EPA 450/5-80-002
CAPITAL
AND OPERATING COSTS
OF SELECTED AIR POLLUTION
CONTROL SYSTEMS
by
R. B. Neveril
GARD, INC.
7449 North Natchez Avenue
Niles, Illinois 60648
Contract No. 68-02-289S
EPA Project Officer: Frank Bunyard/Winiam Vatavuk
Prepared for
ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Waste Management
Office of Air Quality Planning and Standards
Research Triangle Park, North Caroline 27711
December, 1978
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NOTICE
This report was furnished to the Environmental Protection Agency by GARD, INC.,
Niles, Illinois in fulfillment of Contract No. 68-02-2899. The contents of
this report are reproduced herein as received from the contractor. 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.
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TABLE OF CONTENTS
Section
2
3
4
6
7
APPENDIX
APPENDIX
APPENDIX-
APPENDIX
APPENDIX
LIST OF TABLES
LIST OF FIGURES
INTRODUCTION
1.1 Purpose of Manual
1.2 Organization of Manual
APPLICATION TO INDUSTRY
COST ESTIMATING PROCEDURES
3.1 Capital Costs
3.1.1 Purchased Equipment Costs
3.1.2 Installation Costs
3.2 Annualized Costs
3.2.1 Direct Operating Costs
3.2.2 Indirect Operating Costs
AUXILIARY EQUIPMENT
4.1 Capture Hoods
4.2 Ducting
4.3 Gas Conditioning
4.4 Pollutant Removal and Treatment (Dust)
4.5 Ancillary Equipment (cooling towers, pumps)
4.6 Fans
4.7 Stacks
CONTROL DEVICES
5.1 High Voltage Electrostatic Precipitators
5.2 Venturi Scrubbers
5.3 Fabric Filters
5.4 Thermal and Catalytic Incinerator Systems
5.5 Adsorbers
5.6 Absorbers
5.7 Refrigeration
5.8 Flares
SAMPLE COST ESTIMATES AND SYSTEM COST COMPARISON
UPDATING COSTS TO FUTURE TIME PERIODS
7.1 General
7.2 Equipment Cost Updating Procedures
A COMPOUND INTEREST FACTORS
B EQUIPMENT COST INDEXES
C GUIDE TO REFERENCES TO THE INDUSTRIES
D GUIDE TO ASSOCIATIONS FOR THE INDUSTRIES
E CONVERSION FACTORS TO SI MEASUREMENTS
1-1
1-1
1-2
2-1
3-1
3-2
3-5
3-9
3-10
3-13
3-18
4-1
4-2
4-15
4-29
4-44
4-47
4-57
4-67
5-1
5-1
5-9
5-19
5-31
5-39
5-50
5-65
5-72
6-1
7-1
7-1
7-6
ii
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LIST OF TABLES
TABLE PAGE
NUMBER NUMBER
2.1 INDUSTRY POLLUTANT SOURCES AND TYPICAL 2-4
CONTROL DEVICES
2.2 DESIGN PARAMETERS FOR RESPECTIVE INDUSTRIES 2-10
FOR HIGH EFFICIENCY PERFORMANCE
2.3 EFFICIENCY OF CARBON ADSORPTION AND LEL'S 2-11
FOR COMMON POLLUTANTS
3.1 CAPITAL COSTING 3-3
3.2 COST ADJUSTMENTS 3-7
3.3 CAPITAL COST SUMMARY 3-11
3.4 BASIS FOR ESTIMATING ANNUALIZED COSTS 3-12
3.5 ESTIMATED LABOR HOURS PER SHIFT 3-14
3.6 GUIDELINES FOR PARTS AND EQUIPMENT LIFE 3-16
4.1 MINIMUM VELOCITIES AND VENTILATION RATES 4-7
FOR LOW CANOPY HOODS
4.2 MATERIAL COSTS 4-14
4.3 REFRACTORY ESTIMATING COSTS 4-25
4.4 DEFINITIONS FOR COOLING TOWER 4-50
4.5 PRICE ADJUSTMENT FACTORS FOR WET-BULB 4-50
TEMPERATURES
4.6 PRICE ADJUSTMENT FACTORS FOR APPROACH AT 4-50
4.7 MOTOR RPM SELECTION GUIDE 4-62
4.8 PRICING FACTORS FOR OTHER MOTOR TYPES 4-62
4.9 MOTOR TYPE SELECTION 4-62
4.10 FAN SIZING FACTORS: AIR DENSITY RATIOS 4-63
5.1 BAG PRICES 5-32
5.2 APPROXIMATE GUIDE TO ESTIMATE GROSS CLOTH 5-32
AREA
iii
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LIST OF TABLES
TABLE PAGE
NUMBER NUMBER
5.3 TECHNICAL ASSUMPTIONS FOR ESTIMATION OF 5-48
DIRECT OPERATING COSTS
5.4 MINIMUM SHELL THICKNESS AT AMBIENT 5-63
TEMPERATURE
5.5 COST OF TOWER PACKING 5-63
5.6 ADDITIONAL COSTS FOR FABRICATOR'S 5-64
ENGINEERING, PURCHASING, ADMINISTRATION
AND PROFIT
IV
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LIST OF FIGURES
FIGURE PAGE
NUMBER TITLE NUMBER
4-1 CONTROL SYSTEM FLOW CIRCUIT 4-3
4-2 LOW CANOPY HOODS FOR COLD PROCESSES 4-6
4-3 RECTANGULAR CANOPY HOOD PLATE AREA 4-10
REQUIREMENTS VS. HOOD LENGTH AND L/W
4-4 CIRCULAR HOODS PLATE REQUIREMENTS 4-11
4-5 LABOR COST FOR FABRICATED 10 GA. CARBON 4-12
STEEL RECTANGULAR CANOPY HOODS
4-6 LABOR COST FOR FABRICATED 10 GA. CARBON 4-13
STEEL CIRCULAR CANOPY HOODS
4-7 CARBON STEEL STRAIGHT DUCT FABRICATION 4-19
PRICE PER LINEAR FOOT VS. DUCT DIAMETER
AND PLATE THICKNESS
4-8 STAINLESS STEEL STRAIGHT DUCT FABRICATION 4-20
PRICE PER LINEAR FOOT VS. DUCT DIAMETER
AND PLATE THICKNESS
4-9 WATER COOLED CARBON STEEL STRAIGHT DUCT 4-21
FABRICATION PRICE PER FOOT VS. DUCT
DIAMETER
4-10 CARBON STEEL ELBOW DUCT RRICE VS. DUCT 4-22
DIAMETER AND PLATE THICKNESS
4-11 STAINLESS STEEL ELBOW DUCT PRICE VS. DUCT 4-23
DIAMETER AND PLATE THICKNESS
4-12 CARBON STEEL EXPANSION JOINT COSTS VS. 4-24
DUCT DIAMETER
4-13 CARBON STEEL RECTANGULAR DAMPER PRICES 4-27
VS. AREA FOR L/W = 1.3
4-14 CARBON STEEL CIRCULAR DAMPER PRICES VS. 4-28
DIAMETER
4-15 CAPACITY ESTIMATES FOR MECHANICAL 4-31
COLLECTORS
4-16 CRITICAL PARTIAL SIZE ESTIMATES FOR 4-32
MECHANICAL COLLECTORS
4-17 MECHANICAL COLLECTOR PRICES FOR CARBON 4-33
STEEL CONSTRUCTION VS. INLET AREA
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LIST OF FIGURES
FIGURE PAGE
NUMBER TITLE NUMBER
4-18 MECHANICAL COLLECTOR PRICES FOR STAINLESS 4^34
STEEL CONSTRUCTION VS. INLET AREA
4-19 MECHANICAL COLLECTOR SUPPORT PRICES VS. 4-35
COLLECTOR INLET AREA
4-20 MECHANICAL COLLECTOR DUST HOPPER PRICES 4-36
FOR CARBON & STAINLESS STEEL CONSTRUCTION
VS. COLLECTOR INLET AREA
4-21 MECHANICAL COLLECTOR SCROLL OUTLET PRICES 4-37
FOR CARBON & STAINLESS STEEL CONSTRUCTION
VS. COLLECTOR INLET AREA
4-22 FABRICATED 40 FT HIGH "U" TUBE HEAT EXCHANGER 4-39
PRICES WITH HOPPERS AND MANIFOLDS
4-23 SPRAY CHAMBER COST VS. INLET GAS NOLUME 4-41
4-24 QUENCHER COSTS VS. INLET GAS VOLUME 4-43
4-25 PRICES FOR FABRICATED CARBON STEEL DILUTION 4-45
AIR PORTS VS. DIAMETER AND PLATE THICKNESS
4-26 PRICES FOR SCREW CONVEYORS VS. LENGTH AND 4-46
DIAMETER
4-27 PRICES FOR INSTALLED COOLING TOWERS FOR 4-48
UNITS OF CAPACITY < 1000 TONS
4-28 PRICES FOR INSTALLED COOLING TOWER BASED ON 4-49
WET-BULB TEMPERATURE = 82°F AND APPROACH
= 10°F
4-29 CAST IRON, BRONZE FITTED, VERTICAL TUBINE 4-53
WET SUMP PUMP PRICES FOR 3550 RPM
4-30 CAST IRON, BRONZE FITTED, VERTICAL TURBINE 4-54
WET SUMP PUMP PRICES FOR 1750 RPM
4-31 CAST IRON, BRONZE FITTED, VERTICAL TURBINE 4-55
WET SUMP PUMP PRICES FOR 1170 RPM
4-32 PUMP MOTOR HP VS. CAPACITY AND HEAD FOR 4-66
VERTICAL TURBINE PUMPS
4-33 BACKWARDLY CURVED FAN PRICES VS. CLASS, CFM 4-59
' AND AP FOR ARRANGEMENT NO. 1
VI
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LIST OF FIGURES
FIGURE PAGE
NUMBER TITLE NUMBER
4-34 BHP, FAN RPM AND MOTOR AND STARTER PRICES 4-61
VS. AP AND CFM
4-35 FAN INLET AND OUTLET DAMPER PRICES AS A 4-65
FUNCTION OF CFM AND AP
4-36 V-BELT DRIVE PRICES 4-66
4-37 RADIAL FAN PRICES VS. SCFM AND AP FOR 4-68
ARRANGEMENT NO. 1
4-38 FAN RPM AND MOTOR BHP FOR RADIAL FANS 4-69
4-39 RADIAL TIP FAN PRICES 4-70
4-40 STARTER AND MOTOR PRICES FOR VENTURI 4-71
SCRUBBER APPLICATIONS (HIGH PRESSURE,
HIGH BHP)
4-41 FABRICATED CARBON STEEL STACK PRICE VS. 4-73
STACK HEIGHT & DIAMETER FOR 1/4 INCH
PLATE
4-42 FABRICATED CARBON STEEL STACK PRICE VS. 4-74
STACK HEIGHT & DIAMETER FOR 5/16 & 3/8
INCH PLATE
S
4-43 PRICES FOR TALL STEEL STACKS, INSULATED 4-75
AND LINED
5-1 ELECTROSTATIC PRECIPITATOR CONTROL SYSTEM 5-5
5-2 DRY TYPE ELECTROSTATIC PRECIPITATOR PURCHASE 5-7
PRICES VS. PLATE AREA
5-3 VENTURI SCRUBBER CONTROL SYSTEMS 5-12
5-4 1/8 INCH THICK CARBON STEEL FABRICATED 5-13
SCRUBBER PRICE VS. VOLUME
5-5 METAL THICKNESS REQUIRED VS. VOLUME AND 5-14
DESIGN PRESSURE
5-6 PRICE ADJUSTMENT FACTORS VS. PLATE THICKNESS 5-15
AND VOLUME
5-7 SCRUBBER INTERNAL SURFACE AREA AND SEPARATOR 5-16
DIAMETER AND HEIGHT VS. WASTE INLET GAS
VOLUME
vii
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LIST OF FIGIRES
FIGURE PAGE
NUMBER TITLE NUMBER
5-8 INTERNAL GAS COOLER BUBBLE TRAY COST VS. 5-17
SEPARATOR DIAMETER
5-9 FABRIC FILTER CONTROL SYSTEMS 5-25
5-10 INTERMITTENT, PRESSURE, MECHANICAL SHAKER 5-26
BAGHOUSE VS. NET CLOTH AREA
5-11 CONTINUOUS, SUCTION OR PRESSURE, PULSE JET 5-27
BAGHOUSE PRICES VS. NET CLOTH AREA
5-12 CONTINUOUS, PRESSURE, MECHANICAL SHAKER 5-28
BAGHOUSE PRICES VS. NET CLOTH AREA
5-13 CONTINUOUS, PRESSURE, RESERVE AIR BAGHOUSE 5-29
PRICES VS. NET CLOTH AREA
5-14 CUSTOM PRESSURE OR SUCTION BAGHOUSE PRICES 5-30
VS. NET CLOTH AREA
5-15 PRICES FOR THERMAL INCINERATORS WITHOUT 5-36
HEAT EXCHANGERS
5-16 PRICES FOR THERMAL INCINERATORS WITH PRIMARY 5-37
HEAT EXCHANGER
5-17 CATALYTIC INCINERATOR PRICES 5-38
5-18 ADSORPTION ISOTHERM FOR TOLUENE 5-43
5-19 PRICES FOR PACKAGED STATIONARY BED CARBON 5-45
ADSORPTION UNITS WITH STEAM REGENERATION
5-20 PRICES FOR CUSTOM CARBON ADSORPTION UNITS 5-46
5-21 FABRICATED COST OF CARBON STEEL VESSEL 5-58
5-22 SKIRT AND SUPPORT COSTS FOR CARBON STEEL VESSEL 5-59
5-23 COST OF NOZZLES 5-60
5-24 COST OF TRAY, SUPPORT PLATE OR DISTRIBUTOR 5-61
5-25 CASCADE REFRIGERATION SYSTEM FOR VAPOR RECOVERY 5-67
5-26 REFRIGERATION VAPOR RECOVERY UNITS 5-70
5-27 INSTALLED COST OF INDUSTRIAL VAPOR COMPRESSION 5-73
REFRIGERATION SYSTEMS
5-28 COST OF ELEVATED FLARES 5-77
5-29 COST OF GROUND LEVEL FLARES 5-78
viii
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LIST OF FIGURES
FIGURE PAGE
NUMBER TITLE NUMBER
6-1 FABRIC FILTER SYSTEM DESIGN 6-4
6-2 ELECTROSTATIC PRECIPITATOR SYSTEM DESIGN 6-12
6-3 VENTURI SCRUBBER SYSTEM DESIGN 6-17
7-1 CHEMICAL ENGINEERING PLANT COST INDEX 7-3
ix
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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 responsible for controlling air pollution. The purpose of this manual
is to assist those agencies in estimating the cost of air pollution control
systems for various manufacturers and processors who must comply with existing
and future standards or codes. At present, literature is available which gives
generalized cost data for control systems based on industry averages. However,
there is a wide range of magnitude in the cost data 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 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 identify 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 so that
annualized costs can be estimated.
1-1
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1.2 Organization 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
6) Absorbers
7) Refrigeration
8) Flares
In Section 2, a list of the design parameters for the various control
devices is provided and crossreferenced to the applicable industries and
pollutant sources that use these systems. Section 3 describes the procedures
used in estimating the capital and annualized costs of these systems. A
description of the operation and basic cost curvesVor these control devices
and the auxiliary equipment required in a completely integrated pollution
control system is presented in Sections 4 and 5. This description outlines
the various design options available to the engineer and the impact these
options have on the total system cost. These data represent equipment costs
based on a reference date of December, 1977 and are estimated to be accurate
to ± 20 percent, on a component basis, except where noted. In Section 6, an
example is provided of a typical application which can be controlled by each
one of three possible particulate control devices. However, the methods and
procedures, demonstrated in the example, are applicable to all industries where
the control of emissions uses one or more of these eight control systems. A
method of extrapolating the costs to a future date is discussed in Section 7.
