601
6.472
7.325
8.162
8.983
9.787
10.575
11.348
12.106
12.849
13.578
14.292
14.992
15.678
16.351
17.011
17.658
18.292
18.914
19.523
20.121
20.707
21.281
21.844
22.396
22.938
23.468
23.989
24.499
24.999
27.355
29.490
31.424
A-2
-------
Table A-3 3% COMPOUND INTEREST FACTORS
Single Payment
Present
Worth
Factor
n P/F
1 0.9709
2 0.9426
3 0.9151
4 0.8885
5 0.8626
6 0.8375
7 0.8131
8 0.7894
9 0.7664
10 0.7441
11 0.7224
12 0.7014
13 0.6810
14 0.6611
15 0.6419
16 0.6232
17 0.6050
!8 0.5874
19 0.5703
20 0.5537
21 0.5375
22 0.5219
23 0.5067
24 0.4919
25 0.4776
26 0.4637
27 0.4502
28 0.4371
29 0.4243
30 0.4120
31 0.4000
32 0.3883
33 0.3770
34 0.3660
35 0.3554
40 0.3066
45 0.2644
50 0.2281
Uniform Series
Capital
Recovery
Factor
A/P
1.03000
0.52261
0.35353
0.26903
0.21835
0.18460
0.16051
0.14246
0.12843
0.11723
0.10808
0.10046
0.09403
0.08853
0.08377
0.07961
0.07595
0.07271
0.06981
0.06722
0.06487
0.06275
0.06081
0.05905
0.05743
0.05594
0.05456
0.05329
0.05211
0.05102
0.05000
0.04905
0.04816
0.04732
0.04654
0.04326
0.04079
0.03887
Present
Worth
Factor
P/A
0.971
1 . 913
2.829
3.717
4.580
5.417
6.230
7.020
7.786
8.530
9.253
9.954
10.635
11.296
11.938
12.561
13.166
13.754
14.324
14.877
15.415
15.937
16.444
16.936
17.413
17.877
18.327
18.764
19.188
19.600
20.000
20.389
20.766
21.132
21.487
23.115
24.519
25.730
A-3
-------
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
40
45
50
Table A-4 4% COMPOUND INTEREST FACTORS
Single Payment Uniform Series
Present
Worth
Factor
P/F
0.9615
0.9246
0.8890
0.8548
0.8219
0.7903
0.7599
0.7307
0.7026
0.6756
0.6496
0.6246
0.6006
0.5775
0.5553
0.5339
0.5134
0.4936
0.4746
0.4564
0.4388
0.4220
0.4057
0.3901
0.3751
0.3607
0.3468
0.3335
0.3207
0.3083
0.2965
0.2851
0.2741
0.2636
0.2534
0.2083
0.1712
0.1407
Capital
Recovery
Factor
A/P
1.04000
0.53020
0.36035
0.27549
0.22463
0.19076
0.16661
0.14853
0.13449
0.12329
0.11415
0.10655
0.10014
0.09467
0.08994
0.08582
0.08220
0.07899
0.07614
0.07358
0.07128
0.06920
0.06731
0.06559
0.06401
0.06257
0.06124
0.06001
0.05888
0.05783
0.05686
0.05595
0.05510
0.05431
0.05358
0.05052
0.04826
0.04655
Present
Worth
Factor
P/A
0.962
1.886
2.775
3.630
4.452
5.242
6.002
6.733
7.435
8.111
8.760
9.385
9.986
10.563
11.118
11.652
12.166
12.659
13.134
13.590
14.029
14.451
14.857
15.247
15.622
15.983
16.330
16.663
16.984
17.292
17.588
17.874
18.148
18.411
18.665
19.793
20.720
21.482
A-4
-------
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
40
45
50
Table A-5 5% COMPOUND INTEREST FACTORS
Single Payment Uniform Series
Present
Worth
Factor
P/F
0.9524
0.9070
0.8638
0.8227
0.7835
0.7462
0.7107
0.6768
0.6446
0.6139
0.5847
0.5568
0.5303
0.5051
0.4810
0.4581
0.4363
0.4155
0.3957
0.3769
0.3589
0.3418
0.3256
0.3101
0.2953
0.2812
0.2678
0.2551
0.2429
0.2314
0.2204
0.2099
0.1999
0.1904
0.1813
0.1420
0.1113
0.0872
Capital
Recovery
Factor
A/P
1.05000
0.53780
0.36721
0.28201
0.23097
0.19702
0.17282
0.15472
0.14069
0.12950
0.12039
0.11283
0.10646
0.10102
0.09634
0.09227
0.08870
0.08555
0.08275
0.08024
0.07800
0.07597
0.07414
0.07247
0.07095
0.06956
0.06829
0.06712
0.06605
0.06505
0.06413
0.06328
0.06249
0.06176
0.06107
0.05828
0.05626
0.05478
Present
Worth
Factor
P/A
0.952
1.859
2.723
3.546
4.329
5.076
5.786
6.463
7.108
7.722
8.306
8.863
9.394
9.899
10.380
10.838
11.274
11.690
12.085
12.462
12.821
13.163
13.489
13.799
14.094
14.375
14.643
14.898
15.141
15.372
15.593
15.803
16.003
16.193
16.374
17.159
17.774
18.256
A-5
-------
Table A-6 6% COMPOUND INTEREST FACTORS
Single Payment
Uniform Series
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
40
45
50
Present
Worth
Factor
P/F
0.9434
0.8900
0.8396
0.7921
0.7473
0.7050
0.6651
0.6274
0.5919
0.5584
0.5268
0.4970
0.4688
0.4423
0.4173
0.3936
0.3714
0.3503
0.3305
0.3118
0.2942
0.2775
0.2618
0.2470
0.2330
0.2198
0.2074
0.1956
0.1846
0.1741
0.1643
0.1550
0.1462
0.1379
0.1301
0.0972
0.0727
0.0543
Capital
Recovery
Factor
A/P
1.06000
0.54544
0.37411
0.28859
0.23740
0.20336
0.17914
0.16104
0.14702
0.13587
0.12679
0.11928
0.11296
0.10758
0.10296
0.09895
0.09544
0.09236
0.08962
0.08718
0.08500
0.08305
0.08128
0.07968
0.07823
0.07690
0.07570
0.07459
0.07358
0.07265
0.0717?
0.07100
0.07027
0.06960
0.06897
0.06646
0.06470
0.06344
Present
Worth
Factor
P/A
0.943
1.833
2.673
3.465
4.212
4.917
5.582
6.210
6.802
7.360
7.887
8.384
8.853
9.295
9.712
10.106
10.477
10.828
11.158
11.470
11.764
12.042
12.303
12.550
12.783
13.003
13.211
13.406
13.591
13.765
13.929
14.084
14.230
14.368
14.498
15.046
15.456
15.762
A-6
-------
1
2
3
4
5
6
7
3
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
40
45
50
Table A-7 7% COMPOUND INTEREST FACTORS
Single Payment Uniform Series
Present
Worth
Factor
P/F
0.9346
0.8734
0.8163
0.7629
0.7130
0.6663
0.6227
0.5820
0.5439
0.5083
0.4751
0.4440
0.4150
0.3878
0.3624
0.3387
0.3166
0.2959
0.2765
0.2584
0.2415
0.2257
0.2109
0.1971
0..1842
0.1722
0.1609
0.1504
0.1406
0.1314
0.1228
0.1147
0.1072
0.1002
0.0937
0.0668
0.0476
0.0339
Capital
Recovery
Factor
A/P
1.07000
0.55309
0.38105
0.29523
0.24389
0.20980
0.18555
0.16747
0.15349
0.14238
0.13336
0.12590
0.11965
0.11434
0.10979
0.10586
0.10243
0.09941
0.09675
0.09439
0.09229
0.09041
0.08871
0.08719
0 08581
0.08456
0.08343
0.08239
0.08145
0.08059
0.07980
0.07907
0.07841
0.07780
0.07723
0.07501
0.07350
0.07246
Present
Worth
Factor
P/A
0.935
1.808
2.624
3.387
4.100
4.767
5.389
5.971
6.515
7.024
7.499
7.943
8.358
8.745
9.108
9.447
9.763
10.059
10.336
10.594
10.836
11.061
11.272
11.469
11.654
11.826
11.987
12.137
12.278
12.409
12.532
12.647
12.754
12.854
12.948
13.332
13.606
13.801
A-7
-------
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
40
45
50
Table A-8 8% COMPOUND INTEREST FACTORS
Single Payment Uniform Series
Present
Worth
Factor
P/F
0.9259
0.8573
0.7938
0.7350
0.6806
0.6302
0.5835
0.5403
0.5002
0.4632
0.4289
0.3971
0.3677
0.3405
0.3152
0.2919
0.2703
0.2502
0.2317
0.2145
0.1987
0.1839
0.1703
0.1577
0.1460
0.1352
0.1252
0.1159
0.1073
0.0994
0.0920
0.0852
0.0789
0.0730
0.0676
0.0460
0.0313
0.0213
Capital
Recovery
Factor
A/P
1.08000
0.56077
0.38803
0.30192
0.25046
0.21632
0.19207
0.17401
0.16008
0.14903
0.14008
0.13270
0.12652
0.12130
0.11683
0.11298
0.10963
0.10670
0.10413
0.10185
0.09983
0.09803
0.09642
0.09498
0.09368
0.09251
0.09145
0.09049
0.08962
0.08883
0.08811
0.08745
0.08685
0.08630
0.08580
0.08386
0.08259
0.08174
Present
Worth
Factor
P/A
0.926
1.783
2.577
3.312
3.993
4.623
5.206
5.747
6.247
6.710
7.139
7.536
7.904
8.244
8.559
8.851
9.122
9.372
9.604
9.818
10.017
10.201
10.371
10.529
10.675
10.810
10.935
11.051
11.158
11.258
11.350
11.435
11.514
11. .587
11.655
11.925
12.108
12.233
A-8
-------
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
13
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
40
45
50
Table A-9 10% COMPOUND INTEREST FACTORS
Single Payment Uniform Series
Present
Worth
Factor
P/F
0.9091
0.8264
0.7513
0.6830
0.6209
0.5645
0.5132
0.4665
0.4241
0.3855
0.3505
0.3186
0.2897
0.2633
0.2394
0.2176
0.1978
0.1799
0.1635
0.1486
0.1351
0.1228
0.1117
0.1015
0.0923
0.0839
0.0763
0.0693
0.0630
0.0573
0.0521
0.0474
0.0431
0.0391
0.0356
0.0221
0.0137
0.0085
Capital
Recovery
Factor
A/P
1.10000
0.57619
0.40211
0.31547
0.26380
0.22961
0.20541
0.18744
0.17364
0.16275
0.15396
0.14676
0.14078
0.13575
0.13147
0.12782
0.12466
0.12193
0.11955
0.11746
0.11562
0.11401
0.11257
0.11130
0.11017
U. 10916
0.10826
0.10745
0.10673
0.10608
0.10550
0.10497
0.10450
0.10407
0.10369
0.10226
0.10139
0.10086
Present
Worth
Factor
P/A
0.909
1.736
2.487
3.170
3.791
4.355
4.868
5.355
5.759
6.144
6.495
6.814
7.103
7.367
7.606
7.824
8.022
8.201
8.365
8.514
8.649
8.772
8.883
8.985
9.077
9.161
9.237
9.307
9.370
9.427
9.479
9.526
9.569
9.609
9.644
9.779
9.863
9.915
A-9
-------
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
40
45
50
Table A-10 12% COMPOUND INTEREST FACTORS
Single Payment Uniform Series
Present
Worth
Factor
P/F
0.8929
0.7972
0.7118
0.6355
0.5674
0.5066
0.4523
0.4039
0.3606
0.3220
0.2875
0.2567
0.2292
0.2046
0.1827
0.1631
0.1456
0.1300
0.1161
0.1037
0.0926
0.0826
0.0738
0.0659
0.0588
0.0525
0.0469
0.0419
0.0374
0.0334
0.0298
0.0266
0.0238
0.0212
0.0189
0.0107
0.0061
0.0035
Capital
Recovery
Factor
A/P
1.12000
0.59170
0.41635
0.32923
0.27741
0.24323
0.21912
0.20130
0.18768
0.17698
0.16842
0.16144
0.15568
0.15087
0.14682
0.14339
0.14046
0.13794
0.13576
0.13388
0.13224
0.13081
0.12956
0.12846
0.12750
0.12665
0.12590
0.12524
0.12466
0.12414
0.12369
0.12328
0.12292
0.12260
0.12232
0.12130
0.12074
0.12042
Present
Worth
Factor
P/A
0.893
1.690
2.402
3.037
3.605
4.111
4.564
4.968
5.328
5.650
5.938
6.194
6.424
6.628
6.811
6.974
7.120
7.250
7.366
7.469
7.562
7.645
7.718
7.784
7.843
7.896
7.943
7.984
8.022
8.055
8.085
8.112
8.135
8.157
8.176
8.244
8.283
8.305
A-10
-------
Table A-ll 15% COMPOUND INTEREST FACTORS
Single Payment
Present
Worth
Factor
P/F
Uniform Series
Capital
Recovery
Factor
A/P
Present
Worth
Factor
P/A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
\7
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
40
45
50
0.8696
0.7561
0.6575
0.5718
0.4972
0.4323
0.3759
0.3269
0.2843
0.2472
0.2149
0.1869
0.1625
0.1413
0.1229
0.1069
0.0929
0.0808
0.0703
0.0611
0.0531
0.0462
0.0402
0.0349
0.0304
0.0264
0.0230
0.0200
0.0174
0.0151
0.0131
0.0114
0.0099
0.0086
0.0075
0.0037
0.0019
0.0009
1.15000
0.61512
0.43798
0.35027
0.29832
0.26424
0.24036
0.22285
0.20957
0.19925
0.19107
0.18448
0.17911
0.17469
0.17102
0.16795
0.16537
0.16319
0.16134
0.15976
0.15842
0.15727
0.15628
0.15543
0.15470
0.15407
0.15353
0.15306
0.15265
0.15230
0.15200
0.15173
0.15150
0.15131
0.15113
0.15056
0.15028
0.15014
0.870
1.626
2.283
2.855
3.352
3.784
4.160
4.487
4.772
5.019
5.234
5.421
5,
5,
5,
6.
6.
583
724
847
5.954
6.047
6.128
6.198
6.259
6.312
6.359
6.399
6.434
6.464
6.491
6.514
6.534
6.551
6.566
6.579
6.591
600
609
6.617
6.642
6.654
6.661
A-ll
-------
Table A-12 20% COMPOUND INTEREST FACTORS
Single Payment
Uniform Series
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
40
45
50
Present
Worth
Factor
P/F
0.8333
0.6944
0.5787
0.4823
0.4019
0.3349
0.2791
0.2326
0.1938
0.1615
0.1346
0.1122
0.0935
0.0779
0.0649
0.0541
0.0451
0.0376
0.0313
0.0261
0.0217
0.0181
0.0151
0.0126
0.0105
0.0087
0.0073
0.0061
0.0051
0.0042
0.0035
0.0029
0.0024
0.0020
0.0017
0.0007
0.0003
0.0001
Capital
Recovery
Factor
A/P
1.20000
0.65455
0.47473
0.38629
0.33438
0.30071
0.27742
0.26061
0.24808
0.23852
0.23110
0.22526
0.22062
0.21689
0.21388
0.21144
0.20944
0.20781
0.20646
0.20536
0.20444
0.20369
0.20307
0.20255
0.20212
0.20176
0.20147
0.20122
0.20102
0.20085
0.20070
0.20059
0.20049
0.20041
0.20034
0.20014
0.20005
0.20002
Present
Worth
Factor
P/A
0.833
1.528
2.106
2.589
2.991
3.326
3.605
3.837
4.031
4.192
4.327
4.439
4.533
4.611
4.675
4.730
4.775
4.812
4.844
4.870
4.891
4.909
4.925
4.937
4.948
4.956
4.964
4.970
4.975
4.979
4.982
4.985
4.988
4.990
4.992
4.997
4.999
4.999
A-12
-------
APPENDIX B
EQUIPMENT COST INDEXES
-------
Table B-l CHEMICAL ENGINEERING PLANT COST INDEXES
INDEX
CE Plant Index
Engineering &
Supervision
Building
Construction Labor
Equipment, Machinery
Supports
Fabricated Equipment
Process Machinery
Pipe, Valves &
Fittings
Process Instruments &
Controls
Pumps & Compressors
Electrical Equipment
& Materials
Structural Supports
Insulation & Paint
1975
ANNUAL
182.3
141.8
176.9
168.4
194.7
192.2
184.7
217.0
181.4
208.3
143.0
198.6
JAN FEB MAR
i/9.4 179.5 180.7
139.6 139.8 140.2
173.1 173.6 174.7
166.7 164.2 167.4
191.6 192.3 192.9
190.7 190.6 191.6
179.1 179.9 181.4
209.8 212.9 212.8
17/.6 177.8 177.7
208.7 208.7 208.7
141.5 141.7 142.4
198.6 198.2 198.4
APR MAY JUN
180.7 180.8 181.8
140.7 141.1 141.6
175.5 175.8 176.3
166.6 165.5 167.3
193.0 193.3 194.3
191.6 191.1 191.5
182.5 182.8 184.7
213.5 217.2 217.8
178.8 178.9 180.4
206.2 206.2 208.3
141.4 141.8 142.0
198.0 195.5 196.4
JUL AUG SEP
182.1 181.9 183.7
142.0 142.4 142.9
177.1 177.5 178.8
168.4 168.7 171.9
194.2 193.7 195.2
190.0 190.0 191.4
185.5 185.1 186.3
216.0 216.7 219.9
180.2 181.2 183.3
209.1 207.6 209.4
151.5 141.6 141.8
198.5 198.5 197.9
OCT NOV DEC
185.6 185.5 186.2
143.3 143.7 144.2
180.2 179.4 181.1
172.0 171.2 171.1
198.1 198.2 199.1
195.8 195.2 196.4
188.8 189.6 190.9
221.6 222.6 223.3
186.3 186.6 187.8
209.1 209.1 209.0
143.1 143.7 143.3
200.7 200.7 201.2
CO
I
SOURCE: Chemical Engineering, Economic Indicators
-------
Table B-l CHEMICAL ENGINEERING PLANT COST INDEXES (cont'd)
INDEX
CE Plant Index
Engineering &
Supervision
Building
Construction Labor
Equipment, Machinery
Supports
Fabricated Equipment
Process Machinery
Pipe, Valves &
Fittings
Process Instruments &
Controls
Pumps & Compressors
Electrical Equipment
& Materials
Structural Supports
Insulation. & Paint
1974
ANNUAL
165.4
134.4
165.5
163.4
171.2
170.1
160.3
192.2
164.7
175.7
126.4
172.4
JAN FEB MAR
150.0 150.7 153.8
131.6 131.9 132.2
156.7 156.4 158.8
162.7 162.4 162.3
147.7 149.0 153.7
147.3 148.7 152.7
143.1 143.7 146.8
162.6 163.2 169.9
152.0 153.4 158.2
144.0 145.8 150.6
109.7 110.3 112.3
145.0 147.5 155.0
APR MAY JUN
156.7 161.4 164.7
132.5 132.8 132.8
162.3 164.3 165.4
162.7 160.0 159.4
157.8 166.2 171.8
155.1 165.1 169.3
149.4 154.8 159.2
179.6 189.6 197.1
157.2 159.7 162.7
157.9 168.2 175.6
114.0 121.5 127.1
158.5 165.1 173.4
JUL AUG SEP
168.8 172.2 174.8
134.0 134.3 134.5
167.1 170.6 172.7
159.5 164.1 166.6
178.0 181.6 184.7
179.0 181.4 184.0
163.5 167.9 170.3
203.0 206.7 209.4
165.8 168.2 173.2
182.7 186.8 187.3
131.5 133.5 136.3
173.5 180.8 188.1
OCT NOV DEC
176.0 177.4 177.8
138.2 138.7 139.1
170.5 172.1 172.5
165.8 166.9 166.6
186.5 188.1 188.8
186.0 186.1 186.8
172.9 175.7 177.2
209.7 208.3 208.7
174.1 175.2 176.9
195.8 206.9 206.9
138.2 141.4 141.4
187.4 191.9 192.4
SOURCE: Chemical Engineering, Economic Indicators
-------
Table B-l CHEMICAL ENGINEERING PLANT COST INDEXES (cont'd)
INDEX
1973
ANNUAL
JAN
FEB MAR
APR MAY JUN
JUL
AUG SEP
OCT NOV DEC
CE Plant Index
Engineering &
Supervision
Building
144.1
122.84
150.6
140.8 140.4 141.5
112.0 112.0 122.3
146.5 146.9 148.3
141.8 142.4 144.5
122.4 112.5 129.8
150.3 151.1 150.4
144.6 145.0 146.4
130.1 130.1 130.1
149.8 150.4 153.0
146.7 147.5 148.2
130.7 130.8 131.3
150.9 154.7 155.0
Construction Labor
Equipment, Machinery
Supports
Fabricated Equipment
157.9
141.9
142.5
158.9 155.8 154.8
138.3 138.8 140.7
140.0 140.0 140.9
155.0 155.4 155.6
140.9 141.7 142.2
141.7 142.6 143.0
156.3 156.3 161.8
142.1 142.0 142.6
143.0 143.0 143.4
161.7 161.6 162.0
143.5 144.3 145.2
143.7 144.1 144.8
CD
I
CO
Process Machinery
Pipe, Valves &
Fittings
Process Instruments &
Controls
137.6
151.3
147.1
134.3 134.5 135.1
146.1 146.1 149.2
145.0 144.9 145.8
137.1 137.6 137.9
150.1 151.1 151.7
146.1 146.9 146.9
137.9 138.5 139.1
151.8 151.8 151.8
147.0 147.4 147.9
139.6 140.3 142.0
153.9 156.6 157.8
148.1 148.8 150.4
Pumps & Compressors
Electrical Equipment
& Materials
Structural Supports
Insulation & Paint
139.5
104.2
140.9
137.0 137.0 138.4
100.6 100.6 102.1
137.2 137.2 140.0
138.4 138.4 141.3
103.9 104.5 105.2
141.2 142.0 141.8
140.9 140.9 140.9
105.1 105.1 105.1
141.2 141.2 141.2
140.8 141.4 142.4
105.3 106.0 107.2
141.5 143.5 142.8
SOURCE: Chemical Engineering, Economic Indicators
-------
Table B-l CHEMICAL ENGINEERING PLANT COST INDEXES (cont'd)
INDEX
CE Plant Index