1-2
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Section 2
APPLICATION TO INDUSTRY
None of these eight control systems can be applied universally throughout
the various industries. For instance, adsorbers, absorbers and refrigeration
are effective only with gaseous pollutants while thermal and catalytic inciner-
ators require combustible particulates or vapors for proper operation. Non-
combustible particulate-laden gas streams must be controlled by precipitators,
scrubbers, or fabric filters. Precipitators and fabric filters are used solely
for particulate collection while scrubbers may be used for both particulates
and gases (when used as a contactor/absorber). The selection of a control
system for a particular process, therefore, may be limited to only one or two
types of control devices. Table 2.1 lists industries with typical sources of
pollutants and applicable control devices that are used to control these
emissions.
In some cases, a control device may be compatable with the process but
not selected due to the particular plant location or cost of utilities. For
instance, the potentially high cost of maintenance and repair for damage due
to freezing with scrubber systems may preclude the use of these systems in
some colder northern states. The high use of electrical power and utilities
associated with venturi scrubbers would make these systems less attractive in
areas where water is scarce or electrical power is costly. Combustion processes
such as those that occur in flares and incinerators may present safety hazards
in some areas.
Product recovery is possible with all of the control devices with the
exception of flares and incinerators which chemically dispose of the pollu-
tants. In many cases, the recovered product must be further treated to produce
a reuseable item, particularly with scrubbers which may replace an air
2-1
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pollution problem with a water pollution problem if waste water treatment is
not incorporated into the system.
Typical design parameters for the collection of particulates with, fabric
filters, venturi scrubbers, and precipttators are shown in Table 2.2. These
represent the normal range of air-to-cloth ratios, venturi pressure drops, and
drift velocities associated with those control systems used in the collection
of parti oil ate pollutants from industries listed.
For gaseous pollutants, the design parameters are specifically related to
the physical and chemical characteristics of the pollutant and the concentration
of the pollutant in the gas stream. In the adsorption process, the concentra-
tion of pollutants is generally below the lower explosive limit and gas streams
are usually at atmospheric pressure where vapor pressures of pollutants are
low. An adsorbent such as activated carbon is ideally suited for these
conditions in controlling hydrocarbon emissions from spray booths, printing
presses, and processes involving the evaporation of solvents. The design
parameters for a carbon adsorber would therefore^depend on the adsorption
efficiencies of carbon. Table 2.3 lists the types of solvents and the lower
explosive limit that might be expected in the exhaust gases from such sources.
The adsorption efficiency listed for each solvent provides the engineer with
the general range of adsorbent capacities required for sizing the control
device at the specified concentrations.
The primary concept in designing an absorber is to provide the maximum
contact between the gas or solute and the liquid solvents since the rate of
mass transfer between the two is dependent on exposed surface. The design para-
meters will depend on both the solubility of the gas in the solvent and the
inlet concentration. Once the constituents and operating conditions are
defined, several different types of absorbers and some scrubbers, can be
2-2
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selected. Preliminary design data and operating parameters for these systems
are found in Sections 4 and 5 and in references 88 and 146.
The chemical and physical properties of the pollutant are most important
when refrigeration is used as a means of collection and removal. The vapor
pressure/temperature relationship for hydrocarbons and other constituents
typically found in commercial and industrial gas streams is provided in
references 88, 146 and 147.
Appendix C is a crossreference of literature information applicable to
each industry. Appendix D lists trade associations related to industries
where additional information may be obtained.
2-3
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Table 2.1 INDUSTRY POLLUTANT SOURCES AND TYPICAL CONTROL DEVICES
INDUSTRY
Asphalt Roofing
Basic Oxygen Furnaces
Benzene Handling &
Storage
Brick Manufacturing
Castable Refractories
Chemical ManufactuHm
Waste Disposal
Clay Refractories
Coal -fired Boilers
Conical Incinerators
Cotton Ginning
Degreasing
SOURCE
1) Saturator and
storage tanks
1) Basic oxygen furnace
2) Charging hood
1) Vents, storage
tanks
1) Tunnel kiln
2 Crusher, mill
3 Dryer
4) Periodic kiln
1 Electric arc
2 Crusher, mill
3 Dryer
4) Mold and shakeout
1) Miscellaneous
sources
1) Shuttle kiln
2) Calciner
3) Dryer
4) Crusher, mill
1) Steam generator
1) Incinerator
1) Incinerator
1) Degreaser tank
CONTROL SYSTEM
1) Scrubber,
preclpltator,
afterburner
1) Preclpltator,
scrubber, bag house
2) Same as 1
1) Afterburners,
adsorbers,
refrigeration
1) Scrubber, baghouse
precipitator
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 ) Afterburners ,
flares
1) Baghouse, precipi-
tator, scrubber
2) Same as 1
3) Same as 1
4) Baghouse, precipi-
tator
1) Preclpltator,
scrubber, baghouse
1) Scrubber
1 Scrubber
1) Adsorber,
refrigeration
CAPTURE DEVICE
1 ) Canopy hood and
direct exhaust
1) Full -canopy hood
2) Canopy hood
1) Direct exhaust
1) Direct exhaust
2) Canopy hood
3) Same as 1
4) Same as 1
1 Direct exhaust
2 Canopy hood
3 Direct exhaust
4 Canopy hood
1) As required
1 Direct exhaust
2 Same as 1
3) Same as 1
4) Canopy hood
1 Direct exhaust
1) Direct exhaust
1) Direct exhaust
1) Slot or canopy hood
TYPICAL GAS FLOW
DESIGN RATE
1) 10,000-20,000 cfm
Per saturator hood
handling a 36" wide
roll at line speeds
of up to 500 fpm
1) Function of lance
rate and hood
design
2) 300 fpm hood face
1) As required
1) Combustion air fan
capacity
2) 250 fpm hood face
3) Same as 1
4) Same as 1
1 Infilt. air
2 250 fpm hood face
3 Fan capacity
4 Same as 2
1) As required
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 air rate
1 50 cftn/ft open area
TYPICAL GAS
TEMPERATURE
1) 80-300F
1 ) 3500-4000F
2) 150-400F
1) 70-1 OOF
1 ) 200-600F
2) 70F mill
3} 250F
4) Same as 1
1 3000-4000F
2 70F
3 300F
4) 150F
1) As required
1 150-800F kiln
2 Same as 1
3) 250F
4) 70F
1) 300F-700F
1) 400-700F
1 500- 7 OOF
1 70F
-------
Table 2.1 (Continued)
INDUSTRY
Detergent
Manufacturing
Direct Fjring of Meat
Distilled Whiskey
Processing
Dry Cleaning
Electric Arc
Furnaces
Feed Mills
Ferroalloy Plants
a) HC Fe Mn
b) 50% Fe Si
c) HC Fe Cr
Gasoline Bulk
Terminals & Storage
Glass Manufacturing
Graphic Arts
SOURCE
1) Spray dryer
1) Smokehouse
1) Distillation
process
1) Washer, extractor,
tumbler
1) Arc furnace
2) Charging and
tapping
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) Vents, storage
tanks
1) Regenerative tank
furnace
2) Weight hoppers and
mixers
1) Presses
2) Lithographies, meta
decorating ovens
CONTROL SYSTEM
1) Scrubber, baghouse
1 ) Afterburners ,
electrical
precipitators
1) Adsorbers,
afterburners
1) Adsorber
1) Baghouse, scrubber,
precipitator
2) Same as 1
1) Baghouse, scrubber
2} Same as 1
3) Same as 1
4) Same as 1
1) Scrubber, baghouse,
precipitator
2) Scrubber
3) Same collector or
baghouse
1) Afterburners,
adsorbers,
refrigeration
1) Baghouse, scrubber
precipitator
2) Same as 1
1 ) Adsorbers ,
afterburners
2) Afterburners
CAPTURE DEVICE
1) Direct exhaust
1) Direct exhaust
1) As required
1) Direct exhaust
1) Direct exhaust,
full /side draft hood
2) Canopy hood
1) Direct exhaust
2) Canopy hood
3) Direct exhaust
4) Canopy hood
1) Full or canopy hood
2) Direct exhaust
3) Canopy
1) Direct exhaust
1) Direct exhaust
2) Canopy
1 ) Hoods
2) Hoods
TYPICAL GAS FLOW
DESIGN RATE
1) Fan capacity
1) 1-4 cfm/sf floor area
1) As required
1) Fan capacity
1) Function of lance
rate and hood design-
up to 200,000 acfm
2) 250 fpm hood face
1) 250 fpm canopy hood
face velocity
2) Same as 1
3) Air heater flow rate
(dryer)
4) Same as 1
1) 2500-5500 scfm/mw
with scrubber
2) a) 220 scfm/mw
b) 180 scfm/mw
c) 190 scfm/mw
3) 200 cf in/ft/
1) As required
1) Fan capacity
2) 200 fpm/ft2
1) 3,000-11,000 cfm/ press
2} 3,000-60,000 cfm/oven
TYPICAL GAS
TEMPERATURE
1) 180-250F
1) 120-150F
1 ) As requ i red
1) 70F
1) 3000F (direct
exhaust)
2) 150F (canopy)
1) 70F
2) 70F
3) 170-250F
4) 70F
1) 400-500F open arc
2) 1000-1200F
closed arc
3) 150F hood
1) 70-100F
1) 600-850F furnace
2) 100F mixers
1) 100F
2) 400-600F
ro
i
in
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Table 2.1 (Continued)
INDUSTRY
Gray Iron Foundries
Industrial & Utility
Boilers
Insulation Mire
Varnish
Iron Ore
Benefication
Iron & Steel
(Sintering)
Kraft Recovery
Furnaces
Lime Kilns
Maleic Anhydride
Miscellaneous
Refinery Sources
SOURCE
1) Cupola
2) Electric arc furnace
3) Core oven
4) Shakeout
1) Boiler
1) Spray booths
2) Flow coating
machines
3) Dip tanks
4) Roller coating
machines
1) Crusher
2) Sinter machine
1) Sinter machine
a) Sinter bed
b) Ignition fee.
c) Wind boxes
z) a) sinter crusher
b) Conveyors
c ) Feeders
1) Recovery furnace
and direct contact
evaporator
1) Vertical kilns
2) Rotary sludge kiln
1) Benzene storage
tanks, process vent
& Vac. refin. vent
1) Vents, storage
tank, etc.
CONTROL SYSTEM
1) Afterburner-baghouse
for closed cap,
Af terburner-prec 1 pi -
tator for closed cap
scrubber
2) Bag house, scrubber
pr eel pi tator
3) Afterburner
4) Bag house
1) Precipitator,
baghouse
1) Adsorbers, absorbers,
afterburners
2) Same as 1
3) Same as 1
4) Same as 1
1) Baghouse, scrubber
2) Same as 1
1) Precipitator,
baghouse, scrubber
2) Baghouse, scrubber
S
1) Precipitator,
scrubber
1) Baghouse, scrubber,
precipltator
2) Scrubber, precipi-
tator
1) Adsorbers, after-
burners
1) Afterburner, flare
adsorbers, absorbers
refrigeration
CAPTURE DEVICE
1) Direct exhaust
2) Direct exhaust, full/
side draft hood
3) Direct exhaust
4) Full/side draft hood
1) Direct exhaust
1) Direct exhaust
2) Exhaust hood
3) Exhaust hood
4) Exhaust hood
1) As required
2) As required
1) Down draft hood
2) Canopy hood
1) Direct exhaust
1) Direct exhaust
2) Direct exhaust
1) Direct exhaust
1) As required
TYPICAL GAS FLOW
DESIGN RATE
1) Tuyere air
+ Infll. door air
+ afterburner
second air
2) 2000 cfm/ft2 hood
opening
3) Fan capacity 9
4) 200-500 cfm/ft hood
1) Fan capacity
1) 100-150 cfm/ft2
booth opening
1) As required
2) As required
1) Based on bed size
2) 250 fpm hood face
1) Primary and
secondary air supply
capacity
1) Combustion air
rate
2) Combustion air
rate
1) As required
1) As required
TYPICAL GAS
TEMPERATURE
1) 1200-2200F
2) -2500F direct exh.
-400F hood
3) 150F
4) -150F
1) 250-800F
1) 100F
1) As required
2) As required
1 ) 150-400F
sinter machine
2) 70F conveyors
1) 350F
1) 200-1200F
2) 200-1200F
1) 70-100F
1) As required
ro
i
en
-------
Table 2.1 (Continued)
INDUSTRY
Municipal Incinerator
Non-Metatllc
Minerals Industry
Onshore Crude 011
Production
Organic Chemicals
Paint Manufacturing
Petroleum Catalytic
Cracking
Petroleum Storage
Pharmaceuticals
Phosphate
Fertilizer
Phosphate Rock
Crushing
SOURCE
1) Incinerator
1) Miscellaneous
sources
1) Vents, storage tanks
1) Miscellaneous
sources
1) Varnish kettles
1) CO boiler from FCC
1) Vents, storage
tanks
1) Reactor
2) Crystal Hzer
3) centrifuge
4) Filter, dryer
5) Dlst. column
1) Digester vent air
2) Filters
3) Sumps
1) Crusher & screens
2) Conveyor
3) Elevators
4) Fluldlzed bed calci-
ner, grinder & dryer
CONTROL SYSTEM
1) Scrubber, preclpl-
tator, baghouse,
afterburner
1} Scrubbers, baghouse
1) Adsorbers, after-
burners, refrlgeratlor
1) Scrubbers, adsorbers,
absorbers, refrigera-
tion flares
1 ) Afterburners
1) Predpltator
1 ) Afterburners ,
adsorbers,
refrigeration
1) Adsorbers, refrigera-
tion, Incineration
2) Sajne as 1
3) Same as 1
4) Same as 1
5) Same as 1
1 Scrubber, baghouse
2 Same as 1
3 Same as 1
1} Baghouse, scrubber,
preclpltator
2) Same as 1
3) Same as 1
4) Same as 1
CAPTURE DEVICE
1) Direct exhaust
1) As required
1) As required
1) As required
1) Exhaust hood
1) Direct exhaust
1) Direct exhaust
1) Direct exhaust
2) Direct exhaust
3) Direct exhaust
4) Direct exhaust
5) Direct exhaust
1) Hood
2) Sane as 1
3) Same as 1
1) Canopy hood
2) Same as 1
3) Same as 1
4) Direct exhaust
TYPICAL GAS FLOW
DESIGN RATE
1) Combustion air fan
capacity where
applicable
1) As required
1) As required
1) As required
1) 100-300 cfm/200-375
gal. Kettle
1) Regeneration air
rate + boiler
combustion air
1) As required
1) 50-300 scfm
2) 50-300 scfm
3) 10-50 scfm
4) 10-800 scfm
5) 500-900 scfm
1) Process stream rate
2) Same as 1
3) Same as 1
1) 350 cfm/ft belt width
at speeds ~200 fpm
500 cfm/ft belt width
at speeds ~200 fpm
2) 100 cfm/ft of casing
cross-section
(elevator)
50 cfm/ft of screen
area
3) Combustion air rate
4) Blower rate
TYPICAL GAS
TEMPERATURE
1) 500-700F
1) As required
1) 70-100F
I) As required
1) 500F
1 ) 500F
1) 70-100F
1) As required
2) As required
3) As required
4) As required
5) As required
1) 150F
2) Same as 1
3) Same as 1
1) 70F hoods
2) Same as 1
3) Same as 1
4) 600-1500F calciner
-------
Table 2.1 (Continued)
INDUSTRY
Poly vinyl Chloride
Production
Portland Cement
Primary Copper, Lead,
Z1nc Smelters
Pulp and Paper
Refuse Waste Disposal
Rubber Products
(Tires)
Secondary Aluminum
Secondary Copper
Smelters
Service Stations
SOURCE
1) Process equipment
vents
1) Rotary Mln
a) Wet
b) Dry
2) Crushers and
conveyors
3) Dryers
1) Roaster, converter
1) Flu1d1zed bed
reactor
1 ) Furnace
1) Rubber mill and
mixers
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
furnace
4 ) Converters
5. El. Induction
furnaces
1) Loading rack
CONTROL SYSTEM
1 ) Adsorbers ,
afterburners
1) Predpltators,
baghouses
2) Baghouses
3) Predpltators,
baghouses
1) Preclpltator,
scrubber, absorber
1) Scrubber
1 ) Afterburner
1) Baghouse
1) Scrubber (low energy)
+ baghouse,
preclpltator
2) Same as 1
3) Same as 1
4) Same as 1 *
5) Same as 1
6) Same as 1
1) Baghouse, scrubber,
preclpltator
2) Same as 1
3) Same as 1
4) Same as 1
5) Same as 1
1 ) Adsorbers ,
refrigeration
CAPTURE DEVICE
1) Direct exhaust
1) Direct exhaust
2) Canopy hoods
3) Direct exhaust
1) Direct exhaust
1) Direct exhaust
1) Direct exhaust
1) Canopy hood
1) Canopy hood (hearths)
direct exhaust
2) Same as 1
3) Same as 1
4) Same as 1
5) Same as 1
6) Same as 1
1) Direct exhaust,
canopy hood, full
hood
2) Same as 1
3) Same as 1
4) Same as 1
5) Same as 1
1) Balanced system/
direct exhaust
TYPICAL GAS FLOW
DESIGN RATE
1) Process gas stream
rate
1) Combustion air rate
where applicable
2) 250 fpm hood face
3) Same as 1
1) As required
1) Combustion air rate
1) As required
1) 100 fpm through face
1) Max. plume vol .