Engineering &
Supervision
Building
Construction Labor
Equipment, Machinery
Supports
Fabricated Equipment
Process Machinery
Pipe, Valves &
Fittings
Process Instruments &
Controls
Pumps & Compressors
Electrical Equipment
& Materials
Structural Supports
Insulation & Paint
1972
ANNUAL
137.2
111.9
142.0
152.2
135.4
136.3
132.1
142.9
143.8
135.9
99.1
133.6
JAN FEB MAR
136.0 136.0 137.0
111.8 111.9 111.7
139.8 140.0 140.7
151.9 151.6 150.8
133.8 133.9 135.8
135.1 136.1 137.8
130.5 129.6 131.8
141.4 141.9 143.1
141.9 142.7 143.6
132.4 134.4 135.7
98.2 98.3 98.2
131.2 131.9 132.1
APR MAY JUN
137.1 137.1 136.5
111.6 111.9 111.9
141.4 141.6 140.3
151.3 151.7 149.7
135.3 135.5 135.4
136.2 135.9 135.7
132.2 132.2 132.2
143.1 143.2 143.3
143.9 144.1 144.0
135.7 135.7 136.3
98.6 99.1 99.4
132.7 134.9 134.1
JUL AUG SEP
136.5 137.0 137.8
112.0 112.1 112.1
141.4 141.9 143.0
149.7 150.6 153.1
135.2 135.6 135.9
135.6 136.3 135.7
132.2 132.3 132.9
142.9 142.9 143.0
144.0 144.3 144.2
136.6 136.7 136.7
99.3 99.5 99.4
133.8 134.2 134.4
OCT NOV DEC
138.2 138.4 139.1
112.0 112.1 112.1
144.1 144.5 145.0
154.5 154.7 156.7
135.9 136.0 136.5
136.8 136.6 137.5
132.9 133.1 133.6
143.3 143.6 143.6
144.1 144.2 144.7
137.7 137.0 137.0
99.3 100.0 100.1
134.5 134.5 134.6
DO
I
SOURCE: Chemical Engineering, Economic Indicators
-------
Table B-l CHEMICAL ENGINEERING PLANT COST INDEXES (cont'd)
INDEX
CE Plant Index
Engineering &
Supervision
Building
Construction Labor
Equipment, Machinery
Supports
Fabricated Equipment
Process Machinery
Pipe, Valves &
Fittings
Process Instruments &
Controls
Pumps & Compressors
Electrical Equipment
& Materials
Structural Supports
Insulation & Paint
1971
ANNUAL
132.3
111.4
135.5
146.2
130.4
130.3
127.1
137.3
139.9
133.2
98.7
126.6
JAN FEB MAR
11Q.2 129.1 129.9
111.1 111.2 111.2
130.0 131.5 132.9
142.5 143.3 142.8
125.7 126.7 128.0
125.5 125.6 127.9
125.4 125.7 126.3
131.0 132.0 132.7
134.0 138.6 139.3
129.1 135.8 135.8
101.1 100.2 99.2
120.1 120.6 123.6
APR MAY JUN
130.2 131.6 131.4
111.3 111.4 111.3
132.9 134.3 133.6
142.5 144.2 144.0
128.6 130.0 130.0
128.8 129.6 129.3
126.5 127.1 127.6
133.9 137.7 137.7
139.6 140.0 140.2
132.5 133.1 133.1
98.8 98.5 98.1
124.5 126.6 126.7
JUL AUG SEP
132.3 134.4 135.0
111.4 111.4 111.5
136.2 138.2 139.0
146.1 147.4 149.9
130.3 133.1 133.1
129.4 133.4 133.5
128.4 129.4 129.5
138.0 141.2 141.1
140.7 141.5 141.2
133.1 133.7 133.7
97.9 98.6 98.3
127.5 132.2 131.9
OCT NOV DEC
135.1 134.9 135.3
111.6 111.6 111.7
138.9 138.8 139,2
150.4 150.1 150.6
133.0 132.7 133.2
133.5 133.4 134.1
129.4 129.4 130.4
140.9 140.2 140.7
141.2 141.1 141.5
133.7 132.4 132.4
98.3 97.7 97.7
131.9 131.9 132.0
CD
I
en
SOURCE: Chemical Engineering, Economic Indicators
-------
Table B-l CHEMICAL ENGINEERING PLANT COST INDEXES (cont'd)
INDEX
CE Plant Index
Engineering &
Supervision
Building
Construction Labor
Equipment, Machinery
Supports
Fabricated Equipment
Process Machinery
Pipe, Valves &
Fittings
Process Instruments &
Controls
Pumps & Compressors
Electrical Equipment
& Materials
Structural Supports
Insulation & Paint
1970
ANNUAL
125.7
110.6
127.2
137.4
123.8
122.7
122.9
132.0
132.1
125.6
99.8
117.9
\
JAN FEB MAR
123.1 123.0 123.7
110.3 110.4 110.5
125.0 124.6 124.7
134.6 134.1 134.6
120.8 120.9 122.2
118.5 118.8 121.1
120.1 119.1 121.4
130.3 130.4 130.0
130.6 130.8 130.9
123.1 123.1 123.7
96.8 97.6 98.3
114.7 114.9 116.7
APR MAY JUN
124.5 125.0 125.4
110.6 110.5 110.6
125.5 126.2 126.1
134.7 134.7 134.8
123.0 123.7 124.4
122.2 122.5 124.0
121.8 122.2 122.7
130.5 132.9 133.0
131.2 131.5 132.0
124.8 124.1 124.1
98.3 98.7 98.9
117.7 118.1 118.5
JUL AUG SEP
126.2 127.0 127.6
110.7 110.8 110.8
127.4 128.6 130.1
136.6 139.0 141.4
124.9 125.1 125.1
124.1 124.2 123.8
123.3 123.5 124.8
133.8 133.9 132.4
132.0 132.6 133.6
125.6 125.6 129.1
100.8 101.5 102.1
118.9 118.9 119.4
OCT NOV DEC
127.6 128.0 127.7
110.8 110.9 110.0
130.1 129.7 129.5
141.4 141.7 141.4
125.1 125.6 125.3
123.8 124.0 124.8
124.3 127.2 124.9
132.4 133.0 131.6
133.6 133.7 133.7
129.1 129.2 129.1
102.1 101.8 101.1
119.4 118.9 119.0
CD
I
cr>
SOURCE: Chemical Engineering, Economic Indicators
-------
Table B-l CHEMICAL ENGINEERING PLANT COST INDEXES (cont'd)
INDEX
CE Plant Index
Engineering &
Supervision
Building
Construction Labor
Equipment, Machinery
Supports
Fabricated Equipment
Process Machinery
Pipe, Valves &
Fittings
Process Instruments 8
Controls
Pumps & Compressors
Electrical Equipment
& Materials
Structural Supports
Insulation & Paint
1969 1968 1967
ANNUAL ANNUnL. ANNUAL
119.0 113.6 109.7
110.9 108.6 107.9
122.5 115.7 110.3
128.3 120.9 115.8
116.6 111.5 107.7
115.1 109.9 106.2
116.8 112.1 108.7
123.1 117.4 113.0
126.1 120.9 115.2
119.6 115.2 111.3
92.8 91.4 90.1
112.6 105.7 102.1
1966 1965 1964
ANNUAL ANNUAL ANNUAL
107.2 104.2 103.3
106.9 105.6 104.2
107.9 104.5 103.3
112.5 109.5 108.5
105.3 102.1 101.2
104.8 103.4 102.7
106.1 103.6 102.5
109.6 103.0 101.6
110.0 106.5 105.8
107.7 103.4 101.0
86.4 84.1 85.5
101.0 98.8 98.3
1963 1962 1961 1960
ANNUAL ANNUAL ANNUAL ANNUAL
102.4 102.0 101.5 102.0
103.4 102.6 101.7 101.3
102.1 101.4 100.8 101.5
107.2 105.6 105.1 103.7
100.5 100.6 100.2 101.7
101.7 101.0 100.1 101.2
102.0 101.9 101.1 101.8
100.7 100.6 101.1 104.1
105.7 105.9 105.9 105.4
100.1 101.1 100.8 101.7
87.6 89.4 92.3 95.7
97.3 99.2 99.8 101.9
1959 1958 1957
ANNUAL ANNUAL ANNUAL
101.8 99.7 98.5
102.5 99.3 98.2
101.4 99.5 99.1
101.4 100.0 98.6
101.9 99.6 98-5
100.9 99.6 99-5
101.8 100.1 91
103.3 98.8 9;
102.9 100.4 9i
102.5 100.0 9;
101.0 100.6 9(
101.6 100.4 9!
3.1
7.9
5.7
'.5
J.4
J.O
CO
SOURCE: Chemical Engineering, Economic Indicators
-------
MONTH
ANNUAL
Table B-2
WHOLESALE PRICE INDEXES
FOR COTTON BROADWOVEN GOODS,
BLS # 0312, 1967=100
1971
1972
1973
110.6 122.3
144.3
1974
177.8
1975
JAN
FEB
MAR
APR
MAY
JUN
JUL
AU6
SEP
OCT
NOV
DEC
108.0
108.2
108.5
109.0
109.8
111.0
112.1
112.2
111.6
111.6
112.1
113.1
116.9
118.0
119.6
120.5
121.5
122.9
123.3
123.1
124.4
' 125.2
125.7
126.4
127.7
130.3
132.0
135.8
137.8
141.8
146.2
147.7
152.0
154.4
160.6
165.5
170.6
172.4
173.0
174.8
174.7
184.4
188.5
185.4
184.6
178.3
176.0
171.1
167.3
163.3
161.3
163.9
168.6
170.6
173.7
175.7
176.6
189.2
MONTH
ANNUAL
Table B-3 WHOLESALE PRICE INDEXES
FOR MANMADE FIBER BROADWOVEN
GOODS, BLS #0334, 1967=100
1971
1972
1973
101.5
116.9
144.5
1974
161.7
1975
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
94.1
94.0
94.6
96.8
99.2
102.4
103.6
106.0
106.1
105.1
106.7
109.3
111.5
112.5
112.7
114.9
116.6
118.0
118.6
118.4
118.2
118.3
120.3
122.4
124.. 7
125.8
133.0
139.4
145.3
147.7
147.1
147.8
152.8
154.9
156.6
158.4
159.7
161.5
161.7
162.7
168.3
173.4
169.2
165.3
160.7
154.6
153.4
149.9
146.7
144.7
128.4
128.3
131.6
134.5
139.9
143.1
143.1
147.1
B-8
-------
Table B-4 WHOLESALE PRICE INDEXES FOR
RUBBER AND PLASTIC PRODUCTS
BLS # 07, 1967=100
MONTH 1971 1972 1973 1974 1975
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL 109.2 109.3 112.4 136.2
108.4
109.1
109.1
109.0
108.7
108.7
109.7
109.8
109.7
109.5
109.5
109.4
109.5
109.2
108.9
108.7
108.8
108.9
109.2
109.5
109.5
109.5
109.8
109.8
110.0
110.1
110.3
110.6
111.5
112.6
112.9
113.1
112.8
114.0
114.8
116.5
117.7
119.8
123.8
129.4
133.7
135.6
139.5
143.4
145.6
147.5
148.5
149.4
149.6
150.0
149.7
149.4
148.9
148.6
150.1
150.0
150.8
151.5
Table B-5 WHOLESALE PRICE INDEXES FOR
CARBON STEEL PLATES, A36
BLS # 10130246, 1967=100
MONTH 1971 1972 1973 1974 1975
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
119.0
119.0
128.8
128.8
128.8
128.8
128.8
141.0
141.0
141.0
141.0
141.0
141.0
141.0
141.0
141.0
141.0
141.0
141.0
141.0
141.0
141.0
141.0
141.0
146.7
146.7
146.7
146.7
146.7
146.7
146.7
146.7
146.7
146.7
146.7
146.7
152.1
152.1
161.3
161.3
173.3
173.4
199.7
199.7
201.7
201.7
201.7
201.7
212.9
212.9
212.9
212.9
212.9
212.9
208.9
207.8
207.8
218.8
ANNUAL 132.3 141.0 146.7 181.6
B-9
-------
Table B-6 WHOLESALE PRICE INDEXES FOR
STAINLESS STEEL PLATE
BLS # 10130247, 1967=100
MONTH 1971 1972 1973 1974 1975
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
140.2
140.2
140.2
140.2
140.2
148.1
148.1
148.1
148.1
148.1
148.1
146.1
146.1
146.1
121.3
121.3
121.3
121.3
121.3
127.6
127.6
•127.6
127.6
127.6
132.8
132.8
132.8
132.8
132.8
132.8
132.8
132.8
132.8
132.8
132.8
132.8
134.2
134.3
139.2
145.5
157.7
166.0
169.2
187.8
190.4
193.0
193.0
193.0
197.1
195.7
195.7
195.7
195.7
195.7
195.7
195.7
195.7
195.7
206.3
ANNUAL 144.6 128.1 132.8 166.9
Table B-7 WHOLESALE PRICE INDEXES FOR
CARBON STEEL SHEET,
BLS #10130262, 1967=100
YONTH 1971 1972 1973 1974 1975
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
:EC
119.5
119.5
119.5
119.5
119.5
119.5
127.5
127.5
127.5
127.5
127.5
127.5
124.1
134.5
134.5
134.5
134.5
134.5
134.5
134.5
134.5
134.5
134.5
134.5
134.5
134.5
134.5
134.5
134.5
134.5
134.5
134.5
134.5
137.5
137.5
137.5
137.5
137.5
142.0
146.6
155.8
165.4
182.3
188.5
188.5
188.5
188.5
190.0
189.1
189.1
189.1
189.1
185.0
185.0
184.8
184.8
184.8
197.0
•ANUAL 123.5 133.6 135.3 167.6
B-10
-------
Table B-8
MONTH
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL
1971
WHOLESALE PRICE INDEXES FOR
STAINLESS STEEL SHEET
BLS # 10130264, 1967=100
1972
1973
1974
1975
130.8
130.8
130.8
130.8
130.8
138.1
138.1
138.1
138.1
138.1
138.1
137.1
137.1
137.1
138.1
138.1
138.1
120.4
120.4
117.5
117.5
117.5
117.5
117.5
117.5
117.5
117.5
117.5
123.4
124.5
124.5
124.5
124.5
124.5
124.6
124.6
126.8
128.6
134.9
140.1
153.6
159.6
163.9
173.1
174.9
174.9
175.8
178.9
178.9
169.6
169.3
169.3
169.3
162.6
162.9
162.9
162.9
162.4
135.0 126.4 122.1
157.1
MONTH
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL
Table B-9 WHOLESALE PRICE INDEXES FOR
PUMPS, COMPRESSORS, AND EQUIPMENT
BLS # 1141, 1967=100
1971
1972 1973
1974 1975
119.3
120.0
120.5
121.6
121.9
121.9
121.9
122.3
122.3.
122.6
122.2
122.2
122.4
123.2
123.5
123.5
123.0
124.2
124.9
124.6
124.6
124.7
124.8
124.8
125.0
125.1
125.2
125.9
126.2
127.7
127.5
127.7
127.6
128.6
131.4
131.7
132.1
133.4
135.5
138.7
142.5
147.7
154.0
162.7
163.8
168.8
176.8
179.5
180.5
184.3
184.4
186.2
187.3
187.3
187.9
188.8
189.2
189.9
121.6 124.0 127.5
153.0
B-ll
-------
Table B-10 WHOLESALE PRICE INDEXES FOR
V-BELT SHEAVES
BLS # 11450133, 1976=100
MONTH 1971 1972 1973 1974 1975
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL 117.6 123.6 126.8 150.2
117.6
117.6
117.6
117.6
117.6
117.6
117.6
117.6
117.6
117.6 •
117.6
117.6
117.6
117.6
117.6
122.4
124.4
126.3
126.3
126.3
126.3
126.3
126.3
126.3
126.3
126.3
126.3
126.3
126.3
126.3
126.3
126.3
126.3
126.3
128.2
130.4
130.4
133.3
133.3
133.3
137.7
139.9
150.9
162.6
162.6
171.6
171.6
175.4
175.4
175.4
175.4
175.4
174.1
174.1
174.1
172.8
172.8
172.8
Table B-ll WHOLESALE PRICE INDEXES FOR
FANS AND BLOWERS, EXCEPT PORTABLE
BLS # 1147, 1967=100
MONTH 1971 1972 1973 1974 1975
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL 123.8 129.0 135.2 168.3
120.8
121.0
123.1
122.2
122.2
124.6
124.9
124.9
125.3
125.3
125.3
125.5
125.6
127.3
128.6
128.8
128.8
128.8
128.8
128.8
129.9
130.0
130.0
122.4
132.4
132.6
133.1
134.4
134.4
135.0
135.0
135.2
137.5
137.7
137.6
137.6
138.2
138.5
145.5
146.4
158.6
171.8
178.6
183.2
185.3
188.6
192.3
192.6
197.9
198.2
198.6
198.8
201.3
202.4
205.4
205.4
205.8
206.4
B-12
-------
Table B-12
MONTH
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL
1971
WHOLESALE PRICE INDEXES FOR
MOTORS, INTEGRAL HORSEPOWER, A.C., 10 HP
BLS # 11730112, 1967=100
1972 1972
1974
1975
122.1
113.6
109.1
104.0
104.0
104.0
102.2
101.6
101.6
101.6
101.6
101.6
99.6
99.6
99.6
101.1
105.6
105.6
105.6
105.6
105.6
105.6
111.5
111.5
112.1
112.1
115.2
118.2
119.7
120.9
120.9
120.9
119.7
119.7
121.8
124.2
125.8
125.8
127.9
130.9
134.9
155.1
160.0
161.7
167.6
172.4
175.9
179.8
184.0
186.1
186.1
186.1
186.1
N/A
N/A
186.1
186.1
186.1
105.6
104.7 118.8
151.5
N/A = Not Available
MONTH
Table B-13 WHOLESALE PRICE INDEXES FOR
MOTORS, INTEGRAL HORSEPOWER, A.C., 250 HP
BLS # 11730113, 1967=100
1971
1972 1973
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL
N/A =
123.9
123.9
123.9
125.6
129.0
129.0
130.7
130.7
130.7
130.7
130.7
130.7
128.3
Not Available
125.1
125.1
125.1
127.8
127.8
127.8
127.8
129.5
129.5
129.5
129.5
129.5
127.8
129.5
129.5
131.9
136.3
136.3
136.3
139.3
139.3
139.3
139.3
139.3
139.3
136.3
1974 1975
142.0
143.9
143.9
141.3
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
142.8
B-13
-------
Table B-14 WHOLESALE PRICE INDEXES FOR
MOTORS, INTEGRAL HORSEPOWER, A.C., 50 HP
BLS # 11730119, 1967=100
MONTH 1971 1972 1973 1974 1975
JAN 115.1 99.6 111.5 123.5 178.0
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL 98.3 104.7 117.6 149.9
98.9
98.9
98.2
98.2
98.2
95.9
95.2
95.2
95.2'
95.2
95.2
99.6
99.6
101.5
105.6
105.6
105.6
105.6
105.6
105.6
111.5
111.5
111.5
113.4
117.1
119.0
120.5
120.5
120.5
119.0
119.0
119.0
120.1
123.5
126.1
126.1
140.7
152.4
160.9
163.1
164.3
172.8
172.8
172.8
180.6
184.9
184.9
184.9
184.9
184.9
184.9
184.9
184.9
Table B-15 WHOLESALE PRICE INDEXES FOR
A.C. STARTERS, 75 HP, 440 VOLTS
BLS #11750781, 1967=100
MONTH 1971 1972 1973 1974 1975
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL 108.5 112.4 112.4 128.5
106.8
105.5
105.5
105.5
105.5
105.5
105.7
112.4
112.4
112.4
112.4
112.4
112.4
112.4
112.4
112.4
112.4
112.4
112.4
112.4
112.4
112.4
112.4
112.4
112.4
112.4
112.4
112.4
112.4
112.4
112.4
112.4
112.4
112.4
112.4
112.4
115.4
116.1
116.1
116.1
123.4
130.0
132.0
132.0
133.0
141.0
143.7
143.7
143.7
143.7
143.7
143.7
143.7
143.7
143.7
143.7
147.0
N/A
B-14
-------
MONTH
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL
Table B-16 WHOLESALE PRICE INDEXES FOR
REFRACTORTFS
BLS # 135, 1967=100; for 1975, Dec '74=100
1971
1972 1973
1974 1975
126.7
126.7
126.7
126.7
126.7
126.9
126.9
126.9
126.9
127.1
127.1
127.1
127.1
127.1
127.1
127.1
127.1
127.1
127.1
129.6
132.1
132.1
132.1
132.1
136.3
136.3
136.3
136.3
136.3
136.3
136.3
136.3
136.3
136.3
136.3
136.3
136.3
136.3
136.3
136.3
136.3
136.3
137.8
137.8
153.4
157.0
157.8
160.5
100.4
103.2
103.5
103.7
103.9
103.9
103.8
104.1
104.6
104.7
126.9
129.0 136.3 143.5
Table B-17
MONTH
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL
1971
129.0
WHOLESALE PRICE INDEXES FOR
FIRE CLAY BRICK, SUPER DUTY
BLS # 13520111, 1967=100
1972
1973
130.5 134.5
N/A = Not Available
1974 1975
129.0
129.0
129.0
129.0
129.0
129.0
129.0
129.0
129.0
129.0
129.0
129.0
129.0
129.0
129.0
N/A
N/A
N/A
129.0
131.0
132.3
N/A
132.3
132.3
134.5
134.5
134.5
134.5
N/A
134.5
N/A
N/A
134.5
134.5
134.5
N/A
134.5
134.5
134.5
134.5
134.5
134.5
135.3
N/A
156.0
164.2
164.2
167.1
167.1
170.3
170.3
170.3
170.3
170.3
170.3
170.3
170.3
170.3
144.9
B-15
-------
MONTH
Table B-18
1971 1972
WHOLESALE PRICE INDEXES FOR
HIGH ALUMINA BRICK, 70 PCT.
BLS # 13520131, 1967=100
1973
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL
N/A =
119.8
119.8
119.8
119.8
119.8
121.5
121.5
121.5
121.5
122.7
122.7'
122.7
121.1
Not Available
122.7
122.7
122.7
N/A
N/A
N/A
122.7
130.4
134.5
N/A
134.5
134.5
128.1
146.9
146.9
146.9
146.9
N/A
146.9
N/A
N/A
146.9
146.9
146.9
N/A
146.9
1974 1974
,9
,9
146.9
146.9
146.9
146.9
146.