+ 20% (hearths)
2) Infiltrated air
3) Sane as 2
4) Sajne as 2
5) Same as 2
6) Same as 2
1) 200 fpm/ft2
canopy hood
2) Max. plume vol. + 20%
3) 1800 fpm Infiltrated
air (full hood)
4) Based on type capture
5) Same as 4
1) Loading flow rate
TYPICAL GAS
TEMPERATURE
1) -15 to 130F
1) 150-850F kilns
2) 70F crushers and
conveyors
3) 200F dryers
1) As required
1) 600-1500F
1) 500-700F
1) 70F
1) 1600F fluxing,
600F holding
hearth
2) Based on type
capture
3} Same as 2
4) Same as 2
b) 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) 70-1 OOF
ro
i
CD
-------
Table 2.1 (Continued)
INDUSTRY
Sewage Sludge
Incinerators
Surface Coatings -
Spray Booths
Vegetable 011
Processing
SOURCE
1) Multiple hearth
Incinerator
2) Flu1d1zed bed
Incinerator
1) Spray booth
1} Solvent extraction
process
CONTROL SYSTEM
1) Scrubber
2) Same as 1
1 ) Adsorber ,
afterburner
1) Adsorbers, scrubbers
CAPTURE DEVICE
1) Direct exhaust
2) Same as 1
1) Canopy hood
1} As required
TYPICAL GAS FLOW
DESIGN RATE
1) Combustion air
blower capacity
2) Same as 1
1) 150cfm/ft2 hood,
100 fpm booth
face velocity
1) As required
TYPICAL GAS
TEMPERATURE
1) 600 to 1500F
2) Same as 1
1) 70F
1) 100F
ro
10
1) The table and listings are only intended as a guide to Illustrate the typical range of flow rates and temperatures that might be expected with the
designated control systems. The source of these data are contained In Appendix C and cross-referenced to industries on page C-l For further detail
the user can refer to the appropriate EPA control technique documents for the various industries and sources " '
-------
Table 2.2 DESIGN PARAMETERS FOR RESPECTIVE
INDUSTRIES FOR HIGH EFFICIENCY PERFORMANCE
1.2
Industry
Basic oxygen furnaces
Brick manufacturing
Castable refractories
Clay refractories
Coal fired boilers
Detergent manufacturing
Electric arc furnaces
Feed mills
Ferroalloy plants
Glass manufacturing
Gray iron foundries
Iron and steel (sintering)
Kraft recovery furnaces
Lime kilns
Municipal incinerators
Petroleum catalytic cracking
Phosphate fertilizer
Phosphate rock crushing
Polyvinyl chloride production
Secondary aluminum smelters
Secondary copper smelters
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-.15
1.5-2.0
2.0
1.5
1.5-2.0
1.5-2.0
1.5-2.0
1.8-2.0
Pulse
Jet
6-8
9-10
8-10
8-10
5-6
6-8
10-15
9
7-8
7-8S
8-9
8-9
5-10
7
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
Venturi
Scrubber
In. of
Water
40-60
35
11
15
10-40
40-80
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
.17-. 25
.2-. 33
.'12-.18
.35
.12-. 14
1) High Efficiency - an outlet loading of less than 0.04 gr/scf.
2) Source - see page C-l, Appendix C.
2-10
-------
Table 2.3 EFFICIENCY OF CARBON ADSORPTION FOR SELECTED
SOLVENTS AND SPECIFIED OPERATING CONDITIONS
Solvent
Acetone
Benzene
n-Butyl acetate
n-Butyl alcohol
Carbon tetrachloride
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 Naphtha 2
Xylene
Average Inlet
Concentration
(ppm)
1,000
10
150
100
10
300
400
1,000
500
500
100
250
400
200
200
500
200
100
100
200
100
1,000
500
100
Acceptable
Ceiling
Concentration
(ppm)
25
25
1,000
200
300
200
Lower Explosive
Limit
(% by volume
in air)
2.15
1.4
1.7
1.7
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
Ib solvent/
100 Ib
carbon
8
6
8
8
10
6
8
8
6
6
8
8
8
7
7
10
8
7
20
7
15
8
7
10
NOTE:
2-11
1) Efficiencies are based on 200 cfm of 100 F solvent-laden air (at the
specified concentrations) per hundred pounds of carbon per hour.
Source: Manzone, R.R. et al., "Profitability Recycling Solvents from
Process Systems", Hoyt Manufacturing corp, Pollution Engineering Oct. 1973.
More precise carbon estimation procedures are given in Section 5.5
2) Varnish makers & painters naphtha.
-------
Section 3
COST ESTIMATING PROCEDURES
Several methods of varying degrees of accuracy are available for estimating
the capital costs of systems. These methods range from presenting overall
installed costs on a per unit basis, to detailed cost estimates based on
preliminary designs, schematics, and contractor quotes. The least accurate
method is the equating of overall capital costs to a basic operating parameter
such as tons per hour or cfm. An example is a typical installed cost for a
fabric filtration system of approximately seven dollars per cfm. This figure
is developed from average costs of many installations which may range from
three to twelve dollars per cfm. The low end of the range might represent an
installation using standard equipment, installed by plant personnel, and just
marginally meeting current regulations. The high end of the cost range may
represent a system designed for: 1) the inclusion of standby equipment and
redundant systems, 2) overprovision for safety, 3) fully automated operation
with complex controls, and 4) expensive materials of construction or other
custom features. These factors affect both equipment and installation costs,
and therefore the degree of accuracy produced using an estimating method
based on cfm alone would, at best, provide accuracies in an "order of magnitude"
category (probable accuracy of +50%, -30%) Ref. 149.
The detailed cost estimate, in turn, can produce accuracies of ±5 percent
depending on the amount of perliminary engineering involved. These estimates
take many months of engineering effort and require process and engineering
flow sheets, material and energy balances, plot plans, and equipment arrange-
ment drawings before a cost estimate can be developed. For first-cut estimating
purposes,, a technique for developing capital costs must be used that is between
these two extremes that can provide accuracies of approximately ±20- percent.
3-1
-------
The technique used in this manual for determining capital costs for a specific
pollution control system is based on the factored method of establishing direct
and indirect installations costs as a function of known equipment costs. This
approach is basically a modified "Lang Method" of cost estimating whereby cost
factors for installation are applied to the cost of the equipment. The result-
ing cost estimates using this technique can provide accuracies of plus or minus
20 percent for new installations. This is somewhat better than a "study
estimate" which has an error limit on the order of plus or minus 30 percent.
The cost factors developed in this manual are based on both quoted and
estimated installation costs of pollution control systems. The annual operating
costs for these systems are based on unit costs for utilities and operating
and maintenance labor and materials together with fixed percentages of capital
costs for the indirect costs.
3.1 Capital Costs
The capital costs of a pollution control system consisting of the delivered
s
equipment costs for the control device and all the auxiliary equipment and
appurtenances plus the direct and indirect costs of installation are shown in
Table 3.1. The equipment costs represent a firm cost since these are obtain-
able from the supplier's quoted prices or from curves compiled from average
costs for the specific type of equipment such as those provided in Section 4
and 5. The cost of installation can vary substantially from one system to
another depending on such features as: 1) the degree of assembly of the control
device; i.e., whether it is delivered as a packaged unit or must be field
assembled, 2) the geographic location of the plant in regard to local wage
rates and availability of contractors, 3) the topography of the land site
(whether the land is within the battery limits or outside and must be purchased),
4) the availability of service facilities, i.e., whether electricity, water,
steam, etc., are at or near the site, and 5) whether the equipment is to
3-2
-------
TABLE 3.1 CAPITAL COSTING
- (FABRIC FILTERS)
DIRECT COSTS
D
a) Control Device
b) Auxiliary
Instrument
Taxes
Freight
TOTAL
c)
d)
e)
2)
a) Foundation
Erection &
Electrical
Pi pi ng
Insulation
Painting
Site Preparation
Facilities &
TOTAL
b)
c)
d)
e)
f)
9)
h)
INDIRECT COSTS
3) INSTALLATION IN
a) Engineering
b) Construetio
c) Construction Fee
d) Start Up
e) Performance Test
f) Model Study
g) Contingencies
TOTAL
1* 2*
TYPICAL COST v COST
FACTOR ADJUSTMENT RANGE
IENT COSTS
ce
uipment
& Controls
L
ECT COSTS
& Supports
and! ing
tion
Buildings
[RECT COSTS
i Supervision
& Field Expenses
Fee
Test
>
i
Cost Per
Cost Per
0.10
0.03
0.05
1.00
0.04
0.50
0.08
0.01
0.07
0.02
As Req'd.
As Req'd.
1.72
0.10
0.20
0.10
0.01
0.01
None
0.03
9 17
X .5-3
X .3-1.6
X .2-2
X .2-2
X 0-2
X 0-2
X .5-3
X .5 - 1.5
X .5-2
X 1-10
3*
SYSTEM
COST FACTOR
0.05 to
0.01 to
0.01 to
l no
n Q4.
0.10 to
n Oft
o m
n n?
- 0.02
0 to
0 to
-1.28 to
0.05 to
0.10 to
0.05 to
- 0.01
- 0.01
0.03 to
-.1 « tn
0.30
0.05
0.10
1.0
2
2
6.18
0.30
0.30
0.20
0.30
7 in
* Based on Tables 3.2 and 3.3.
3-3
-------
be outside or enclosed in buildings. The cost of retrofitting an existing
plant process may involve one or more of the conditions 1 to 5 plus it often
involves the dismantling and removal of existing equipment, a task which could
be both costly and time consuming.
In assessing the relationship between direct and indirect costs of
installation to the cost of equipment, it is necessary to apply some adjust-
ments to those cost items that have a minor impact on equipment costs but are
heavily influenced by such items as plant size, plant location, safety and
type of process. This is particularly true when considering the indirect
costs such as engineering, construction fees, and contingencies. Cost factors
for engineering and construction fees will depend on whether the system
utilizes standard or custom designed equipment and if the process entails
new technology or is simply a duplicate of an existing system. Contingencies
may be based on whether the process is firm or tentative and subject to changes
The cost factors and cost adjustments must also be evaluated on a per
system basis. For instance, the cost of piping may be negligible for a fabric
filtration system but it becomes an accountable item for scrubbers or wet
precipitators. The cost of insulation is only relevant to those processes
that handle hot gas streams or provide some type of cooling in the collection
process.
The use of the cost factors and adjustments must be applied with some
engineering judgement. The application of these factors will depend, to some
extent, on what is included in the cost of the equipment. As shown in
Table 3.1, a typical cost factor can be developed which represents the
average cost factor based on the analysis of several similar systems. In
the analysis of these systems, a deviation in some cost factors for the same
item can be attributed to some cost adjustment. For instance, if a fabric
3-4
-------
filter is purchased as a standard unit and factory-assembled, the equipment
cost will be higher than the same unit shipped "broken-down" or in modules;
however, the installation costs for handling and erection will be lower for
the factory-assembled unit. If a typical cost factor for handling and
erection was applied to the equipment cost of both units without a cost ad-
justment, the error in the handling and erection costs of the factory-assembled
unit essentially would be compounded. Therefore, the typical cost factors,
shown in column 1 of Table 3.1, which indicate the average values for each
component cost for a particular type of pollution control system, are then
multiplied by a cost adjustment to establish the system cost factor for a
specific application. The cost adjustments are used for any type of system
and are solely provided as modifiers for the cost factor. The cost adjustment
can be considered as a means of compensating for cost variations that are not
directly attributable to the cost of equipment. The system cost factor is
then multiplied by the total equipment cost to determine the estimated
component cost in dollars. A description of the capital cost components with
their cost factors, adjustments, and their usage is presented in the following
sections.
3.1.1 Purchased Equipment Costs
The purchased equipment costs represent the delivered costs of the
control device, auxiliary equipment, and instrumentation. These costs are
developed by first establishing the design and operating characteristics of
the equipment that will satisfy the pollution control requirements of a
specific industrial process. The F.O.B. costs are then established from
curves, graphs, and data found in Sections 4 and 5 of this manual which cover
the cost of-the control device and selected auxiliary equipment. The prices
listed represent flange-to-flange costs and generally include internal
3-5
-------
electricals and controls except where noted. Instrumentation is not included
in Sections 4 and 5 since it is usually provided as an optional feature in
most equipment costs. The typical cost factor for instrumentation can be
considered as 10% of the equipment costs as shown in Table 3.1 (Ref. 156). A
cost adjustment is also provided for this component cost as shown in Table 3.2.
Freight costs within the U.S. are generally 5% of the equipment cost although
a cost adjustment must also be included for unusually remote or distant sites
as shown in Table 3.2 (Ref. 150). The purchased equipment costs, which includes
the F.O.B. equipment cost, instrumentation, freight and taxes, then becomes the
basis for determining the direct and indirect installation costs. This is
done by multiplying the appropriate factor for each element by the purchased
equipment cost (NOTE: Table 3.1 expresses the purchased equipment cost as
unity).
Since the cost of delivered purchased equipment represents the basis for
determining installation costs, those items that are not field fabricated
should be accounted for as purchased components and included in the purchased
s
equipment costs. In typical factorial cost estimating methods such as the
Lang method, the cost of items such as hoods, ducting, etc., are only
included in the installation costs and usually represented as a percentage of
equipment costs. These costs, however, can be as much as the cost of the
control device itself. Since most of the ductwork is shop fabricated, cost
of the ductwork should be developed for each specific application and
included in the cost of auxiliary equipment. Curves are provided in Section
4 to estimate the cost of these components. Only the handling, erection,
insulation, and painting of the ductwork are included in the installation
costs and are designated as a percentage of the total equipment costs. Thus,
the cost of items normally shop fabricated are accurately accounted for as
3-6
-------
*
TABLE 3.2 COST ADJUSTMENTS
A) INSTRUMENTATION COST ADJUSTMENT
1) Simple, continuous manually operated 0.5 to 1.0
2) Intermitten operation, modulating flow with
emissions monitoring instrumentation 1.0 to 1.5
3) Hazardous operation with explosive gases
and safety backups 3
B) FREIGHT
1) Major metropolitan areas in continental U.S. 0.2 to 1.0
2) Remote areas in continental U.S. 1.5
3) Alaska, Hawaii, and foreign 2
C) HANDLING AND ERECTION
1) Assembly included in delivered cost with
supports, base, skids included. Small to
moderate size equipment 0.2 to 0.5
2) Equipment supplied in modules, compact
area site with ducts and piping less than
200 ft. in length. Moderate size system 1
3) Large system, scattered equipment with
long runs. Equipment requires fabrication
at site with extensive welding and erection 1 to 1.5
4) Retrofit of existing system; includes
removal of existing equipment and renova-
tion of site. Moderate to large system 2
D) SITE PREPARATION
1) Within battery limits of existing plant;
includes minimum effort to clear, grub,
and level 0
2) Outside battery limits; extensive leveling
and removal of existing structures;
includes land survey and study 1
3) Requires extensive excavation and land
ballast and leveling. May require
dewatering and pilings 2
*
Based on data obtained in refs. 150, 156, 159.