146.
154.6
N/A
170.4
178.7
178.7
181.2
158.6
183.4
189.0
189.0
190.
190.
190.1
190.1
192.4
192.4
192.4
Table B-19
MONTH
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
1975
100.8
100.8
100.8
101.9
101.9
101.9
101.9
102.
102,
,7
,7
102.7
WHOLESALE PRICE INDEXES FOR
CASTABLE REFRACTORIES
BLS # 13520151, DEC 1974=100
B-16
-------
Table 20 WHOLESALE PRICE INDEXES FOR
INSULATION MATERIALS
BLS #1392, 19b/=100
MONTH 1971 1972 1973 1974 1975
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL 131.7 136.9 137.4 150.5
126.2
126.2
126.2
126.2
134.5
134.5
134.5
134.5
134.5
134.5
134.5
134.5
134.5
134.5
134.5
134.5
142.7
138.8
136.8
136.8
137.5
137.5
137.5
137.5
137.5
137.5
138.4
138.4
138.4
138.4
138.4
138.4
135.0
135.0
135.0
137.9
139.2
139.2
139.2
139.9
146.9
149.8
152.0
156.0
169.6
169.6
187.2
189.2
189.7
189.7
189.7
189.7
189.7
194.1
203.0
203.0
201.4
201.4
Table B-21 WHOLESALE PRICE INDEXES FOR
NATURAL GAS
BLS # 05310101, 1967 = 100
MONTH 1971 1972 1973 1974 1975
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL 112.2 121.0 131.3 155.1 215.3
109.5
107.9
109.7
110.8
112.2
113.0
113.2
112.6
114.2
114.7
114.7
113.5
116.3
116.6
117.6
119.6
120.3
120.2
120.6
122.1
122.8
123.9
125.9
126.2
125.1
125.4
125.8
127.4
129.1
130.1
131.1
133.3
135.8
135.9
135.4
141.5
140.9
145.0
147.8
148.4
149.8
151.7
152.6
154.3
159.8
162.1
173.1
175.3
180.5
190.5
190.0
205.8
222.0
219.7
228.3
223.1
229.4
229.5
225.7
239.5
B-17
-------
TaMe B-22
MONTH
JAN
FEE
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL
1971
WHOLESALE PRICE INDEXES FOR
INDUSTRIAL'POWER, 500 KWD
BtS # 0543, Dec 19/0 = 1=90
1972
1973
1974
1975
111.2
111.8
112.5
114.2
114.6
115.2
115.4
117.0
118.5
118. 4
118.3
118.5
121.2
122.7
122.5
123.0
123.9
124.0
124.3
124.4
124.9
125.4
125.4
125.6
126.9
129.0
130.1
131.0
131.5
131.2
131.8
132.0
134.0
135.6
137.3
140.3
142.3
147.0
154.3
158.8
166.8
174.1
178.1
182.2
185.2
191.0
193.2
195.1
198.3
202.7
208.0
212.5
208.7
206.0
207.5
210.5
213.7
215.8
217.2
215.2
115.5
123.9 132.6 172.3 209.7
Table B-23
MONTH
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL
1971
INDEXES OF AVERAGE HOURLY EARNINGS:
MANUFACTURING
1967 = 100
1972
1973
1974
1975
129.3
129.0
131.3
132.1
132.7
133.2
133.6
134.5
135.0
135.5
136.1
136.8
137.5
138.0
138.8
139.5
139.7
140.4
141.1
141.8
142.7
143.7
144.5
145.4
146.5
147.0
147.9
148.7
149.6
150.6
151.7
153.5
155.5
156.6
158.0
159.6
161.3
162.5
163.7
164.8
166.1
167.7
168.6
169.7
171.0
172.2
173.3
174.5
176.0
177.0
177.4
127.5 135.4 143.6 156.0 171.5
SOURCE: U.S. Dept. of Commerce, Survey of Current Business
B-18
-------
APPENDIX C
GUIDE TO REFERENCES TO THE 27 INDUSTRIES
-------
LIST OF REFERENCES CROSS-INDEXED TO INDUSTRY SOURCE
INDUSTRY (or source of pollution)
Basic Oxygen Furnaces
Brick Manufacturing
Castable Refractories
Clay Refractories
Coal Fired Boilers
Conical Incinerators
Cotton Ginning
Detergent Manufacturing
Electric Arc Furnaces
Feed Mills
Ferroalloy Plants
Glass Manufacturing
Grey Iron Foundries
Iron & Steel (Sintering)
Kraft Recovery Furnaces
Lime Kilns
Municipal Incinerators
Petroleum Catalytic Cracking
Phosphate Fertilizer
Phosphate Rock Crushing
Polyvinyl Chloride Production
Portland Cement
Pulp and Paper (Fluidized Bed
Reactor)
Secondary Aluminum Smelters
Secondary Copper Smelters
Sewage Sludge Incinerators
Surface Coatings - Spray Booths
List rvf References
5, 10, 11, 15, 24, 26, 34, 35, 36, 117
5, 24, 26, 35, 36, 82, 96, 97
5, 10, 26, 96, 97
5, 6, 24, 26, 36, 52, 96, 97
5, 6, 15, 24, 26, 34, 35, 36, 52, 61, 71,
76, 77, 83, 115, 123
5, 15, 26, 113, 116,'117
10, 26
5, 10, 24
5, 10, 11, 15, 16, 17, 24, 26, 28, 34, 35,
36, 67, 103, 104, 117
5, 10, 24, 26, 35, 78, 80, 117, 118
5, 10, 11, 15, 24, 26, 67, 82, 89, 99, 117
24, 36, 117
5, 6, 10, 15, 16, 17, 24, 26, 28, 32, 35,
37, 55, 78, 93, 101, 110, 117
5, 6, 10, 11, 15, 24, 26, 34, 35, 36, 37,
56, 82, 102, 103, 104, 105, 110, 117
1, 2, 3, 5, 10, 26, 27, 30, 31, 34, 35, 63,
64, 72, 82, 90, 112, 117
4, 6, 15, 19, 26, 35, 78
6, 15, 25, 26, 34, 58, 92, 94, 106, 107, 114,
115, 116, 117
5, 6, 15, 26, 34, 35, 37, 42, 82, 109, 117
5, 6, 10, 24, 26, 34, 35, 37, 78, 117
5, 24, 26, 34, 36, 117
5, 10, 24,.36, 37, 43
5, 6, 12, 15, 24, 26, 34, 35, 36, 74, 98, 117
1, 2, 3, 5, 10, 15, 27, 30, 31, 34, 63, 64,
90, 101, 112, 117
5, 13, 15, 19, 26, 34, 35, 36, 69, 95, 117
5, 15, 19, 26, 34, 35, 36, 69, 95, 100, 117
5, 15, 26, 59, 114, 116, 117
24, 35, 37, 40, 42, 45, 57, 115
Multi-Industry General Articles
7, 8, 9, 14, 20-23, 24, 30, 33, 34, 37, 38,
39, 40, 41, 44, 46-51, 53, 54, 60, 61, 62,
65, 66, 68, 70, 71, 73, 75, 78, 79, 81, 82,
84, 85, 86, 87, 88, 91, 111, 115, 119-122,
124-127, 128, 129, 130, 131
C-l
-------
LIST OF REFERENCES
Source
No.
Title
With the Alcoa 398 Process for Fluoride
Recovery", Alcoa, Journal of the Air pollu-
tion Control Assoc.. 21(8):479-483, Aug. 1971.
APT 1C
No.
1 Anon., "Control of Atmospheric Emissions in 21385
the Wood Pulping Industry", Vol. 1, Mar. 15,.
1970. Contract No. CPA 22-69-18, NAPCA.
2 Ibid Item #1, Vol. 3. 21724
3 Ibid Item #1, Vol. 2. 21728
4 Minnick, L. J., "Control of Particulate 27434
Emissions-From Lime Plants", June 14, 1970.
63rd Annual Meeting APCA Paper 70-73.
5 Billings, C. E. and Wilder, J. E., "Engineering 28580
Analysis of the Field Performance of Fabric
Filter Systems", June 14, 1970. 63rd Annual
Meeting APCA Paper 70-129 (performed under
NAPCA Contract CPA 22-69-38).
6 Anon., "Efficiency Versus Particle Size and 28821
Approximate Cost Information of Mechanical
Collectors", IGCI Pub. Ml, Jan. 1968.
7 Heneghan, W. F., "Activated Carbon - A Final 29088
Filter", Pollution Engineering, Jan/Feb, 1970,
pp. 18-20.
8 Ashman, R., "A Practical Guide to Industrial 29089
Dust Control", JIHVE, Mar. 1971, Vol. 38,
pp. 273-282.
9 Anderson, L. W., "Odor Control in Rendering 29261
by Wet Scrubbing - A Case History", 1970,
Carolina By-Products Company, Greensboro, N.C.
10
11
12
13
Anon., "Pollution Control Update, 1970" , McGraw-
Hill, Modern Manufacturing, July 1970, 6 pp.
Vaiga, J., et al., "A Systems Analysis of the
Iron & Steel Industry", Battelle, May, 1969.
Walling, I. C. , "Cement Plant Dust Collectors",
Pit & Quarry, July, 1971, 64(1 ):143-148.
Cook, C. C. , et al., "Operating Experience
30462
30698
31538
31567
NTIS
No.
184577
C-2
-------
Source
No.
Title
APTIC
No,
NTIS
No.
14 Wright T. J., et al., "A Model for Estimating
Air Pollution Control Costs", TRW, 64th Annual
Meeting APCA, June 27, 1971, Paper 71-144.
Work performed under Contract PH 22-68-60 (EPA).
15 Anon., "An Electrostatic Precipitator Systems
Study", SRI, Oct. 1970, NAPCA Contract CPA 22-
69-73.
16 Anon., "Systems Analysis of Emissions and
Emissions Control in the Iron Foundry Industry",
Vol. II, Feb. 1971, EPA Contract CPA 22-69-106,
A. T. Kearney & Co., Inc.
17 Ibid Item 16, Vol. I.
18 Ibid Item 16, Vol. III.
19 Anon., "Study of Technical and Cost Information
for Gas Cleaning Equipment in the Lime and
Secondary Non-Ferrous Metallurgical Industries",
IGCI, NAPCA Contract CPA 70-150, Dec., 1970.
20 Anon., "Fabric Filter Systems Study", Vol. II,
GCA Corp., Dec. 1970, NAPCA Contract CPA 22-69-
38.
21 Ibid Item 20, Vol. I.
22 Ibid Item 20, Vol. IV.
23 Ibid Item 20, Vol. III.
24 Anon., "Air Pollution Control: A Practical Guide
'•o Information Sources for Business, Industry,
and Municipalities", Purdue University Libraries
Industrial and Technical Information Service, Apr.,
1974. Bibliography listing of sources.
25 Stear, J. R., "Municipal Incineration: A Review of
the Literature", EPA, June, 1971, Office of Air
Programs, RTP.
26 Anon., "Particulate Pollutant Systems Study",
Vol. Ill, Handbook of Emission Properties, EPA
Contract CPA 22-69-104, May, 1971, MRI.
27 Weiner, J. and Roth, L., "Air Pollution in the
Pulp & Paper Industry", The Institute of Paper
Chemistry, Bibliographic Series No. 237, Sup-
plement I, 1970.