3-7
-------
TABLE 3.2 COST ADJUSTMENTS (CONTINUED
COST ADJUSTMENT
E) FACILITIES & BUILDINGS
1) Outdoor units, utilities at site 0
2) Outdoor units with some weather enclosures.
Requires utilities brought to site, access
roads, fencing, and minimum lighting 1
3) Requires building with heating and cooling,
sanitation facilities, with shops and office.
May include railroad sidings, truck depot,
with parking area 2
F) ENGINEERING & SUPERVISION
1) Small capacity standard equipment, duplication
of typical system, turnkey quote 0.5
2) Custom equipment, automated controls 1 to 2
3) New process or prototype equipment, large
system 3
6) CONSTRUCTION & FIELD EXPENSES
1) Small capacity systems .5
2) Medium Capacity systems ^ 1
3) Large capacity systems 1.5
H) CONSTRUCTION FEE
1) Turnkey project, erection and installation
included in equipment cost .5
2) Single contractor for total installation 1
3) Multiple contractors with A&E firm's super-
vision 2
I) CONTINGENCY
1) Firm process 1
2) Prototype or experimental process subject
* u 3 to 5
to change
3) Guarantee of efficiencies and operating
specifications requiring initial pilot tests, 5 to 10
deferment of payment until final certification
of EPA tests, penalty for failure to meet
completion date or efficiency.
3-8
-------
purchased equipment. The cost burden for handling and erecting these items
becomes a smaller portion of the total installed cost of the system, and
hence, any inaccuracies in the percentage factors will have a lesser effect
on the total estimated cost of the system.
3.1.2 Installation Costs
Installation costs consist of the direct expenses of material and labor
for foundations, structural supports, handling and erection, electrical,
insulation, painting, site preparation, and facilities; plus the indirect
expenses for engineering and supervision, construction and field expenses,
construction fees, start up, performance tests, model studies, and contingen-
cies. In considering the direct costs, site preparation, buildings and
facilities are items that have little or no relationship to the cost of the
purchased equipment and therefore some cost adjustment, as shown in Table 3.2,
must be used to compensate for added costs due to unusual requirements.
Examples of unusual site preparation would be the removal of existing structures
before construction or a potential site which is a bog or swamp. Although
handling and erection are related to equipment costs, some adjustment must
also be made for either field erection or factory assembly of the control
device and auxiliary equipment as well as the type of installation, i.e., new
or retrofit of an existing process.
Variations in the indirect expenses can be substantial since items such
as engineering, construction fees, and contingencies are related to contracting
methods and the overall magnitude of the project rather than the equipment
costs. These items all require some adjustment based on system size and
contracting arrangement. Other cost items such as model studies may appear in
unusual circumstances such as large electrostatic precipitator systems or
*
other systems where the level of previous experience may be limited.
3-9
-------
In evaluating the installation costs of all systems, it is assumed that
the installation is performed by an outside contractor and not by plant
personnel. In addition, the cost factors will change for different types of
systems since many of the components are dissimilar items. Table 3.3 summarizes
the estimated cost factors for each system. Cost adjustments of Table 3.2
should be applied to these cost factors, where appropriate, to develop the
estimated capital costs of a specific application.
3.2 Annualized Costs
The typical annualized costs, shown in Table 3.4, consist of the direct
expenses of labor and materials for operation and maintenance, the cost of
replacement parts, utility costs, and waste disposal; plus the indirect costs
of overhead, taxes, insurance, general administration and the capital recovery
charges. The unit costs are only samples and can vary significantly from
installation to installation. The direct costs of labor and utilities are
based on average rates as of December, 1977 that have been developed by the
s
Bureau of Labor Statistics. The cost of replacement parts is based on the
purchased list price of those components and materials that have a known
limited life or replacement schedule. Waste disposal costs are only applicable
to some systems where the collected pollutant has no value and must be removed
to a disposal site. In most cases, the controlled pollutant can either be
recovered and used again in the primary process or is disposed of by the pollu-
tion control system itself, e.g., by combustion in incinerators and flares.
The indirect operating costs are basically related to the capital invest-
ment with the possible exception of overhead. Overhead expenses include the
cost of employee fringe benefits, medical and property protection, cafeteria
expenses, etc. and are accounted for as a percentage of direct salaries or
payrol1.
3-10
-------
TABLE 3.3 CAPITAL COST SUMMARY*
DIRECT COSTS
1) PURCHASED EQUIPMENT. COSTS
a) Control Device
b) Auxiliary Equipment
c) Instruments & Controls
d) Taxes
e) Freight
TOTAL
2) INSTALLATION DIRECT COSTS
a) Foundations & Supports
b) Erection & Handling
c) Electrical
d) Piping
e) Insulation
f) Painting
g) Site Preparation**
h) Facilities & Buildings**
TOTAL
INDIRECT COSTS
3) INSTALLATION INDIRECT COSTS
a) Engineering & Supervision
b) Construction & Field Expenses
c) Construction Fee
d) Start Up
e) Performance Test
f) Model Study
,g) Contingencies
TOTAL
Values based on average of cost factors reduced from cost estimates.(Ref. 148, 160)
** Costs for site preparation, facilities, and buildings can be obtained from Reference 171,
ESP
As Req'd
As Req'd
0.10
0.03
0.05
1.00
0.04
0.50
0.08
0.01
0.02
0.02
As Req'd
As Req'd
1.67
0.20
0.20
0.10
0.01
0.01
0.02
0.03
2.24
VS
0.06
0.40
0.01
0.05
0.03
0.01
1.56
0.10
0.10
0.10
0.01
0.01
0.03
1.91
FF
0.04
0.50
0.08
0.01
0.07
0.02
1.72
0.10
0.20
0.10
0.01
0.01
0.03
2.17
T&CI
0.08
0.14
0.04
0.02
0.01
0.01
1.30
0.10
0.05
0.10
0.02
0.01
0.03
1.61
ADS
0.08
0.14
0.04
0.02
0.01
0.01
1.30
0.10
0.05
0.10
0.02
0.01
0.03
1.61
ABS
0.12
0.40
0.01
0.30
0.01
0.01
1.85
0.10
0.10
0.10
0.01
0.01
0.03
2.20
R
0.08
0.14
0.08
0.02
0.10
0.01
1.43
0.10
0.05
0.10
0.02
0.01
0.03
1.74
F
0.12
0.40
0.01
0.02
0.01
0.01
1.57
0.10
0.10
0.10
0.01
0.01
0.03
1.92
-------
TABLE 3.4 BASIS FOR ESTIMATING ANNUALIZED COSTS
ISJ
DIRECT OPERATING COSTS
1) Operating Labor
a) Operator
b) Supervisor
2) Operating Materials
3) Maintenance
a) Labor
b) Material
4) Replacement Parts
5) Utilities
a) Electricity
Fuel Oil
Natural Gas
Plant Water
Water Treatment & Cooling Water
Steam
Compressed Air
6) Waste Disposal
INDIRECT OPERATING COSTS
7) Overhead
8) Property Tax
9) Insurance
10) Adminstration
11) Capital Recovery Cost
CREDITS
12) Recovered Product
b)
c)
d)
e)
f)
g)
COST FACTOR
$7.87/man-hour
15% of la
As Required
$8.66/man-hour
100% of 3a
As Required
$0.0432/Kwh
$0.47/gal
$1.98/Mcf
$0.25/1000 gal
$0.10/1000 gal
$5.04/Mlb
$0.02/1000 cf
$5-ld/Ton
80% of la + Ib + 3a
1% of capital costs
1% of capital costs
2% of capital costs
0.16275 (as an example
of 10% and an equipment
life of 10 years)
As Required
REFERENCE
USDL, BLS average mill workers rate $6.56/h
plus fringes of 20%, May 1977.
Ref. 150
Hourly rate of 10% premium
labor
over operating
USDL, BLS Consumer Price Index for
500/Kw/md., May,-1977.
USDL, BLS Consumer Price Index, May 1977
USDL, BLS Consumer Price Index, May 1977
Ref. 156 updated 1977
Ref. 156 updated 1977
Fuel @ $4.19/M Lb steam plus ~ 16% oper & Main.
Ref. 156 updated 1977
Ref. 150
Ref. 150
Ref. 150
Ref. 150
-------
The operating costs must be adjusted for any credits that are obtained
from the reuse or sale of recovered products or from the recovery of heat and
energy from the process. Credits such as solvent recovery can significantly
offset control expenses and must be considered as an important factor in an
accurate cost analysis.
3.2.1 Direct Operating Costs
Labor and material costs for operation and maintenance of pollution
control systems vary substantially between plants due to the degree of
automation of the system, equipment age, characteristics of the gas stream,
operating periods and some generalizations must be made to develop a reason-
able method of estimating these costs. Normally these costs represent from
2 to 8 percent of the total annualized costs with the remainder reflecting
the cost of utilities and capital charges. In general, operating labor and
supervision will be reduced with increased system automation. Small systems
which operate intermittently or on demand may require a full time operator
for start-up, control, and shutdown while the system is in operation. In
contrast, larger automated systems operating continuously may only require
a short period per shift for monitoring purposes. The total annual labor
cost is also a function of the number of 8-hour operating shifts per year.
Small plants may be expected to operate one shift per day, five days per
week, and fifty weeks per year while large plants such as those in the basic
metals, petroleum, and chemical industries would be expected to operate
three shifts per day for 365 days. The operator labor, therefore, should be
estimated on a man-hours per shift basis for the particular types of system.
For large, automated, continuously operated systems, the operating labor can
be estimated as shown in Table 3.5. Estimates of maintenance labor are also
provided for large capacity systems handling non-corrosive materials. These
estimates only reflect the cost of preventative maintenance. Where periodic
3-13
-------
TABLE 3.5 ESTIMATED LABOR HOURS PER SHIFT*
CONTROL DEVICE OPERATING LABOR MAINTENANCE LABOR
(man-hours/shift) (man-hours/shift)
Fabric Filters 2-4 1-2
Precipitators .5-2 .5-1
Scrubbers 2-8 1-2
Incinerators • .5 .5
Adsorbers .5 .5
Absorbers .5 .5
Refrigeration .5 .5
Flares - .5
Based on discussions with manufacturers and operators with corroborating
data from refs..78s 82, 126 and 141.
3-14
-------
replacement of major parts are required such as the replacement of filter
bags in a fabric filter or the replacement of adsorbent in adsorbers, the
labor cost for replacement should be equal to the material cost of the replace-
ment parts. For small to medium size systems where the installed cost is
approximately $100,000, or less, the total cost of maintenance is assumed to
be 5 percent of the installed capital cost.
The annual cost of replacement parts represents the cost of the parts
or components divided by their expected life. Replacement parts are those
components and materials such as filter bags, catalyst, and absorbents
which have a limited life and are expected to be replaced on a periodic
schedule. An estimate of the life of the parts as well as equipment, as
shown in Table 3.6, is based on a qualitative judgement of the type of appli-
cation, maintenance service and duty cycle. The guideline for average life
represents a process operating continuously with 3 shifts per day , 5 to 7
days per week, handling moderate concentrations of non-abrasive dusts or non-
corrosive gases. The guideline for low life applications is based on a
continuous process handing moderate to high temperature gas streams with high
concentrations of corrosive gases or abrassive dusts. Applications having
high life expectancies for parts and equipment would be those operating inter-
mittently or approximately one shift per day with gas streams with low con-
centrations and at ambient gas stream temperatures.
The cost of waste disposal considers only the removal and hauling of a
dry contaminant to a nearby landfill area by an outside contractor.
To assist the user in developing the approximate utility costs for the
auxiliary equipment and control devices, the following equations and data
are provided.
3-15
-------
TABLE 3.6 GUIDELINES FOR PARTS AND EQUIPMENT LIFE1
MATERIALS AND PARTS LIFE
Filter bags
Adsorbents
Catalyst
Refractories
LOW
(Years)
.3
2
2
1
AVERAGE
(Years)
1.5
5
5
5
HIGH
(Years)
5
8
8
10
EQUIPMENT LIFE
Electrostatic Precipitators
Venturi Scrubbers
Fabric Filters
Thermal Incinerators
Catalytic Incinerators
Adsorbers
Absorbers
Refrigeration
Flares
5
5
5
5
5
5
5 S
5
5
20
10
20
10
10
10
10
10
15
40
20
40
20
20
20
20
20
20
Based on discussions with manufacturers and operators with corroborating
data from refs. 19, 20, 37, 38, 40, 78 and 82.
3-16
-------
Fan Power
The horsepower for various fans is shown in Section 4, however, the
following formulas can also be used.
kwh = 0.746 (hp)(H) = 0.7«6gFH)(tf)(S6)(H)
where :
kwh = kilowatt-hours
hp = horsepower
CFM = actual volumetric flow rate, acfm
AP = pressure loss, inches WG
n = efficiency, usually 60 - 70%
H = hours of operation
SG = specific gravity as compared to air @ 70°F, 29.92 inches
mercury.
Pump Power
The horsepower for pumps operating at various flow rates and pressure
levels is shown in Section 4, however, the following formulas can also
be used.
kwh = 0.746 (hp)(H) = °-
where :
GPM = flow rate, U.S. gpm
hd = head of fluid, feet
SG = specific gravity relative to water @60°F, 29.92 inches
mercury
Baghouse Power (auxiliaries, motors, etc.)
Horsepower requirements for baghouse shaker motors, reverse air fan motors,
etc. can j?e estimated at approximately 0.5 hp per 1000 sq. ft. of cloth. Power
usage will depend on dust loading and cleaning cycle. Assuming a 50% usage
factor, power requirements would be approximately 0.2 Kwh per 1000 sq. ft.
3-17
-------
Precipitator Power
For approximation purposes, the power requirements for a precipitator can
be assumed to be 1.5 watts per square foot of collection area, the range
varying from 0.3 to 3 watts per square foot (ref. 168).
Incinerator Fuel
The fuel requirements for incinerators depends on the exhaust gas flow
rate, the inlet, outlet, and combustion temperatures, inlet gas composi-
tion, and control efficiency. The utility costs for incinerators can be
determined from the operating cost curves and fuel requirements developed
in the-EPA manual 450/3-76-031 "Report of Fuel Requirements, Capital Cost
and Operating Expense for Catalytic and Thermal Afterburners", ref. 141.
3.2.2 Indirect Operating Costs
The indirect operating costs include the cost of taxes, insurance,
administration expenses, overhead, and capital charges. Taxes, insurance, and
administration can collectively be estimated at 4 percent of the capital costs
while overhead charges can be considered assSO percent of the labor charges
for operation and maintenance of the system. The annualized capital charges
reflect the costs associated with capital recovery over the depreciable life
of the system and is determined as follows:
i (1 + i\^
Capital Recovery Cost = (capital costs) x n + -j)n . -j
where:
i = annual interest rate
n = capital recovery period
For average interest rates of 10 percent over a recovery period of 10
years, the capital recovery cost factor amounts to 0.16275 and the annual
capital charges are accounted for as 0.16275 times the capital costs.
3-18
-------
For a 20-year period, the capital recovery cost decreases to 0.11746 times
the capital costs. There are other depreciation methods such as Straight-
line, Declining Balance, etc. which can be used. The Capital Recovery Factor
method is preferred by the EPA and 1s used in this manual.
3-19
-------
Section 4
AUXILIARY EQUIPMENT
The gas cleaning methods used by industry today are categorized by the
technique of gas or particulate removal. These techniques include: (1)
electrostatic precipitation, (2) fabric filtration, (3) wet scrubbing,
(4) incineration, (5) adsorption, (6) absorption, (7) refrigeration, and
(8) flares. The properties and characteristics of the particular gas stream
will generally dictate which control option is appropriate. In some cases,
several techniques may be suitable or the selection of one type in lieu of
the others may be based on efficiency and/or total costs (capital, maintenance,
and operating).