31747
32021 198150
32247 198349
32251 198348
32252 198350
32248 198137
34691 200649
34698
34799
34799
34894
200648
200651
200650
34955 200514
35574 203522
35581
C-3
-------
Source
No.
Title
APTIC
No.
NTIS
No.
28 Greenberg, J. H., "Systems Analysis of Emissions: 35925
The Iron Foundry Industry", Chem Tech 1(12): 728-
736, Dec. 1971.
29 Victor, I., "Control of Gases and Vapor Emissions 37254
From Industrial and Dry Cleaning Processes Com-
paring Efficiency and Operating Cost of Incineration,
Absorption, Condensation and Absorption Methods",
Dec., 1971, Conference paper preprint, U. S. Dept.
of Commerce and WPCF.
30 Mueller, J. H., "Fume and Odor Control Systems 38195
Compared and Analyzed", Wood & Wood Products,
76(3): 48-50, Mar., 1971.
31 Anon., "Harmonizing Pulp and Paper Industry vnth 59245
Environment", Proc. of XV EUCEPA Conference, Rome,
May 7, 1973.
32 Anon., "Economic Impact of Air Pollution Controls 196500
on Gray Iron Foundry Industry", NAPCA Pub. AP 74,
Nov., 1970.
33 Oglesby, Sabert, et al., "A Manual of Electrostatic 196380
Precipitator Technology, Part I - Fundamentals",
SRI, PHS CPA 22-69-73, Aug. 25, 1973.
34 Ibid Item 33, Part II, Application Areas. 196381
35 Anderson, H. S., et al., "User's Manual, Automated 198779
Procedures for Estimating Control Costs and Emission
Reductions, Etc.", RTI, PHS CPA 70-60, 1970.
36 Anon., "Engineering and Cost Effectiveness Study of 207506
Fluoride Emissions Control", Jan. 1972, Vol. I, EPA
Contract EHSD 71-14.
37 Rolke, R. W., et al., "Afterburner Systems Study", 21^560
EPA EHSD 71-3, Aug. 1972.
33 Calvert, J., et al., "Wet Scrubber System Study", 213016
Vol. I, Scrubber Handbook, APT, Inc.,EPA R2 72 118A, CPA
70-95, July, 1972.
39 Ibid Item 38, Vol. II, Final Report and Bibliography. 213017
40* Juhola, A. J., "Package Sorption Device System Study", 221138
MSA Res. Corp., EPA R2 73 202, EHSD 71-2, Apr. 1973.
C-4
-------
Source
No.
Title
APTIC
No.
NT IS
No.
41 Anon., "Proceedings of a Symposium on Control of 235829
Fine-Particulate Emissions, Etc.", 1974, U.S.-U.S.S.R.
Working Group Stationary Source Air Pol. Control Technology.
42 Anon., "Systems and Costs to Control Hydrocarbon 236921
Emissions from Stationary Sources.
43 Carpenter, B. H., "Vinyl Chloride; An Assessment 237343
of Emissions Control Techniques and Costs", RTP,'
EPA/650/2. 74097 EPA 68-02-1325, Sept., 1974.
44 Anon., "Proceedings, Symposium on the Use of Fabric 237629
Filters for the Control of Sub-Micron Particulates",
EPA 650-2-74-043, EPA 68-02-1316, Meeting, 1974.
45 Dowd, E. J., "Air Pollution Control Engineering and 238058
Cost Study of the Paint and Varnish Industry",
ARI, EPA 450-3-74-031, EPA 68-02-0259, June, 1974.
46 Anon., "Air Pollution: Control Techniques for 240578
Nitrogen Oxide", NATO Comm. on the Challenge of
Modern Society, NATO CCMS 20, Oct., 1973.
47 Ibid Item 46, Hydrocarbon and Organic Sol vent,CCMS 19. 240577
48 Ibid Item 46, Carbon Monoxide, CCMS 18. 240576
49 Ibid Item 46, Particulates, CCMS 13, 240573
50 Ibid Item 46, Sulfur Oxide, CCMS 12. 240572
51 "Control Techniques For Particulate Air Pollutants", 190253
USN6W, 1969, AP-51.
52 "Sulfur Codes Pose Dilemma for Coal", Envir. Sci. 37826
Tech., 4(12):1104-1106, Dec., 1970.
53 Diamant,.R. M. E., "The Prevention of Pollution, 38620
Part XII", Heating and Ventilating Eng.,
4-S(535): 398-406, Feb., 1972.
54 "Low Cost Electrostatic Precipitation", Filtration 38088
Separation, 9(1): 52-59 Jan/Feb, 1972.
55 Anon., "Ford's Michigan Casting Center, Environmental 37498
Control", Foundry, 100(3): F8-F11, Mar., 1972.
56
Anon., "When It Comes to Pollution Control, Steel
Isn't Dawdling- It's Acting", 33 Mag. 10(1): 23-29,
Jan., 1972.
3623C
C-5
-------
Source
No.
57
58
59
60
61
62
63
64
65
66
67
68
69
Title
Hayes, C. T., "Cut Industrial Pollution by
Eliminating Gaseous Waste", Automation,
Cleveland 18(3):64-65, Mar., 1971.
APTTC
No.
36516
NTIS
No.
Fife, J. A., "Design of the Northwest Incinera- 28261
tor for the City of Chicago", Proc. of Nat'l.
Incinerator Conf., Cincinnati, Ohio, 1970, pp. 149-160.
Sebastian, F. P. and Isheim, NL C., "Advances 28262
in Incineration and Resource Reclamation",
Proc. of Nat'l. Incinerator Conf., Cincinnati,
Ohio, 1970, pp. 71-78.
Mueller, J. H., "Cost Comparison for Burning 34716
Fumes and Odors", Pollution Eng. 3(6):18-30,
Nov/Dec, 1971.
Jaeger, W. and Keilpart, T., "Pollution Control 31915
Can Pay Its Way - Even When Retrofit", Elec.
Light Power, 48(6):73-75, June, 1970.
Ottaviano, V. B. and Lazan, S., "Air Pollution 31805
Abatement Market for the Sheet Metal Industry",
Heating Air Conditioning Contractors, Vol.
bZ:Zb-3\, Aug., 1971.
Burgess, T. L., et al., "Incineration of Malodor- 63161
ous Gases in Kraft Pulp Mills", Pulp Paper
Mag. Can., 75(5):92-96, May, 19747"^
Roberson, J. E., et al., "The NAPCA Study of the 28095
Control of Atmospheric Emissions in the Wood
Pulping Industry", TAPPI, 54(2): 239-244, Feb.,
1971.
Jones, A. H., "The Basics of Dust Collection", 27279
Plant Eng., 25(4):71-73, Feb. 18, 1971
Ellison, W. , "Wet Scrubbers Popular for Air 27282
Cleaning", Power, 115(2):62-63, Feb., 1971.
Person, R. A., "Control of Emissions from 29325
Ferroalloy Furnace Processing", J. Metals,
23(4):17-29, Apr., 1971.
Mueller, J. H., "What It Costs to Control 29299
Process Odors", Food Eng., 43(4):62-65, Apr.,
1971.
Swan, D., "Study of Costs for Complying with 29376
Standards for Control of Sulfur Oxide Emissions
from Smelters", Mining Congr. J., 57(4):76-85,
Apr., 1971.
C-6
-------
Source
No.
Title
APTIC
No.
NTIS
No.
70
71
72
73
74
75
76
77
78
79
30
Calvert, Seymour, "Source Control by Liquid Scrub- 30868
bing", In: Air Pollution, Arthur C. Stern (Ed.),
Vol. 3, 2nd Ed., N.Y., Academic Press, 1968.
Olds, F. C., "S09 Control: Focusing on New Targets", 31673
Power Eng., 75(8J:24-29, Aug., 1971.
Lardieri, N. T., "Present Treatment Practices in < 35660
Kraft Mills of Air-borne Effluents", Paper Trade
J.., 142(15):28-33, 14 April, 1958.
Taylor, D. H., "Recommendations for Dust Collection 35087
Systems", Metal Progr. 98(6):63, Dec., 1970.
Van DeWouwer, R., "Clinker Cooler Dust Collector 35990
Recovers 60 TPD at Inland's Winnepeg Plant", Pit
Quarry, 64(7):104-105, Jan., 1972.
Alonso, J. R.F., "Estimating the Costs of Gas 35532
Cleaning Plants", Chem. Eng., 78(28):86-96.
Benson, J. R. and Corn. M., "Costs of Air Cleaning 61840
with Electrostatic Precipitators at TVA Steam Plants",
J. Air Pollution Control Assoc., 24(4):340-348, Apr.,
1974, 7 Refs.
Selzler, David R. and Watson, W. D., "Hot Versus 58903
Enlarged Electrostatic Precipitation of Fly Ash:
A Cost-Effectiveness Study". J. Air Poll. Control
Assoc.. 24(2):115-121, Feb., 1974, 25 Refs.
Hardison, L.C., "Air Pollution Control Technology 62087
and Costs in Seven Selected Industries (Final Report)",
Industrial Gas Cleaning Institute, Stamford, Conn.
Office of Air and Water Programs, Contract 68-02-
0289, Rept. EPA-450/3-73-010, IGCI Rept. 47-173,
724 p., Dec. 1973, 82 Refs.
Nichols, Richard A., "Hydrocarbon-Vapor Recovery"
Chem. Eng.. 80(6):85-92, 5 Mar., 1973. Presented
at the Petroleum Mech. Engrg.Conf., New Orleans, La.,
Sept. 17-21, 1972.
Shannon, Larry J.; Gerstle, Richard W.; Gorman,
P. G.; Epp, P.G.; Devitt, T. W.; Amick, R.,
•"Emissions Control in the Grain and Feed Industry.
Vol. I- Engineering and Cost Study", Midwest Res.
Inst., Kansas City, Mo., Office of Air Quality
Planning and Standards, Contract 68-02-0213, Rept.
EPA 450/3-73-003a, 583 pp., Dec., 1973, 128 Refs.
60808
59566
C-7
-------
Source APTIC NTIS
No- Title No. .No.
81 Larson, Dennis M., "Control of Organic Solvent 56967
Emissions by Activated Carbon", Metal Finishing,
71(12):62-65, 70, Dec., 1973, 4 Refs.
82 Hardison, L.C. and Greathouse, Carroll A., "Air 57616
Pollution Control Technology and Costs in Nine
Selected Areas (Final Report)", Industrial
Gas Cleaning Inst., Stamford, Conn., EPA Contract
68-02-0301,APTD-1555, 616 pp., Sept.30, 1972,
74 Refs.
83 Schultz, E, A.; Miller, W.E.; Barnard, R. E.; 60847
and Horlacher, W. R., "The Cat-Ox Project at
Illinois Power", Proc. Am. Power Conf., Vol. 34:
484-490, April, 1972.
84 Stout, Bruce G., "Selection of Air Pollution 62011
Control Equipment", Army Logistics Management
Center, Texarkana, Tex., Product/Production
Engineering Program. Training Center Rept.
USAMC-ITC-2-71-12, 82 pp., July, 1971, 13 Refs.
85 Bagwell, F. A., Cox, L. F. and Pirsh, E. A., 58729
"Flue-Gas Filtering Proves Practical on Oil-
Fired Unit", Elec. World, 171(10):26-27, Mar. 10,
1969.
86 Cosby, W. T. and Punch, G., "Cost and Perform- 57907
ance of Filtration and Separation Equipment,
Dust Filters and Collectors", Filtration
Separation (Purley), 5(3):252-255, May/June,
1968, 1 Ref.
87 Squires, B. J., "New Developments in the Use of 57370
Fabric Filter Dust Collectors", Filtration Separa-
tion (Purley), 6(2):161-170, Mar/Apr, 1969, 5 Refs.
Presented at the Filtration Society, London,
10 Sept., 1968.
83 Danielson, J. A., "Air Pollution Engineering
Manual", Air Pollution Control District County of
Los Angeles, U. S. Environmental Protection Agency,
Pub. No. AP-40, May, 1973.
89 Dealy, J. 0. and Kill in, A. M., "Engineering and
Cost Study of the Ferroalloy Industry", U. S.
EPA, EPA 450/2-74-008, May, 1974.
90 Hendrickson, E. R., etal., "Control of Atmos-
pheric Emission in the Wood Pulping Industry",
Environmental Engineers, Inc. and J. E. Sirrine Co.,
Contract No. CPA 22-69-18, March, 1970, Report PB
190-351.
r-ft
-------
Source APTIC
No. Title No.
91 Cadman, T. W., "Elements of Pollution Control
Economics", ICARUS Corp., Dec., 1973.
92 "Interim Guide of Good Practice for Incineration at
Federal Facilities", U. S. Dept. of Health, Education,
and Welfare, Nov., 1969.
93 Cowen, P. S., "Cupola Emission Control", Gray and
Ductile Iron Founder's Society, Cleveland, Ohio,
1967.
94 Fernandes, J. H., "Incineration Air Pollution Control",
Proceedings ofT968 National Incinerator Conference,
New York, N. Y., American Society of Mechanical Engi-
neers, pp. 101-115.
95 Anon., "Economic Impact of Proposed Water Pollution
Controls on the Nonferrous Metals Manufacturing
Industry"- Phase II, Environmental Protection Agency,
EPA-230/1-75-041, March, 1975.
96 Anon., "Development Document for Effluent Limitations
Guidelines and Standards of Performance", Versar, Inc.,
April, 1975, The Clay, Gypsum, Refractory, and
Ceramic Products Industries, Office of Water and
Hazardous Materials, EPA, Contract No. 68-01-2633.
97 Ibid Item 96, Volume III, December 1974.
98 Kreichelt, T. E., et al., "Atmospheric Emissions from
the Manufacture of Portland Cement", U. S. Dept. of
Health, Education, and Welfare, 1967. PB190236
99 Anon., "Development Document for Interim Final
Effluent Limitations Guidelines and Proposed New
Source Performance Standards for the Calcium Carbide
Segment of the Ferroalloy Manufacturing Point Source
Category',1 U. S. Environmental Protection Agency,
February 1975, EPA 440/1-75/038, Group I, Phase II.
100 Anon., /'Development Document for Proposed Effluent
Limitations Guidelines and New Source Performance
Standards for the Secondary Copper Subcategory of the
Copper Segment of the Nonferrous Metals Manufacturing
Point Source Category, U. S. Environmental Protection
Agency, November 1974, EPA 440/1-75/032-c, Group I,
Phase II.
C-9
-------
Source APTIC NT1S
No. Title No. No.
101 Coughlin, R.W., et al., "Air Pollution and Its
Control", American Institute of Chemical Engi-
neers, Symposium Series 1972, Volume 68, No. 126.
102 Anon., "Development Document for Proposed Effluent
Limitations Guidelines and New Source Performance
Standards for the Steel Making Segment of the Iron
& Steel Manufacturing Point Source Category, U. S.
Environmental Protection Agency, January, 1974,
EPA 440/1-73/024.
103 Anon., "Background Information for Standards of PB 237840
Performance: Electric Arc Furnaces in the Steel
Industry", Volume 1 - Proposed Standards, October,
1974.
104 Ibid Item 103, Volume 2 - Test Data Summary, PB 237841
Report No. EPA-450/2-74-017b.
105 Anon., "Economic Analysis of the Proposed Effluent
Guidelines for the Integrated Iron and Steel Industry1',
February, 1974, Environmental Protection Agency,
Report No. EPA-230/1-73-027, A. J. Kearny, Contract
No. 68-01-1545.
106 Anon., Municipal Refuse Disposal, Institute for Solid
Wastes of American Public Works Association, 1970,
Public Administration Service, Chicago, Illinois.
107 Anon., 1968 National Incinerator Conference, New York,
N. Y., Sponsored by ASME Incinerator Division.
108 Breaux, James C., Control of Particulate Matter in
Asphalt Plants. Preprint, Louisiana Tech. Univ.,
Continuing Engineering Education Div., pp. 80-91,
1970 (Presented at the Institute on Aspects of Air
Pollution Control, Ruston, LA, Oct. 8-9, 1970) 57401
109 American Petroleum Inst., Wash. D. C., Committee
on Refinery Environmental Control, Hydrocarbon
Emissions From Refineries. # Pub-928, 64 p.,
July, 1973. 59178
110 Remmers, K., Dust Extraction From Cupolas by
Means of Venturi Tube Scrubbers, Giesserei
(Duesseldorf), 52(7): 191-193, April 1, 1965,
Translated from German, 11 p. 61061
111 Cheremisinoff, Paul N., "Wet Scrubbers - A Special
Report", Pollution Engineering, May, 1974,
pp. 33-43.
r_in
-------
NTTS
Source '"- ' '„
No. Title No. No.
112 Bunyard, F. L., "Pollution Control for the Kraft Pulping
Industry: Cost and Impact", Annual Meeting of the Air
Pollution Control Association, June 14-19, 1970,
APCA #70-74.
113 Vickerson, George L., "Fly Ash Control Equipment for
Industrial Incinerators", Proc. 1966 ASME Incinerator Conf.
^
114 Guccione, Eugene, "Incineration Slashes Costs of Sewage
Disposal", Chemical Engineering, Apr. 11, 1966, pp.144-146.
115 "New Developments in Air Pollution Control", Proc. MECAR
Symposium, New York, N.Y., Oct. 23, 1967-
116 Corey, Richard, Principles and Practices of Incineration,
Wiley-Interscience, New York, N.Y., 1969.
117 Stern, Arthur C., Air Pollution, 2nd Ed., Vol. II & III,
Academic Press, New York, 1968.
118 Smith, Kenneth D., "Particulate Emissions from Alfalfa
Dehydrating Plants -- Control Costs and Effectiveness",
EPA-650/2-74-007, Jan., 1974.
119 "Capital and Operating Costs of Pollution Control Equip- 224-535
inent Modules", Vol. I & II, EPA-R5-73-023a & b, July, 224-536
1973.
120 Liptak, B. G., Environmental Engineers Handbook, Radnor,
Chilton Book, 1974, 1340 p.
121 Fraser, M. D. and Foley, G. J., Cost Models for Fabric
Filter Systems. In: The 67th Annual Meeting of the Air
Pollution Control Association, Denver, June, 1974, APCA
> 74-96.
122 Reigel, S. A., Bundy, R. P. and Doyle, C. D. Baghouses -
What to Know Before You Buy. Pollution Engineering.
1:32-34, May, 1973.
123 Walker, A. B. Experience with Hot Electrostatic Precipi-
tators for Fly Ash Collection in Electric Utilities.
In: American Power Conference, Chicago, Research-
Cottrell, Inc., April 29-May 1, 1974.
124 Alfonso, J. R. F. Estimating the Costs of Gas Cleaning
Plants. Chemical Engineering, December 13, 1971, pp. 86-96.
125 Schneider, G. G., Horzella, T. I., Cooper, J. and
P. J. Striegl. Selecting and Specifying Electrostatic
Precipitators. Chemical Engineering. 82 11:94-108, May,
1975. ~~
C-ll
-------
Source APTIC NTIS
No. Title No. No.
126 Anon. Survey of Electrostatic Precipitator
Operating and Maintenance Costs. Water and Sewage
Works, Reference Number - 1971, Aug. 31, 1971,
pp. R236-R237.
127 Rymarz, J. M. and Klipstein, D. H. Removing Particulates
From Gases. Chemical Engineering. 82_ (21): 113-120,
October, 1975.
128 "Estimating Costs and Manpower Requirements for Con-
ventional Wastewater Treatment Facilities",
EPA 17090 DAN 10/71. PB 211132
129 Jorgensen, Robert, Editor, "Fan Engineering", 6th Ed.,
Buffalo Forge Company, New York, 1961.
130 Arnold, T. H. and Chi 1 ton, C. H., New Index Shows
Plant Cost Trends, Chemical Engineering,
Feb. 18, 1963, pp. 143-149.
131 Economic Indicators, Chemical Engineering, Every Issue.
C-12
-------
APPENDIX D
GUIDE TO ASSOCIATIONS FOR THE 27 INDUSTRIES
-------
ASSOCIATIONS
1. Air Pollution Control Association
4400 Fifth Avenue
Pittsburgh, Pennsylvania 15213
Lewis H. Rogers
Executive Vice President
412/621-1100
2. Brick Institute of America
1750 Old Meadow Road
McLean, Virginia 22101
R. U. Otterson
Executive Vice President
703/893-4010
3. Refractories Institute (Brick)
1102 One Oliver Plaza
Pittsburgh, Pennsylvania 15222
Bradford S. Tucker
Executive Secretary
412/281-6787
4. Refractories and Reactive Metals
Association
P. 0. Box 2054
Princeton, New Jersey 08540
Kempton H. Roll
Executive Director
609/799-3300
5. American Boiler Manufactures Association
Suite 317, AM Building
1500 Wilson Boulevard
Arlington, Virginia 22209
W. B. Marx
Executive Director
703/522-7298
6. National Grain and Feed Association
501 Folger Building
Washington, D. C. 20005
Alvin E. Oliver
Executive Vice President
202/783-2024
7. Grain Elevator and Processing Society
2144 Board of Trade Building
Chicago, Illinois 60604
Dean M. Clark
Secretary-Treasurer
312/922-3111
8. American Feed Manufactures Association
1701 N. Fort Myer Drive
Arlington, Virginia 22209
Oakley M. Ray
President
703/524-0810
9. Midwest Feed Manufacturers Association
521 E. 63rd Street
Kansas City, Missouri 64110
Rex Parsons
Executive Vice President
816/444-6240
10. American Glassware Association
c/o Organized Service Corp. Managers
One Stone Place
Bronxville, New York 10708
Donald V. Reed
Managing Director
914/779-9602
D-l
-------
11. Associated Glass and Pottery Manufacturers
c/o Harold L. Hayes
Brush Pottery Company
P. 0. Box 2576
Zanesville, Ohio 43701
Harold L. Hayes
Secretary
614/454-1216
12. National Association of Manufacturers of
Pressed and Blown Glassware
c/o John H. Morris
707 Winmar Place
Westerville, Ohio 43081
13. Sealed Insulating Glass Manufactures
Association-
202 S. Cook Street
Barrington, Illinois 60010
Warren W. Findling
Executive Vice President
312/381-8989
14. Gray and Ductile Iron Founders' Society
Cast Metals Federation Building
20611 Center Ridge Road
Rocky River, Ohio 44116
Donald H. Workman
Executive Vice President
216/333-9600
15. Malleable Founder's Society
20611 Center Ridge Road
Cast Metals Building
Rocky River, Ohio 44116
Lowell D. Ryan
Executive Vice President
16. Non-Ferrous Founder's Society
21010 Center Ridge Road
Cleveland, Ohio 44116
Benjamin J. Imburgia
Executive Secretary
216/333-2072
17. Steel Founder's Society of America
20611 Center Ridge Road
Cast Metals Federation Building
Rocky River, Ohio 44116
Jack McNaughton
Executive Vice President
216/333-9600
18. Foundry Equipment Manufacturers
Association
1000 Vermont Avenue
Washington, D. C. 20005
Charles E. Perry
Executive Secretary
202/628-4634
19. American Iron and Steel Institute
150 East 42nd Street
New York, New York 10017
John P. Roche
President
212/697-5900
D-2
-------
20. Ductile Iron Society
P. 0. Box 22058
Cleveland, Ohio 44122
James H. Lansing
Executive Director
216/752-0521
21. Roll Manufacturers Institute
1808 Investment Building
Fourth Avenue
Pittsburgh, Pennsylvania 15222
A. G. Karp
Executive Secretary-
Treasurer
412/281-0908
22. National Council of the Paper Industry
for Air and Stream Improvement
260 Madison Avenue
New York, New York 10016
23. American Paper Institute
260 Madison Avenue
New York, New York 10016
24. Paper Industry Management Association
2570 Devon Avenue
Des Plaines, Illinois 60018
25. Technical Association of the Pulp
and Paper Industry
One Dunwoody Park
Atlanta, Georgia 30341
26. National Lime Association
5010 Wisconsin Avenue, N.W.,
Washington, D.C. 20016
27. National Crushed Stone Association
1415 Elliot Place, N.W.
Washington, D.C. 20007
28. P^tland Cement Association
Old Orchard Road
Skokie, Illinois 60076
29. Fertilizer Industry Round Table
Glenn Arm, Maryland 21057
30. The Fertilizer Institute
1015 18th St. N.W.