For each technique selected in 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 types of auxiliary
equipment required will depend on the application. Hot processes may require
pre-coolers before the control device or the addition of moisture may be
required for proper operation of the control device. The selection of the
auxiliary equipment is directly related to the size and operating characteristics
of the control device. Therefore, to develop the gas stream inlet parameters
to the control device, it is necessary to select and size the auxiliary equip-
ment which may affect those parameters. Since most control systems require
the same auxiliary equipment, a description and estimated cost of the auxiliary
equipment is presented first and followed by the description of the control
devices and system costs.
4-1
-------
The arrangement of the auxiliary equipment with respect to the control
device is shown in Figure 4-1. In general, all systems will require some
auxiliary equipment such as fans and ductwork. The use of other auxiliary
equipment will be dictated by the physical characteristics of the pollutant
and gas stream, and the operating characteristics of the control device.
Descriptions of the various components that may be included as auxiliary
equipment for a system are provided in the following subsections.
4.1 Capture Hoods
Although a variety of hood configurations are used throughout industry,
they can usually be catagorized as either canopy hoods or semi-closed hoods.
Canopy hoods are defined as round or rectangular hoods mounted at a distance
from the pollutant source so that the majority of the collected gas consists
more of induced air than the volume of generated fume, dust or gas. Semi-
closed hoods are described as enclosures attached to or comparatively near
the source of pollutants so that the collected gas is primarily the generated
pollutant and the remaining air is induced through openings in the enclosure
for operational purposes.
The type and location of the capture device is directly related to the
volumetric flow for the system. For example, for fume capture at the source,
a relatively small volumetric exhaust rate is required to contain and capture
the dust .or pollutant. As the capture device is moved farther from the source,
the fume is allowed to disperse and entrain outside air. The resulting dust
envelope or plume increases in size as it mixes with the air, necessitating a
larger capture device to contain it. As the distance between the source and
the capture device increases, the volumetric flow rate for the control system
also increases. Since the cost of a control system is closely related to
4-2
-------
CAPTURE
HOODS
DUCTING
ANCILLARY
EQUIPMENT
Pumps, Cooling Towers,
And Controls
GAS
CONDITIONING
CONTROL
DEVICE
I
CO
Canopy Hoods,
Semi-Closed
Hoods,
Direct Ex-
haust
Side Draft Hoods
Water-Cooled
Refractory,
Carbon Steel,
Stainless Steel
U-Tube Cooler,
Quenchers,
Spray Chamber,
Mechanical
Collectors
POLLUTANT
REMOVAL
&
TREATMENT
FANS
STACK
Backward Curved,
Radial
In some applications the
fan may be ahead of the
control device.
Thickners & Clarifiers,
Vacuum Filters,
Bins and Elevators,
Screw Conveyors
Figure 4-1 CONTROL SYSTEM FLOW CIRCUIT
-------
flow rate (in dollars per cfm), the type, configuration, and location of the
capture device will substantially affect the size and cost of the overall
system.
The volumetric flow rate associated with canopy hoods is a function of
the dimensions of the hood and the average face velocity necessary to cause
induced air currents to direct the pollutant into the hood. For cold
processes emitting pollutants, the configuration of the hood is most important
since this is the controlling feature of the velocity profile between the
source and the hood. For hot processes or where the pollutant is given a
velocity from' the source, the hood has to contain the actual dimensions of
the plume and evacuate it at an exhaust rate at least equal to the rate at
which the plume is being generated. Since cross drafts in the operating area
will affect the plume on the way to the hood, the overall dimensions of the
hood must be enlarged to compensate for the maximum plume drift. The lateral
movement of the plume increases with the height of the hood opening above
the source; therefore, the hood dimensions substantially increase due to this
lateral movement as well as the distance from source to hood.
4-4
-------
Canopy hoods can be round or rectangular, and high or low. A hood may
be considered a low canopy hood when the distance between the hood and the
source does not exceed the approximate diameter of the source, or 3 feet,
whichever is smaller (ref. 88). For best ventilation, the canopy should be
placed as close to the source as possible. In some cases the operation of
equipment, such as overhead cranes, precludes the location of the hood being
very close to the source.
In general, for cold processes, the low canopy should extend around the
source, a distance of approximately 40 percent of the height of the canopy
above the source. The exhaust flow rate can then be determined by the general
formulas shown in Figure 4-2 for both round and rectangular hoods. The required
control velocities are dependent on the particular characteristics and evolu-
tion of the pollutant in the process. Typical velocities are outlined in
Table 4.1 for those industry sources requiring low canopy hoods on cold
processes.
For hot processes, the typical minimum ventilation rates normally required
for low rectangular or circular canopy hoods can also be determined from the
formulas in Table 4.1. The differential temperature (AT) represents the
temperature difference between the source and the ambient air. This is a
generalized method of sizing low canopies and exceptions and modifications to
this method are described in Reference 88.
The sizing of high canopy hoods over hot processes becomes considerably
more complicated. The buoyant effect of the plume is caused by the density
differences between the source and the surrounding air. As the hot gases move
upward, they entrain additional air and the plume expands and cools. The
volume of the plume as a function of height above a circular source can be
-*
expressed as:
4-5
-------
45 Minimum
TANK
OR
PROCESS
Not to be used where material is toxife and worker must bend over
tank or process.
Side curtains are necessary when extreme cross-drafts are present.
1.4PDV
Q = (W+L)DV
WOV
or
LDV
for open type canopy.
P = perimeter of tank, feet.
V = 50-500 fpm.
for two sides enclosed.
W & L are open sides of hood.
V = 50-500 fpm.
for three sides enclosed. (Booth)
V = 50-500 fpm.
Figure 4-2 LOW CANOPY HOODS FOR COLD PROCESSES (ref. 151)
4-6
-------
Table 4.1 MINIMUM VELOCITIES AND VENTILATION RATES FOR LOW CANOPY HOODS
RANGE OF CAPTURE VELOCITIES FOR COLD PROCESSES (ref. 151)
Condition of Dispersion
of Contaminant
Released with practically no
velocity into quiet air.
Released at low velocity into
moderately still air.
Active generation into zone
of rapid air motion.
Released at high initial
velocity into zone of very
rapid air motion.
Examp!es
Evaporation from tanks;
degreasing, etc.
Spray booth; intermittent
container filling; low
speed conveyor transfers;
welding; plating; pickling
Spray painting in shallow
booths; barrel filling;
conveyor loading; crushers
Grinding; abrasive
blasting, tumbling
Capture Velocity, fpm
50-100
100-200
200-500
500-2000
MINIMUM VENTILATION RATES FOR HOT PROCESSES (ref. 88)
Low Circular Hoods:
Q = 4.7 (P)2'33(AT)<42
where Q = ventilation rate, cfm
D = diameter of hood, ft.
AT = temperature difference between hot source and
ambient temperature, °F
Low Rectangular Hoods:
Q = 6.2 (W)1'33(L) (AT)'42
where Q = ventilation rate, cfm
W = width of canopy, ft.
L = length of canopy, ft.
AT = temperature difference between hot source and
ambient temperature, °F
4-7
-------
Q = 7.4(h + 2d)K5 (H)'33
where Q = plume volume, cfm
h = height above source, ft
d = diameter of source, ft
H = heat transfer 'rate from source to plume, Btu/min.
The plume volume from a rectangular source can be determined as follows:
Q = 18.5(h + 2w)'59[L - w + 0.5(h + 2w)'88] (H)'33
where L = length of source, ft.
w = width of source, ft.
The predominant factor in this expression is the rate of heat transfer
to the plume. A complete discussion of the methods of determining this heat
transfer rate is given in References 88 and 152. Since the canopy hood at a
given height above the source is required to collect and exhaust this plume,
the volumetric flow rate must equal or exceed the plume volume.
The semi-closed hood can be designed in many different configurations
which generally enclose the pollutant source. The exhaust rate with these
devices is much lower than that from a canopy hood since collection is
accomplished at the source. In order to contain the pollutant, the semi-closed
hood is usually maintained at a slight negative pressure to insure inward flow
of aspirated air. The velocity of the air through the openings is a function
of the internal static pressure. Different velocities are required for
different applications. In addition, the sizing of the hood and the required
exhaust volume will depend on the particular process being controlled and the
size of the source. Semi-closed hoods operating on hot processes may need
to be fabricated from special materials or water-cooled.
4-8
-------
Because of the variations in applications and designs for each source,
the design and estimated costs for semi-enclosed hoods should be determined
from the data and curves illustrated in Reference 88. For the purposes of
this manual, only canopy hoods will be considered.
Figures 4-3 through 4-6 contain data for estimating the equipment costs
for canopy hoods. Hood dimensions can be determined from Figure 4-2 or from
recommendations in references 88, 129, 151 and 152 for most applications.
Figure 4-3 gives plate area requirements for rectangular canopy hoods
and Figure 4-5 gives the corresponding labor costs for 10 Ga. carbon steel
construction. To establish the equipment cost, 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
2
wide, the L/W = 4, the plate required is approximately 250 ft , and the
fabrication labor cost is approximately $425.
Figure 4-4 gives plate area requirements for circular capture hoods and
Figure 4-6 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 e = 50°, the
2
H/D = .6, the plate required is 550 ft , and the fabrication labor cost is
$2010.
To determine the total fabricated price, the plate weight must be calcu-
lated, including 20% additional for structural supports. The weight of 10 Ga.
carbon steel is 5.625 lb/ft2. The weight of 1/4" plate is about 10.30 lb/ft2.
To determine angle of slope, see Appendix C, ref. 129, Fan Engineering,
especially Figure 57, p 114.
4-9
-------
cr
to
ct
LU
01
o.
o
cr
UJ
cr
Slope of Hood « 350
L = Lenth
W = Width
Curves Include 10% Scrap
Skirt Not Included
For Water Cooled Hoods
Use Double- the Plate Area
*=^E L/W = 4 ,
=f L/W - 8 -
CURVE EQUATIONS
A = 12 + 2.84 L2
A = 4 + 1.25 L2
A = 1 + 0.615 L2
A = .5 + 0.306 L2
20 30 40
L, LENGTH DIMENSION, FT.
Figure 4-3 RECTANGULAR CANOPY HOOD PLATE AREA REQUIREMENTS VS. HOOD LENGTH AND L/W
4-10
-------
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Slope of Hood = 35°
L = Lenqth
W = Width
Skirt not included
Fillet Weldtime for
skirt is included
- — i — '- ^—-
— ;-
1
I
1
i j
i ! '
1
i i !
— j — ]
— :r±d=
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j
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i j
1 i
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1
! ' i
| i ! .
.
(at hood perimeter)
For water cooled hoods,
use douhlp thp man hniir<;
CURVE EQUATIONS
$=70.95+ 8.47L+2.97L
$=61.42+12.71L+1.59L
$=51.89+ 5.51L+ .66L
$=42.36+ 4.24L+ .33L
2
2
2
2
' l
--
_J
•
^
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— t— j
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^^
1
Costs Based :
on data from
Fuller Co.
J_
1
1
20 30 40 50 60 70 80
ti HOOD LENGTH DIMENSION, FT.
90 TOO
Figure 4-5 LABOR COST FOR FABRICATED 10 6A. CARBON STEEL RECTANGULAR CANOPY HOODS
4-12
-------
= 65' m
CURVE EQUATIONS
2
89 + 9.2D+3.30
2
28.50 + 3.6D
101 + 6.3D + 6.4D
615 - 120D + 20.2D
Costs Based
on data from
Fuller Co.
loq
0 10 20 30 40 50 60 70 80 90 100
D, HOOD DIAMETER, FT.
Figure 4-6 LABOR COST FOR FABRICATED 10 GA. CARBON STEEL CIRCULAR CANOPY HOODS
4-13
-------
Table 4.2 MATERIAL COST (Ref. 160), Fuller Co,
CARBON
STEEL
CIRCULAR HOODS
RECTANGULAR HOODS
<. 3/16"
AF + $. 243/1 b
LG + $. 243/1 b
>_ 1/4"
AF + $. 227/1 b
LG + $. 227/1 b
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
4-14
-------
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
The material cost, cut to size, is estimate from Table 4.2.
Using these formulas, the material cost is calculated to be:
550 ft2 x $.45/ft2 + $.243/1b x 3700 Ib = 1150
20 ft x $4/ft + $.243/1b x 1690 Ib = 490
Hence the total price for the two examples is:
35° Rectangular Hood, 20' x 5': $425 + $490 = $915
50° Circular Hood, 20' dia: $2010 + $1150 = $3160
If skirts or booth walls are needed, figure material cost at $.243/lb.
The weight of the wall will be the plate area (summation of the length times
width of each wall) times the material weight, plus 20% additional for
structurals. For labor cost, figure cost at $.30/lb.
4.2 Ducting
Ducting has several effects on the size and cost of a control system.
In addition to conveying the pollutant-laden stream to the control device,
the ductwork can act as a heat exchange means for cooling of hot gases.
Also, it always adds flow resistance or pressure losses that require 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
4-15
-------
is not necessarily based on construction alone but rather on the capability
of each to transport gases at different temperatures. Water-cooled and refrao
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
below 1150°F or where the wall temperature is less than 800°F. In the transfer
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 are
listed as follows:(Ref. 88):
DUST TYPE S 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.
These velocities are presented as guidelines and have been developed from
practical experience and data obtained from industrial applications. The
minimum velocity that must be maintained to prevent dust from settling in a
duct is determined from the following formulas.
4-16
-------
Vh - 105 () d°'4 (ref. 152)
where: V. = horizontal duct velocity, fpm.
SG = specific gravity (relative to water
at 60°F and 14.69 psia)
d = particle diameter, microns
Vy = 0.27 Vhd°'2 (ref. 152)
where: V = vertical duct velocity, fpm.
The diameter of a duct for a specific design velocity and gas flowrate is
determined by:
D = 13.54
where: D = duct diameter, inches
Q = gas flowrate, cfm
V = duct velocity, fpm.
The formulas for determining the minimum duct velocity are based on
experimental data using relatively large clean dust particles (1-5 millimeters
in diameter). In most industrial gas streams, the particulate is a mixture of
dusts inadequately identified as to size, configuration, and adhesive properties;
thus, the formulas tend to predict lower minimum velocities than those
recommended by industry. A more detailed discussion of this is contained in
reference 152.
Since the types and configurations of ductwork are so varied, the cost of
these items must be estimated according to size, type, materials of construction
and plate thicknesses. For ducting, the costs are developed on a per lineal
foot basts.
4-17
-------
The cost of the ductwork for any application must include accessories
normally associated with the conveyance of a gas stream. These include elbows,
tees, expansion joints, dampers and transitions. The costs of these items
are segregated from the cost of straight duct as shown in the following figures.
For straight duct sections, Figure 4-7 gives the price for fabricated
carbon steel duct in dollars per foot as a function of duct diameter and
material thickness. A 48-inch duct, 1/4-inch thick costs $83/ft. Hence 100 ft
costs $8300. Figure 4-8 gives prices for stainless steel construction and
Figure 4-9 gives prices for water cooled carbon steel duct.
Figures 4-10 and 4-11 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
having the same diameter and thickness. For transitions, the price will be
1/2 the corresponding elbow price (use large diameter for sizing).
s,
For expansion joints, Figure 4-12 contains prices for expansion joints
as a function of duct diameter.
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. The thickness of the insulation for these applications depends on the
thermal conductivity of the selected insulation, the temperature of the hot
face (refractory skin temperature), and the required temperature of the cold
face. The following values may be used as a guideline in determining the
amount of insulation required when the temperature of the cold face is in a
still air environment at 80°F (ref. 153).
4-18
-------
o
o
700
650
600
550
500
§ 450
ctP -r r " n ~ ~ " • ' * t *- . • . . -I
Tp-ft • : - :: -[ • 4 -n T :] '• i • ~ ' ' * ^ ^ 14 1 ^ R-"-
• 1 1 1 1 j
i 1 1 , , L .
..i ... - : ::. • it. lit
i 1 4 i
L 4
*ss are based ";_"'"..}.'.' it i| "1 \.f
3 costs to [ 1 1 1 . i i
V-UO V. J VW - - - - t 1 II
ic not <;plf- 1 J .4-Lj
I i (
s \ i '
_ „ . . _ _ - -l-^-.. _i_ J^--Jt-
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rf '
i^ - j .
r j i ^ i j T t
J 1 /Oil TU4^b _ H ' _ 4_ ^ ' '
J 1/Z Thick ^ ? .TT "J ;.4 r " " ~r
iT fl tC^ 4 . 1 ,_*_Ł L_i 1_|
. .. _ ^, . .. . . _ j^y • • ~ i
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f 1 L ' '""^ ""^
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- _^, _ . _ _;. _ j/o iniCK •"" "j
-*_ _. _--^?_.- -_ _ .. 1_: ft! _ 4._ I
? . , :. r Plate
. * * i i 1 1 i
--.. .'-- - UL it" " •
.. -*• . . ~ _ 4 44" ±r —
,* - - - -) -f-f h^ ;
--.--..,---------- - ------ h -- -f-|-|---|- -.---I.
^ I i '
1 lit- L J
j 4 MI t " !
' ' * E I
:":±±''" *?;;;; 1/4" Thick Plate
^ '
'*•- • ~t ' — -i H , 1 1 1 1 1 1 • 1 1 , r ' " •
i i ' 1 1 1 1 i l — . - -r. .
* * | , J
:'!::-: :!'i 3/16" Thick Plate - Ł l
......
1 Illl 1 lllll ^ r
:: : *:::T~ . f T IT \ T X Pp t t'll
., 1 - L LL 1 I
..j ±. _L-tTt" L- M 14
1 -1-1- i i i' i 1 1 . m. . iij t
* • LI ^AIII^^O* Pnc'I'C Ho\rol nnarl fv*ran
— r — T^ ouuii,e. uub L:> ucvc i upcQ iroin —
i i r ' , " Qaia Trom rui ier LO.
fflT" M: -tri- l-m-i+Hl - !- Hlfil •-:
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
D, DUCT DIAMETER, INCHES
Figure 4-7 CARBON STEEL STRAIGHT DUCT FABRICATION PRICE PER LINEAR FOOT VS. DUCT DIAMETER AND PLATE THICKNESS
-------
ro
o
o
o
eg
2
cc
LU
D-
O
UJ
LU
V)
to
Ul
Figure 4-8
Source: Costs developed from
data from Fuller Co.
130 "140 150" 160"" 170 180
D, DUCT DIAMETER, INCHES
STAINLESS STEEL STRAIGHT DUCT FABRICATION PRICE PER LINEAR FOOT VS. DUCT DIAMETER AND PLATE THICKNESS
-------
r\>
' - ...... - ~ .
- -• •-- • -- -
•'-•'• NOTE: 1. Estimates include flanges ever
U A/I n m Ł «.
aw im^jj 24 feet.
. Flanges and inner duct of 3/8
tjjtfg plate construction.
•- M4+44JI * stringers and outer, duct of I/
§ :::::: plate construction .
U_
2 wo --imnjmiiUtiiiuiuuutiimuiiitiiuiiiim^i+iumuiui^H
2 ;:;;; ;:;:::v;;- -:::; ;;::;:;;:::. ;; :-.. ..- .-.;n;:-;:::. --I- -.
z Hittttttttttl 1 H mill Mm m i Hm i r in It m 1 Ml
H- 1 t"" '
_i : . . . - t... .
DC. ' - - L -
UJ ::::::•;• . . - ..- ..[....
Q. ttttrrH til 1 till till lit II t fu 1 1 mil II lluil'JI 1 till "
** 300 : ' ' ' :::;...::..: :::.,..: :...:::.; L . : ; , .
||2 ::::.:::.:• " , ::• . '
10 f - - -
O • ' • • • . . . . . . . : . .
-...['. . • ....
Ł ..::::::-.:- t ' . • '.:•-- 1 •.:.;•-•::.•
" ?no RffliltiMm W
Q - - T • .>•
UJ
_l -•- -.; . . :... .. _ . i: .. .,1! ._ ,.
3 .-.....--- j-j- Jrffr i. ?, -^ +(^(-
O :.::.". . < \\jjf T 1 i -
. i^i ; • • • , I '
f^ ' i ' '• :
UJ " .:. . ..... tl. ,,., L L..f. . ... ill! .
^ ... t : i !:i r . '!| ;|f
3e inn • • - ^ ;: ; ---------- t- ill M
•^ 1 Uu i i i , f , ^ 1 1 i
ji '. •' :' !l I
j. . Ttt||4llli :.:...II : 4
•• • • M ' r
o - -- i J.^iiLllli" 11
0 20 30
D, DUCT DIA
' \ | 1 1 . • 1 1 i 1 1 j • ] . . » • . • • i . .
------.- - j l" | 7 r 1 " f I'l" ' ' 1 '• • • • I j ' ; '•:'•.'. ' . . ' '
1 j j 1 i ! j ! I i ! 1 ! 1 !".'•':;; i :;:;::
|:i L f ^LrtilLiZ[ - ili '• ;; illEiill-Pl;
y 1 ! • 'I i : u i n it, j i |F V
- \ T t r if itt T ifr^trt^ - ^tti
..!..._ .....:. ;....! _ M+i.L^i.l -...+4. ll
- - "' f . . T T T T
411 . . ' ° ' - ~ - ' " " . . - . " " -1.
••: ::•••: - •••:::::•: : : : : 7 7* ~ .
: : • : : .::.-. - • . -:..:• E . . : - . • . : - j ! : • : :
, - I, ;• "- .:. E E:-: | r : : : f i • ' it ' i
|1|JH
- .,.-. \ . , . 4--t.
•;.'-• 3" -
.,.!:.:::. : : , : : : . ! • 1
..,.!•' ;-.. ' : • || . ' 1 ' " .:j ^
- •'' ' H l ! ^ ••: \-±\\\ I!' 1
,,•' • ' . ' ' • [ • 1 ' - - -j "
,.':''• 1 | : : .:•.:.• • ! ! ! I"" L ! : ; i : : j | : :
:,..;.. ., ; 4- -uni '!li- : U;i" * ll:> • '• : ::
.:.+f. * + |t-.: $=51.84+4.450 j 1 : :'''.' '• \ ''•'•• •'•"''
i i •-..::!::: . :
1 I" r:|[ . Tl! ';.;! IMI it|| i :'• ^|j '••; : j
jiUliil iJ4 4i!liii!t 111 ';iilli lli: ;:'! • ''
I '. It!:! 1 i ". ' : : ' ' r U J. J.1 : i_ .. . . : : .
I'-HHj --4li-.il :
1 i; ! :m — J-i t . .. J i .; LL SniiiTTP" Tnctc Hpv/plnnpH fynm
'• ':' ! j ji 1 i ' !( data from Fuller Co.
j i YT JJj^jiN JiJ T ^"" ^T^1 •• • 1
ijiiil ffl ffl 11 i' i iii' ; '?' r j^iEi' :ii LJL :"
40 50 60 70 80
METER, INCHES
Figure 4-9 WATER COOLED CARBON STEEL STRAIGHT DUCT FABRICATION PRICE PER FOOT VS. DUCT DIAMETER
-------
•tfl-
on
CL.
O
E
o
CD
CO
o
«=c
o
30, 000 -, 1
d
NOTE
i i
| !
1 i
H~H
1 I'|J
• i
i '• i
i t ]
' '• ,
'
1,000 =
=
i
LJ — L _
~ •
i.
2.
' i
i ' |
: ' t
i ; i
1 ) 1
f
u
t
Source:
J
inn -
i
MM
Estimc
R/D =
\
i f \
• f' '
/
I/
t ' » • J
/•/
'/]/'j
/!/(/
__L-1
ites
1.5
— 1 — I
ir
i
i i
- 1/2"
^
i— '
— i
-nX-2
/
f
/
f
j
t.
*
Xi Jf . 'V
J
L
Jr ' '
~f~ " '- •
f i ; .
' •
i ! :
I/
p-L-j , 1
- ' . . ' -i
iclude
( i i
Thick
^
«•
_
^
fi_j
i
!
1
i '
J
I j
8" Thi
—i — i — 1 —
i
. -,
flangt
i i
Plate
_
LU=-
t*-1-?
^i-
— ~t>i
, t/v.-
X^ — r~
=^-3,
i 1 - . .
I i | 1
{ i
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-
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ck Pla
i ' '
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i
1 j (
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te
"TT-HT
~"[~~ * 1
JRVE E
S THICKNESS
Costs developed -
from data from -
Fuller Co. -
..
j
I
[J.
i
1
1/2 $=-16
3/8 $=-12
1/4 $=- 8
3/16 $=- 9
1/8 $=.12
JILLLLIU.
1 • ~- • —
— -J — L. -- 1— -I —
— »-+ : jv
1 1^
xW
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lick P
i
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— i — i — ' — • —
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EQUAT
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.07D+.
LiLU.
jx"
Thick
ick PI
_1 1 1 !
ate 3=
— ' — 7-7-
i i
i
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Ml!
MS
IONS
.710+ j
.10D+J
.410+.;
.760+.;
17602"
LUJ_L
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i
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ate :
u i i i -
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i i
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1 i
— 1 ' ; — • —
-4-i-^-t-
180^ t
IBDi t
-4D Jr
?05D^_
1 ~
0 20 40 60 80 100 120 140 160 180 200
D, DUCT DIAMETER, INCHES
Figure 4-10 CARBON STEEL ELBOW DUCT PRICE VS. DUCT DIAMETER AND PLATE THICKNESS
4-22
-------
100,000
LU
o
1— 1
OH
0.
O
Q
3 10,000-
LU
f
LU r
LU
I
i
1
—
1 1
NOTE :
j — i — i —
co pq
co 1-+3
LU j— . '
I— 4
CO
i nnn
-t— H-
1 | . •-—
i : , • — :— t—
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3. C
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i
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OS
roi
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i
rrj/t^
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— L-/.
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r Vp
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/
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H
i
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1 • ••
1 i . •
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TT~
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i mates
= 1.5
ts dev<
Tl Full!
2" Thi
-r-M-!-
— i — ' —
w
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f\ \
—, i — j_
— i . --( - .- -
1- ' '
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inc
slop
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:k P
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j ;/
LL
lu<
ed
0.
la
H-
*
(L.
^
X
^
: > ' —
1
^=PCI
CKNES
1/2
3/8
1/4
3/16
1/8
J
S
J ! 1
de fl
from
te^-
.
f} i ' ,
r
Ą \
\
a
i
i*
r^
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-i.j... j.
1/8"
-r-] r
! 1 '
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T
j
nge
iat
i 1
s =
a ±=
^
p —
1 I L<<
N
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i l I
6
— ! — | — i — t—
hick
P
' :
—, .-,
^
— i '< • . : 1 ' i-
IVE EQUATIONS
ia
$=272+32
$=199+23
$=134+19
$=124+17
$=19.040-
J4-LU-
S^-3/Ł
1
11 1
i
— — i —
fhic
i i i
late-
4 •
• i
— 1 — H-
— f— j-
--i-
1 1
!" Thic
1— I —
Thick
i ' T
k Plat
j i
i i i
JATION
.30+2. 80^
!3D+l!46D,
.eD+l.QSD^
I-.703D2
^ :-:
\LS^f^-
,k Pla1
Plate
i i ;
e . ' ,
i : ! i
1
i
;e
0
40
160
200
80 120
D, DUCT DIAMETER, INCHES
Figure 4-11 STAINLESS STEEL ELBOW DUCT PRICE VS. DUCT DIAMETER AND PLATE THICKNESS
4-23
-------
I
CO
§
o
o
•-3
5000
50 60
DUCT DIAMETER, INCHES
Figure 4-12 CARBON STEEL EXPANSION JOINT COSTS VERSUS DUCT DIAMETER
-------
TABLE 4.3
REFRACTORY ESTIMATING COSTS
TYPE
Super Duty Firebrick, 3200°F
Insulating Castable, 2000°F
Dense Castable, 3000°F
Plastic, 3000°F
Ceramic Fibre Matt, 2300° F
APPLICATION/ FORM
Brick
Cast In Forms,
Trowelled, or Gunned
ii
Rammed w/Pneumatic
Hammer
Like Mineral Wool
THERMAL CONDUCTIVITY
(Btu/hr.-ft2.°F/in.) @
1000°F 2000°F
9.3 10.0
1.9 2.1
5.1 5.7
N/A N/A
N/A N/A
PURCHASED PRICE
($/cu. ft.)
$ 7
$ 6
$25
$13
N/A
INSTALLED COST
($/cu. ft.)
$90
$30
$75
N/A
$25
4*
HO
cn
N/A = Not Available.
Data based on ref. 37.
-------
*
Hot Face Temperature (°F) Cold Face Temperature (°F) L/K.
1200 2.7
300 1.1
400 0.6
1500
4.5
1.8
1.0
200 6.0
2000 ( 300 2.6
WO 1.5
where: L = Insulation thickness, inches
K = Thermal Conductivity, Btu/hr-ft2-°F/inch
(obtained from Table 4.3).
To estimate the cost, determine the surface area to be lined, the thickness
of the lining, and the type of refractory tb be used. Compute the cubic feet
of refractory required and multiply by the price obtained from Table 4.3.
Prices for rectangular and circular dampers, with and without automatic
temperature regulated controls, are contained in Figures 4-13 and 4-14,
respectively. Rectangular dampers are priced as a function of cross-sectional
area for length-to-width (L/W) ratios of 1.0 to 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.
4-26
-------
12
ill
NOTE:
1.
2.
3.
Dampers are louvered type.
For stainless steel construction,
multiply price by 3.0.
Price with controls 1s a nominal
estimate for temperature regulated
dampers.
Source: Damper Design, Inc.
Do not extrapolate beyond range.
o
o
o
o
4* DC
I UJ
rv> O-
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CD
O
UI
o:
23456
DAMPER CROSS-SECTIONAL AREA, 1000 SQ. IN.
Figure 4-13 CARBON STEEL RECTANGULAR DAMPER PRICES VS. AREA
-------
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to
UJ
OL
CL
O.
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18
17
16
15
14
13
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10 20 30 40 50 60 70 80 90 100 110
DAMPER DIAMETER, INCHES
Figure 4-14 CARBON STEEL CIRCULAR DAMPER PRICES VS. DIAMETER
120 130
4-28
-------
4.3 Gas Conditioning
Gas conditioning equipment includes those components which precondition
the gas stream prior to the control device. This equipment consists of mech-
anical collectors, wet or dry coolers, dilution devices, etc., which are used
to temper or process the gas stream to provide the most efficient and economical
operation of the control device.
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
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 large diameter conventional cyclones or as units
having small multiple tubes for higher efficiencies. The efficiency of a
cyclone collector is determined by the entering gas velocity and diameter at
the cyclone inlet. Theoretically, the higher the velocity or the smaller the
diameter, the greater the efficiency and pressure drop. All of these parameters
can be correlated to the collector inlet area to establish the size and
ultimately the cost of conventional cyclones.
Multiple tube cyclones are designed for high efficiencies and are normally
used as a primary control device rather than as precleaners. These devices
consist of banks of tubes, nine inches in diameter or less, and provide
efficiencies of up to 80 percent for particle sizes of approximately 5 microns
(ref. 154). The cost of these units is estimated to be $1.00 per cfm for
4-29
-------
capacities of up to 1000 cfm, $0.60 per cfm for 5000 cfm, and $0.50 per cfm
for capacities of 10,000 cfm or greater (ref. 154).
For the purpose of precleaning, conventional cyclones can remove the
majority of dust particles above 20-30 microns in size to reduce the loading
and wear on the primary control device. Figure 4-15 provides a means of
estimating the volume capacity of mechanical collectors (conventional cyclones)
as a function of inlet cross-sectional area. Figure 4-16 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. A guide to estimating cyclone shell thickness and pressure drop
can be obtained in references 154 and 169.