Washington, D.C. 20036
Ernest J. Bolduc, Jr,
Executive Director
Albert S. Thomas
Secretary-Streasurer
212/889-6200
H. Mac Gregor Tuttle
Executive Director
312/774-6797
Phillip E. Nethercut
Executive Secretary-
Treasurer
404/457-6352
Robert S. Boynton
Executive Director
202/966-3418
W. L. Carter
President
202/333-1536
Robert D. MacLean
President
312/966-6200
Paul J. Prosser
Secretary-Treasurer
301/592-6271
Edwin M. Wheeler
President
202/466-2700
D-3
-------
31. fastern States Blast Furnace and
Coke Oven Association
c/o Paul F. Ross
Bethlehem Steel Corporation
Johnstown, Pa. 15907
32. National Coal Association
1130 17th St. N.W.
Washington, D.C. 20036
33. Soap and Detergent Association
475 Park Avenue South
New York, New York 10016
34. Manufacturing Chemists Association
1825 Connecticut Avenue, N.W.
Washington, D.C. 20009
35. American Petroleum Institute
1801 K Street, N.W.
Washington, D.C. 20006
36. Coordinating Research Council
30 Rockefeller Plaza
New York, New York 10020
37. Independent Refiners Association
of America
1801 K Street, N.W., Suite 1101
Washington, D.C. 20006
38. National Petroleum Refiners
Association
1725 De Sales Street, N.W.
Suite 802
Washington, D.C. 20036
39. Western Oil and Gas Association
602 S. Grand Avenue
Los Angeles, California 90017
40. Copper Development Association
405 Lexington Avenue 57th Floor
New York, New York 10017
41. Copper Institute
50 Broadway
New York, New York 10004
Carl E. Bagge
President
202/628-4322
Theodore E. Brenner
President
212/725-1262
William T. Driver
President
202/483-6126
Frank N. Ikard
President
202/833-5600
M. K. McLeod,
Manager
212/757-1295
Edwin Jason Dryer
General Counsel
202/466-2340
Donald C. O'Hara
Executive Vice President
202/638-3722
Harry Morrison
Vice President
213/624-6386
George M. Hartley
President
212/867-6500
H. Fasting
Secretary
212/944-1870
D-4
-------
42. Aluminum Association
750 Third Avenue
New York, New York 10017
-:. Incinerator Institute of America
2425 Wilson Blvd.
Arlington, Virginia 22201
££. American Public Works Association
1313 East 60th Street
Chicago, Illinois 60637
45. National Sol id-Wastes Management
Association
1730 Rhode Island Avenue, N.W.
Suite 800
Washington, D.C. 20036
46. Conference of State Sanitary
Engineers
Statehouse
Charleston, West Virginia 25305
47. American Society of Sanitary
Engineering
960 Illuminating Building
Cleveland, Ohio 44113
48. National Cotton Ginner's Association
Box 120
Maypearl, Texas 76064
49. The Cotton Foundation
1918 North Parkway
Memphis, Tennessee 38112
50. Cotton Incorporated
1370 Avenue of the America's
New York, New York 10019
51. National Cotton Council of America
1918 North Parkway
Memphis, Tennessee 38112
S. L. Goldsmith, Jr.
Executive Vice President
212/972-1800
Charles N. Sumwalt, Jr.
Executive Director
703/528-0663
Robert D. Bugher
Executive Director
312/324-3400
304/348-2970
Sanford Schwartz
Secretary
216/696-3228
Peary Wilemon
Secretary-Treasurer
214-435-2741
George S. Buck, Jr.
Executive Vice President
J. Dukes Wooters, Jr.
President
212/586-1070
Albert B. Russell
Executive Vice President
and Secretary
901/276-2783
D-5
-------
APPENDIX E
CONVERSION FACTORS TO SI MEASUREMENTS
-------
APPENDIX E
CONVERSION FACTORS TO SI MEASUREMENTS
For a complete description of conversion factors to the International
System of Units (SI), the reader is referred to the "Metric Practice Guide,"
American Society for Testing and Materials, pub. #E 380-72, approved by the
American National Standards Institute, Std. #Z210.1-1973. The following are
selected conversion factors that will accomodate all units found in this
document, as well as other pertinent units. They are arranged alphabetically.
To convert from
atmosphere (normal=760 torr)
British thermal unit (Btu)
Btu/ft2
Btu/hour
Btu/pound-mass
Btu/lbm-deg F (heat capacity)
Btu/s-ft2-deg F
calorie (International Table)
day
degree Celsius (C)
degree Fahrenheit (F)
degree Fahrenheit (F)
foot (ft)
foot2 (ft2)
foot3 (ft3)
foot/hour (fph)
The Btu quantity used herein is that
Multiply by
5
1.01325 * 10*
to
pascal (Pa)
joule (J) 1.05506 * 103
joule/metre2 (J/m2) 1.13565 * 104
watt (W)
joule/kilogram-
(0/kg)
joule/kilogram-
kelvin (J/kg-K)
2
watt/metre -kelvin
(W/m2-K)
joule (J)
second (s)
kelvin (k)
degree Celsius
kelvin (k)
metre (m)
2 2
metre (m )
metre (m )
0.29307
2.326 * 103
4.18680 * 103
2.04418 * 104
4.18680
8.64000 * 104
tk=tc + 273.15
tc =(tf-32)/1.8
V (
0.30480
9.29030 * 10
2.83168 * 10
"2
metre/second (m/s) 8.46667 * 10
based on the International Table.
-5
E-l
-------
To convert from
to
Multiply by
foot/minute (fpm)
foot/second (fps)
3
foot /minute (cfm)
o
foot /second (cfs)
gallon (U.S. liquid) (gal)
gallon (U.S. liquid)/day (gpd)
gallon (U.S. liquid)/minute (gpm)
grain (gr)
horsepower (hp)
hour (hr)
inch (in)
inch2 (in2)
inch of water (60F)
kilowatt-hour (kwh)
minute (min)
parts per million (ppm)
pound-force (Ibf avoirdupois)
2
pound-force/inch (psi)
pound-mass (Ibm avoirdupois)
3 3
pound-mass/foot (Ibm/ft )
pound-mass/minute (Ibm/min)
pound-mass/second (Ibm/sec)
ton (cooling capacity)
ton (short, 2000 Ibm)
metre/second (m/s)
metre/second (m/s)
3 3
metre /second (m/s)
3 3
metre /second (m /s)
metre (m )
metre /second
(m3/s)
metre /second
(m3/s)
kilogram(kg)
watt (w)
second(s)
metre (m)
2 2
metre (m )
pascal (Pa)
joule (J)
second (s)
milligram/metre
(mg/m3)
newton (N)
pascal (Pa)
kilogram (kg)
kilogram/metre
(kg/m3)
kilogram/second
(kg/s)
kilogram/second
(kg/s)
Btu/hr
kilogram (kg)
5.08000 * 10
0.30480
4.71947 * 10
2.83168 * 10
3.78541 * 10
4.38126 * 10*
6.30902 * 10
6.47989 * 10
7.46000 * 102
3.60000 * 10
2.54000 * 10
6.45160 * 10
2.4884 * 102
-3
-4
-2
-3
-5
-5
-2
-4
3.60000 * 10°
60.000
(molecular weight)/24.5
4.44822
6.89476 * 103
0.453592
1.60185 * 10
1
7.55987 * 10
-3
-1
4.53592 * 10
1.2000 * 104
9.07185 * 102
E-2
-------
TECHNICAL REPORT DATA
(Please read laM/iictions an the reverse before completing
1. REPORT NO.
2.
3. RECIPIENT'S ACCESSION-NO.
4. TITLE AND SUBTITLE
Capital and Operating Costs of Selected Air Pollution
Control Systems
5. REPORT DATE
May 1976
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
M. L. Kinkley and R. B. Neveril
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANiZ-TlON NAME AND ADDRESS
GARD, Inc.
7449 North Natchez Avenue
Niles, Illinois 60648
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
EPA 68-02-2072
12. SPONSORING AGE\CV NAME AND ADDRESS
Environmental Protection Agency
Office of Air and Waste Management
Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina 27711
13. TYPE OF REPORT AND PERIOD COVERED
Final
14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
16. ABSTRACT
The purpose of this manual is to provide capital, operating, and maintenance
costs for air pollution control systems. Capital costs are provided for component
equipments, such as ductwork, dampers, heat exchangers, mechanical collectors, fans,
motors, stacks, cooling towers, pumps, and dust removal equipment. Five types of
control devices are included: (1) high voltage electrostatic precipitators, (2)
venturi scrubbers, (3) fabric filters, (4) thermal and catalytic incinerators, (5)
adsorbers. Operating and maintenance costs are provided for complete systems. A
discussion of the control devices and factors affecting costs is included, along
with design parameters for 27 industries. The life cycle cost analysis technique
is briefly described and an example of the cost estimating methodology is given.
Ir preparing this manual, the main objective was to "break-out" the individual
component costs so that realistic system cost estimates can be determined for the
design peculiarities of any specific application. Accuracy of the cost data pre-
sented is generally +_ 20%.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.IDENTIFIERS/OPEN ENDED TERMS C. COSATI Field/Group
Industrial Emission Sources
Costs
Manual
Fabric Filters
Scrubbers
Electrostatic Precipitators
Adsorbers, Incinerators
Cost Estimation
Techniques
Capital Costs
Annualized Costs
Air Pollution Control
Systems
13. DISTRIBUTION STATEMENT
Unlimited
19. SECURITY CLASS (This Report)
Unclassified
21. NO. OF PAGES
208
20. SECURITY CLASS (This page)
Unclassified
22. PRICE
EFA Form 2220-1 (9-73)
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EPA Form 2220-1 (9-73) (Reverse)
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