Figures 4-17 through 4-21 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 inl^t area of 9-1/2 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 $5100. The cost of additional components would be:
support: $3100
hopper: 880
* scroll: 1600
$5580
The total price per collector is thus $5100 + 5580 = 10680. In general,
price of collectors varies directly with inlet area since the mass of the unit
increases with increasing area. However, these curves give prices for only
single-unit collectors. Multiple collectors in parallel can be used for high
*Ductwork at outlet of cyclone to direct flow to horizontal ducting.
4-30
-------
(Ref. 160), Fuller Co
0 1 -2 34 56^78 9 10 11 12 13 14
A, COLLECTOR INLET AREA, SQ. FT.
Figure 4-15 CAPACITY ESTIMATES FOR MECHANICAL COLLECTORS
4-31
-------
(Ref. 160), Fuller Co
5 6 7 8 9 10 11
COLLECTOR INLET AREA, SQ, FT.
12 13 14
Figure 4-16 CRITICAL PARTIAL SIZE ESTIMATES FOR MECHANICAL COLLECTORS
4-32
-------
8.00C
6,000
o
O
4,000
2,000
Q H-nf-rth
;;r;rnT
f^.
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E| (Ref. 160), Fuller Co,
4 5 6 7 8 9 10 11
A, COLLECTOR INLET AREA, FT2
^^
12 13 14
Figure 4-17. MECHANICAL COLLECTOR PRICES FOR CARBON STEEL CONSTRUCTION VS. INLET AREA
4-33
-------
UJ
o
cr
o
o
u
0 1 2 .3 4 5
$ f 8 9 10 11 12 13 14 15
A, COLLECTOR INLET AREA, FT2
Figure 4-18 MECHANICAL COLLECTOR PRICES FOR STAINLESS STEEL CONSTRUCTION VS.
INLET AREA
4-34
-------
3,000
QC
O
Q.
D-
2,000
1,000
400
Segment
1
2
3
EQUATIONS
Equation
P = 570 + 148A
P = 1026 + 143A
P = 1938 + 120A
Do not extrapolate beyond
range.
2 3
7
(Ref. 160), Fuller Co. =
T2
A, COLLECTOR INLET AREA, FT2
Figure 4-19 MECHANICAL COLLECTOR SUPPORT PRICES VS. COLLECTOR INLET AREA
4-35
-------
4,000
3,000
2,000
D-
O.
O
1,000
468
A, COLLECTOR INLET AREA, FT2
Figure 4-20 MECHANICAL COLLECTOR DUST HOPPER PRICES FOR CARBON & STAINLESS STEEL
CONSTRUCTION VS. COLLECTOR INLET AREA
4-36
-------
O
QŁ
O
6,000
5,600
Steel
Stainless
Stainless
Stainless
Carbon
Carbon
Carbon
Curve Equations
Thickness Equation
3/16" P=513+618A-12.9A2
10 Ga. P=462+432A-12.0A2
14 Ga. P=352+307A- 9.W
3/16 P=310+214A- 4.1A2
10 Ga. P=290+165A- 3.0A?
14 Ga.
P=269+143A- 2.2A
(Ref. 160) , Fuller Co.
Do not extrapolate beyond range
A, COLLECTOR INLET AREA, FT'
Figure 4-21 MECHANICAL COLLECTOR SCROLL OUTLET PRICES FOR CARBON & STAINLESS STEEL
CONSTRUCTION VS. COLLECTOR INLET AREA
4-37
-------
flow rate when the flow capacity exceeds that of a single unit. The price
of these combination units can be estimated as the summation of the costs
for each cyclone plus 20 percent for ductwork and structurals.
Coolers and spray chambers are used with 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 elec-
trical characteristics of the dust for electrostatic precipitators. 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 operation of the control device. The
number of required "U-tubes" in series depends on the inlet gas temperature
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. A discussion of the design criteria and a method of sizing U-tubes
coolers is contained in reference 88. The cost of a cooler can be estimated
from the number of modular "U-tubes" of a given diameter and height based on
the desired temperature drop and flow rate for the particular application.
Figure 4-22 contains prices for U-tube radiant coolers as a function of the
number of units, the diameter of the tube, and the height of the tube. The
term "units" refers to the number of U-shaped tubes; e.g., if the cooler
consists of three U-shaped tubes in series and four in parallel, the total
number of units would be 12. The tube diameters shown in Figure 4-22 are
those typically used in industrial applications, however, for other tube
diameters and material thicknesses, a cost estimate based on $1.20 per pound
may be used.
4- 38
-------
NOTE: 1
Price includes manifolds,
and tube.
100
90
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^ PRICE ADJUSTMENT FOR
HEIGHT
10'
20'
30'
40'
50'
60'
t
I ; •
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DEDUCT/ADD PER UNIT
12" 18" 36"
-$690 -$1070 -$222C
-$460 -$ 715 -$148<
-$230 -$ 355 -$ 74C
-0- -0- -0-
+$230 +$ 355 +$ 74C
+$460 +$ 715 +$148Ł
For stainless steel construction
multiply total price by 4.2.
)
) -
) ]
' I
2
8
10 12 14 16 18 20 22 24 26 28
NUMBER OF UNITS
Figure 4-22 FABRICATED 40 FT HIGH "U" TUBE HEAT EXCHANGER PRICES WITH HOPPERS
AND MANIFOLDS
4-39
-------
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 and the materials
of construction. Figure 4-23 contains prices for spray chambers for various
inlet gas volumes. The diameter of the chamber is based on a gas stream
velocity of 10 feet per second and the length is based on an L/D of 3 which
is suitable for most spray cooling applications with water sprays at 100 psig.
A discussion of the relationship between the water droplet diameter and the
time for complete evaporation is contained in reference 155. The quantity of
water required for spray cooling can be estimated from the desired change in
enthalpy of the gas stream divided by the latent heat of evaporation of the
water at the spray water temperature. This assumes that cooling takes place
along a constant wet bulb temperature line. The volume flow rate at the
cooler outlet can be determined by:
n - 1545 T Wdg . Wwv
Q - --
4-40
-------
o
o
o
I
CO
8
o
0Ł
LU
CO
CJ
i
Q.
CO
40
30
NOTE: 1. Based on chamber velocity of
600 fpm.
2. Length/Diameter = 3
3. Carbon Steel construction.
4. Does not include refractory.
5. Spray chamber cost includes
vessel and support rings,
platform, ladder, gratings,
spray system, and controls.
6. Source: Ref. 160, Fuller Co.
40 80 120 160 200
INLET GAS VOLUME - 1000 ACFM
'Figure 4-23 SPRAY CHAMBER -COSTS VS. INLET GAS VOLUME
240
280
4-41
-------
where: Q = Volume flow rate, cfm
T = Outlet temperature, °R
P = Pressure, Ib/ft
Wdq = Weight of dry gas, Ib/min
W = Weight of water vapor, Ib/min.
The quencher, used for hot processes> is fundamentally the same as a
spray chamber; however, it is much simpler in operation and requires minimum
controls. 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 fine atomizing 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 horizontally or vertically oriented. Costs for
quenchers, shown in Figure 4-24 are based on inVet 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 treatment
facility.
The simplest method of cooling is mixing the gas stream with ambient air
introduced through a dilution air port. Dilution air ports are provided to
protect downstream components from "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 equip-
ment such as the control device, 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
4-42
-------
80
70
60
50
o
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or
UJ
z
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UJ
40
30
20
10
40 80
^
Figure 4-24 QUENCHER COSTS VS. INLET GAS VOLUME
120 160 200
INLET VOLUME - 1000's ACFM
4-43
-------
controller. The damper is continually adjusted for inspiring ambient air to
maintain the downstream gas temperature at a pre-set level. The cost of the
equipment for dilution cooling, shown in Figure 4-25, is based on the duct
diameter and represents the cost of ductwork for various plate thicknesses,
damper, sensor and temperature controller.
4.4 Pollutant Removal and Treatment (Dust)
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
(inlet dust concentrations in excess of 1 gr/dscf) screw conveyors are gener-
ally used to continuously remove the dust as it is collected. The cost of
continuous removal equipment for heavy loading is based on the diameter of
the screw conveyor and its overall length. Figure 4-26 contains prices for
s
screw conveyor as a function of conveyor length and diameter. As a general
rule, a 9-inch screw conveyor is satisfactory for gas flow rates of up to
100,000 acfm; 12-inch conveyors should be used for higher flow rates. The
length of the conveyor depends on the physical configuration of the control
device and the distance to the disposal site or storage container.
Waste removal and treatment facilities for both scrubbers and quenchers
generally consist of a thickener and vacuum filter or centrifuge. The over-
flow from the thickener is recycled to the scrubber and quencher while the
heavier solids are removed for dewatering by the filter of centrifuge. The
costs of thickeners, vacuum filters, and centrifuges are completely covered
1n the following reports, also listed 1n Appendix C as source Nos. 119 and
128.
4- 44
-------
22
21
20
19
18
17
16
15
<~ 14
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Dampers are louvered type.
For Stainless Steel constructior
multiply price by 3.5 (includes
damper ductwork, and screens).
Price of included controls is a
nominal estimate for temperature
regulated dampers.
— r-~i::4::..J .. i :| • :!::.: ::. :: - ::. ::: : ' : :
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==F=
. 1
-:;•--)
• --r~[
: : ;
—-; — -] -:•-. 1 ...•.:
::-:
Ei::ii:j:--; -.; ..>. i . „....;.-
— }--
Ref. 160, Full
— l_t_i. _..t — .
er Cc
-:-jz—
).)
.0' 10 20 30 40 .50 60 70
-90 100 110 120 130 140
DUCT & DILUTION AIR PORT DIAMETER, INCHES
Figure 4-25 PRICES FOR FABRICATED CARBON STEEL DILUTION AIR PORTS VS. DIAMETER
AND PLATE THICKNESS
4-45
-------
*
to
LU
a:
a_
LU
I
ce
o
CO
8000
1. Prices include trough, screw,
drive, fittings, and motor.
2. Heavy duty construction.
3. Source: Ref. 160, Fuller Co.
1000
w
50 60 70
LENGTH OF CONVEYOR, FT
'Figure 4-26 PRICES FOR SCREW CONVEYORS VS. LENGTH AND DIAMETER
100
110
-------
"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.
4.5 Ancilliary Equipment
Ancillary equipment includes those items which may be required for the
proper simultaneous operation of several different types of auxiliary equip-
ment and, therefore, the cost of this ancillary equipment can not be attributed
to any single component. For instance, the use of water-cooled duct, spray
chambers, quenchers, scrubbers, and absorbers may require a pump, some piping
and a cooling tower as a water source for a closed-system operation. If a
specific control system included a water-cooled hood, lengths of water-cooled
duct, a quencher and a scrubber, the required cooling tower circuit would
have to be designed to handle the total water requirements.
Two figures are given for pricing installed cooling towers. Figure 4-27
applies for capacities less than 1000 tons. Figure 4-28 applies for capacities
over 1000 tons (1 ton = 12,000 Btu/hr of useful refrigeration effect, or 15,000
Btu/hr of heat rejected). The application of Figure 4-28 is more complicated and
is explained below.
Figure 4-28 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 82°F and
an approach of 10°F. See Table 4.4 for definitions of terminology. If the W.B.
is other than 82°F, Table 4.5 provides factors for adjusting the price. If the
approach is other than 10°F, Table 4.6 provides similar factors.
For example, suppose a cooling tower is to operate under conditions of 72°F
W.B. and a 20°F approach (leaving water temperature = 92°F). If the flow rate
.»
is 50,000 gpm and the range is 60°F, then the price before adjustments is
4-47
-------
o
o
o
Ul
o
1-4
DC
QL,
O
O
o
a
to
1. Price includes cooling tower, fans, pumps,
motors, and installation.
2. Price does not include basin cost.
•;]Cost 1000 $ = 1.035 + 0.093265 T
i an ;j!
Source: Costs developed from data from
l! MARLEY CO. AND ECODYNE COOLING
PRODUCTS CO.
mm itii iMi:sHi"iiH;i iji- iijiii-i
^•ftnR1!'; i7-11 l-t-HinrHllf-hn- r1-' ti't+i*'
0
400 500 600 700
', COOLING TOWER CAPACITY, TONS
900
1000
Figure 4-27 PRICES FOR INSTALLED COOLING TOWERS FOR UNITS OF CAPACITY < 1000 TONS
-------
8QQ :
o
o
o
o
I— I
CtL
Q.
.
Ul
O
O
O
O
a
LU
.:NOTE:
1. See adjustment tables 2 & 3 if conditions
other than WB=82°F and approach « 10*F.
2. Price includes cooling tower, fans, pumps,
motors, and installation. <
3. Price does not include basin cost.
600
500
4. Prices valid for units exceeding J
1000 tons cooling capacity.
400 :iii
200
100
Source: Costs developed from data from
MARLEY CO. AND ECODYNE COOLING
PRODUCTS CO.
0
20
30
CURVE EQUATIONS
Equation
$ = 34500 + 1.17 G
$ = 34500 + 1.10 G
$ = 34500 +1.01 G
$ = 34500 + 8.76 G
$ = 34500 + 7.90 G
$ = 34500 + 6.89 G
$ = 34500 + 5.80 G :
$ = 34500 + 4.43 G""i
90 100 110
40 50 60 70 80
G, INLET FLOW RATE, 1000 GPM
Figure 4-28 PRICES FOR INSTALLED COOLING TOWER BASED ON WET-BULT TEMPERATURE = 82°F AND APPROACH = 10°F
-------
Table 4.4
DEFINITIONS FOR COOLING TOWER
Approach: The difference between the average temperature 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.
Temperature, dewpoint: The temperature at which the condensation
of water vapor in a space begins for a given state of humidity and
pressure as the temperature of the vapor is reduced. The temperature
corresponding to saturation (100 percent relative humidity) 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
temperature at which liquid or solid water, by evaporating into air,
can bring the air to saturation adiabatically at the same temperature.
Wet-bulb temperature (without qualification) is the temperature
indicated by a wet-bulb psychrometer constructed and used according
to specifications.
Table 4.5
Table 4.6
PRICE ADJUSTMENT FACTORS*
FOR WET-BULB TEMPERATURES
WET -BULB, °F
68
70
72
74
76
78
80
82
FACTOR, F2
1.54
1.46
1.38
1.30
1.22
1.15
1.07
1.00
PRICE ADJUSTMENT FACTORS*
FOR APPROACH AT
APPROACH, A°F
6
8
10
12
16
20
24
FACTOR, Fj
1.60
1.20
1.00
.85
.65
.50
.40
* New Price = (P-34500) F]F2 + 34500 where P is the price from Figure 4-28.
** Data developed from MARLEY CO. and ECO'DYNE COOLING PRODUCTS CO.
4-50
-------
$620,000. The adjustment factor for 72°F W.B. is 1.38 and the factor for a
20°F approach is 0.5. The installed cooling tower price is thus:
(620,000 - 34,500) (0.5) (1.38) + 34,500 = - $438,500
The fan motor horsepower is estimated as follows:
p
HP = TEn/ where P is the price of the tower.
The pump motor horsepower is estimated as follows:
HP - gpm x 0.12.
The basin area is estimated as follows:
p p
Basin Area = y^- ft .
Since the approach in this example (the difference between the temperature
of the outlet water and the wet-bulb temperature of the inlet air) is greater
than 10°F, the difference in enthalpy between the air and the water is greater
and consequently a smaller and less costly cooling tower would be required
for the same heat transfer capacity and ratio of gas-to-liquid flow rate.
On the other hand, because the wet-bulb temperature is lower than 82°F (72°F,
in this example), its absolute humidity is also lower. (In other words, one
pound of air with an 82°F wet bulb temperature is capable of carrying more
water than a pound of air with a 72°F wet bulb temperature). As a result,
to cool the same amount of water by evaporation, more air at 72°F W.B.
would be required than at 82°F W.B. This, in turn, would require a relative-
ly larger cooling tower. Hence, the cost adjustment factor taken from
Table 4.5 (1.38 in this example) would be greater than 1.0.
Basins costs have not been provided since they vary so widely with the
individual application. The basin may be used in conjunction with other
4-51
-------
processes, which involves a proration of costs, and the basin may be constructed
in many types of soil and terrain, which can dramatically alter the first cost.
Basin costs should be estimated on an application basis through a basin con-
tractor. As a rough estimate, the installed cost of the basin can be consid-
ered to be approximately $70 per sq. ft. for the size of cooling towers shown
in Figures 4-27 and 4-28.
Figures 4-29, 4-30 and 4-31 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
supply, and similar applications. Prices are a function of pump head in feet
and pump capacity in gpm. The selection of the rpm of these pumps should be
based on the design flow rate range of the application as shown below.
FLOW RATE (gpm) PUMP (rpm)
0-1,000 3,550
500-5,000 S 1,750
2,000-10,000 1,170
Generally, the capital cost of the pump/motor combination varies
inversely with the rpm; however, maintenance costs can be expected to higher
as rpm increases. Figure 4-32 provides a means of estimating pump motor
horsepower for a given pump head and capacity. These curves represent the
nominal motor sizes used for the indicated pump heads and capacities. If the
characteristics of a specific pump (i.e., pump curve and rated efficiency) are
known, the equation in Section 3 may be used to determine the motor size. In
this case, the selected motor must be a standard size. Motor prices may then
be estimated using Figure 4-34 provided in Section 4.6.
4-52
-------
co
(St
IT*
0_
CO
o;
Q-
Qi
m
ro
1400
1300
Ł 1200
1100
~,Ut nn Jtti Mr; n:i : ! ;:: Ult ir umnrrt
CURVES BASED ON WATER.
MOTOR NOT INCLUDED.
PUMPS APPLICABLE FOR SCRUBBERS,
COOLING TOWERS, WATER SUPPLY,
PROCESS LIQUIDS, ETC.
SOURCE: Ref. 160, Fuller Co.
IH
1000
900
400 500 600
PUMP CAPACITY, GPM
Figure 4-29 CAST IRON, BRONZE FITTED, VERTICAL TURBINE WET SUMP PUMP PRICES FOR 3550 RPM
1000
-------
I ; I
I
cn
to
OH
O.
UJ
O
in
4000-T NOTE:
3500
1. CURVES BASED ON WATER
2. MOTOR NOT INCLUDED
3. PUMPS APPLICABLE FOR SCRUBBERS,
COOLING TOWERS, WATER SUPPLY,
PROCESS LIQUIDS, ETC.
4. SOURCE: Ref. 160, Fuller Co.
^ 3000
2500
2000*
1500
looo--
500
o
600 1200 1800 2400 3000 3600 4200 4800 5400
PUMP CAPACITY, GPM
Figure 4-30 CAST IRON, BRONZE FITTED, VERTICAL TURBINE WET SUMP PUMP PRICES FOR 1750 RPM
-------
Ul
cr-
a:
o.
D.
9000 w
8000 i i
7000
mmmmm ^::
mmiiF:ri
CURVES BASED ON WATER.
MOTOR NOT INCLUDED.
PUMPS ARE APPLICABLE FOR SCRUBBERS
COOLING TOWERS, WATER SUPPLY,
PROCESS LIQUIDS, ETC.
SOURCE: REF. 160, Fuller Co.
iii IBIMffltltltlP
3000
2000
0
1000 2000 3000 4000 5000 6000
PUMP CAPACITY, GPM
Figure 4-31 CAST IRON, BRONZE FITTED, VERTICAL TURBINE WET SUMP PUMP PRICES FOR 1170 RPM
-------
10000
o_
IS
n.
«c
u
1000
100
NOTE: CURVES BASED ON WATER EŁr
0 30 60 90 120 150 170 210 240 270 300
PUMP HEAD, FT
Figure 4-32 PUMP MOTOR HP VS. CAPACITY AND HEAD FOR VERTICAL TURBINE PUMPS
4-56
-------
4.6 Fans
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
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
material of construction, total volume, and pressure delivered at standard
conditions.
Radial tip fans are used almost exclusively in venturi scrubber control
systems because of their ability to operate at high pressures and tempera-
tures with abrasive gas streams. With scrubber systems, a certain amount of
carryover 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 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 incre-
mental pressure ranges of 20, 40 and 60 inches W.G. Construction can be
either carbon steel for general purposes or stainless steel for corrosive
4-57
-------
gases. Special linings are also available for unique 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.
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 4-33.
Standard conditions are defined as: S
pressure: 14.69 psia (sea level)
temperature: 70°F
gas density: 0.075 lb/ft3
In many cases, fans are operated at different temperatures and pressures
(altitudes) and, therefore, a correction factor must be applied to equate the
actual operating conditions to a standard condition. This correction factor
may be either a volume adjustment or a pressure adjustment. In the following
figures, a pressure correction factor is used, therefore, the actual pressure
of the fan at operating conditions must be adjusted to standard conditions to
determine the size and cost of the fan. If, for example, a Class III fan is
4-58
-------
loooon
4s.
i
en
1000000
100000
10000
1000
c
Source:
T'i !|i!i'lti''l'-i-
.._jj
• -'i
i.: i •
_tr.;
.^
X
S*
•S
:•!
•^
'
•S
i i i -
•^
*Ł*
'"••\
!iii
Itn
!i(l
i; i
H.
ttr
ii
r -
i- .
P**1
:p
\:-f
fr.
#r
•??
~+~
:ii
Mji
~
ti"
ll::
•jr.
>•*
s?
rtf
*•.-
i**
^
r1
#
••y
'•'
Data obtained from
Fuller Co.
r*
x"
•j-r*
*"^ •
;i;-
**"
r***
^
Hr
^
'"
b-*
^x
^
sf
Jf'.
: l
. : : : •
:-S/**
9 - L""
i^r;L
. -,_,, ,
' "J<*
i^X;
' ! 1 i '
• •>>
. ,
IJ-t!
;TJX
! -
* : ! i
. i . .
: :)!;
i&
r^
v^
^
• '
>•"'
l>*
:;:•
^
riu
>H
I'i
TT"
:'i
:H!
t: '
i i
I1
It*
i !:
j-jj
i<
9
'»
r
PH
»-..
j :!
ft
|:;
J?
a
'
&
•#
#•
i-
!i-
l!i
':'•
x
/
^
x"
X
X
) 2 4 6 10 20 30
AP, in H20
(AT STANDARD CONDITIONS:
14.69 psia, 70°F)
^
/*
^
/-
/-
^
~\ '.:
•j^-
f
^^
X:
.X
^*-
•^
;-:;•
j|ii
•--
i.;_.
X
•X1
>•*
x
i**
_U-
•| ;
#
^
r*1
pr
: •
1
^«
Ą
~
*H
>*
•i:
^
<•"
X
i^
:i-.
Fan
Class
I
II
IV
*Performance Ranc
(inches of v/ater
•\\
|
s
K
^
#
^
>
X
I^1
\
**
\
*
•j
$
(f •
1 *
11 i
\-
*\
-I
Sr
V
,
iff:
, *Ł
•^
k "
• uy
' [Ui
;*z
\
\
n
(p
•-^
.
!•••' •
I
1^
n
x^
•J
^
iS
Ni
TP^
S
. >
1 • •
iq
-••*
'•?
IX
\
•ii
^
X
a
'i^1
|
^
^
fi(
4\
...
%
V
"1 '
:.h
IK
i^
•<
\
u_
ii'
Ff
H
^.
i**
*T
^
\,.
_.
n
tn
*HJ
?7
s
;
s
__
is
:\.
|
<
s
Bl
.
i
-
^
S
<
i
-: T
**• •
d
s
1
c
7
I -wna;
1 :':'!
! [*TTT
j : . '
'r
:^;::
» : *
S."T
• ^t
• -\
i fyt
^4*-
• -v
or
-.-.
' '.','.
&
•&
s
i : : i
V '
::;;
.~.
!l"
N""
_..
-.
-
:.
T
"• iz:
J:::
„
i'--.
•~
-
. — .
... . .
- - •
;::: i ;
nii i
tiu '
.:. :
.. . -
Performance Range*
Single Width
5" (« i!300 fpm to 2-M'i" 0 32UO fpm
8-1/2" @ 3000 fpm to 4-1/4" 0 4175 fpm
13-1/2" @ 3780 fpm to 6-3/4" 0 5260 fpm
Above Class III specifications
e designations are indicated by static pressure
at fan outlet velocity (feet per minute).
(
-
- . 10000
t - v*
* i 3800 w
o;
z
: u_
7-i 1000
inn
"or high temperature
;nvironment add 3*
( 250°F,to 600°F)
For stainless steel
2 construction multiply
price by 2.5.
NOTE: Fan price is lower at higher pressure drop because smaller fan wheel is
used at. higher rpm.
Figure 4-33 BACKWARDLY CURVED FAN PRICES VERSUS CLASS, CFM, AND F FOR ARRANGEMENT HO. 1
-------
to operate at.sea level with gas temperature of 70°F and is to handle a gas
volume of 20,000 CFM at 10" water, the price would be $3800.
However, if a fan operates at a different pressure or temperature, an
adjustment must be made through the use of Table 4.10 to properly cost the
fan. For instance, if actual conditions are:
a. gas temperature = 300°F
b. altitude = 1000 ft.
c. actual cfm = 50,000
d. actual AP = 10" static pressure
then the fan is priced as follows:
1. obtain fan sizing factor from Table 4.10 for 300°F at 1000 ft = .672
2. actual 10" static pressure/.672 = 15" at standard conditions
3. enter Figure 4-33 with 50,000 cfm and 15", read price of $8500 for
Class IV fan. Since this is a high heat application, (temperatures,of
250 to 600°F), the estimated price is $8500 x 1.03 = $8760.
The prices for the motor and the starter are obtained from Figure 4-34.
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 "BMP" guidelines. Read the fan rpm on the scale to the right, read the
bnp 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 deter-
mining 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 $700.*
Prices in Figure 4-33 are based on bhp, however the motor would be
purchased as a 50 hp motor (the closest nominal size).
4-60
-------
1000
-Ł>
FAN RPM
300
500
10" - " 10
DRIP-PROOF MOTOR OR STARTER PRICE, $
10'
NOTE: Prices are for drip-proof motors only, for other types of
motors, see Tables 48 ond 4.9. Motors are purchased in
standard sizes, but for estimating purposes, curve prices
may be used.
Data obtained from Fuller Co.
Figure 4-34 BMP, FAN RPM AND MOTOR AND STARTER
2 3 4 5 6 78 9
10 20
AP, H?0 (AT STANDARD CONDITIONS)
PRICES V?. .'P A'i.: _R-1
-------
Table 4.7
MOTOR RPM SELECTION GUIDE
Table 4.8
PRICING FACTORS FOR OTHER MOTOR TYPES
MOTOR RPM
3600
1800
1200
900
600
FAN RPM RANGE
2400 - 4000
1400 - 2400
1000 - 1400
700 - 1000
< 700
HORSEPOWER
I20
> 20
TOTALLY ENCLOSED
FAN COOLED
1.3
1.5
i
EXPLOSION PROOF
1.6
1.7
-p»
ro
Table 4.9
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 Cooled^
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.
Data obtained from Fuller Co.
-------
Table 4/10 FAN SIZING FACTORS: AIR DENSITY RATIOS
Unity Basis = Standard Air Density of .075 lb/ft3
At sea level (29.92 in. Hg barometric pressure) this is 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
-p»
OJ
SOURCE: AMCA STANDARD #402-66
AIR MOVING AND CONDITIONING ASSOCIATION, INC,
205 West Touhy Avenue
Park Ridge, Illinois 60068
-------
If a magnetic starter is selected, the price is about $450. Prices for motor
types other than drip-proof may be estimated using Table 4.8. A totally
enclosed motor for this example would cost $700 x 1.5 = $1050. The selection
of a motor type may be made from Table 4.9.
For conditions deviating from standard, the following steps must be taken
to establish the motor and starter price. Again consider the 300°F application
from before.
1. Find the bhp from Figure 4-34 using 50,000 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 4-35. Note that the static pressure is measured
for standard conditions, as in Figure 4-33 and 4-34. These dampers are
supplied by the fan manufacturer and designed to match the inlet and outlet
configuration for each fan size.
V-belt drives may be selected for applications where the desired fan
speed is not the same as standard motor speeds (nominally 600, 720, 900, 1200,
1800 and 3600 rpm). These drives are used for fan/motor combinations of up
to approximately 150 hp. Fan drives above 150 hp are usually direct drives.
Figure 4-36 contains 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.
4-64
-------
1,000,000
400,000
200,000
loo.ooo |4
ac
i—*
-------
oo
CD
GO
o
CD
Z
*-^
O
ID
_J
O
CJ
a:
o.
CO
I
till NOTE: 1. Select V-Belt
closest to Fan RPK.
2. Do not "Extrapolate"
prices for belts
above 140 HP
application.
nr (Ref. 160)
40 60 80
MOTOR HORSEPOWER, HP
Figure 4-36 V-BELT DRIVE PRICES
4-66
-------
The method of estimating prices for radial tip fans is the same as for
backwardly curved fans. Prices for radial tip fans operating under 20" S.P.
are given in Figure 4-37. Figure 4-38 provides the data for determining the
fan rpm and motor bhp for radial tip fans. Refer to Figure 4-34 to obtain the
motor and starter prices once the bhp has been determined.
For radial tip fan applications involving greater than 20" S.P., Figures
4-39 and 4-40 should be used to estimate the fan and motor prices, respectively.
The static pressure must be converted to standard conditions as before, using
Table 4.10.
For estimating the cost of custom heavy duty, radial tip induced draft
fans operating at pressures of 15 inches W.G., temperatures to 250°F, and
volumes of up to 400,000 acfm, the collective cost of the fan, motor, and
starter can be considered as 0.38 x ACFM delivered. The breakdown of the
individual costs is approximately 0.19 for the fan, 0.15 for the motor and
0.04 for the starter.
4.7 Stacks
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 asually fabricated of steel, which may be
refractory 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. The design of stacks is influenced
by local conditions such as the maximum design wind load, soil bearing
4-67
-------
100,000^
10,000=^
LU
•M-
LJ
U
cc
Q.
<
u.
3,500^
1,000
100
For High Temperature
Environment add 6%
( 250°F to 600°F)
For Stainless Steel
Construction multiply
Price by 2.5.
Source: Ref. 160
2 3457 10
AP, in H20
20
Figure 4-37 RADIAL FAN PRICES VERSUS ACFM, ANDAP FOR ARRANGEMENT NO. 1
4-63
-------
^100
MOTOR
BHP
Source: Ref. 160
2 3 4 6 8 10 20
AP, IN H20
Figure 4-38 FAN RPM AND MOTOR BHP FOR RADIAL FANS
4-69
-------
*»
o
o
o
o
o
I—I
Q_
1. TP = Fan Pressure measured
at standard conditions
2. For stainless steel construction
and rubber lined housing,
multiply price by 2.5.
3. Source: Ref. 160
200
AIR FLOW RATE, 1,000 CFM
Figure 4-39 RADIAL TIP FAN PRICES
-------
o
o
o
a.
80 nr
70 i
60
40
30
10
NOTE: 1. Accuracy of this curve is t 50%.
vary as a function of:
a) Motor RPM
b) Frame size
c) Voltage
d) Motor enclosure
e) Type of starter
Prices will •
2.
utt
FTP = Fan Total pressure at
Standard Conditions
: ffl
3. Source Ref.
I
j-iLU
m
Mi
U
' '
•m
Jl*
H?
lit
lit
ij'
'. . :
M
i
:
^
I
Ł*
-
n
i
t«
0
20
40
60
140
160
180
200
80 100 120
AIR FLOW RATE, 1000 CFM
Figure 4-40 STARTER AND MOTOR PRICES FOR VENTURI SCRUBBER APPLICATIONS (HIGH PRESSURE, HIGH BHP)
-------
characteristics, seismic zone, and building code requirements. Design
details and formulas for stacks are contained in ref. 157.
Prices for stacks are given in Figures 4-41, 4-42 and 4-43. Figures 4-41
and 4-42 are for carbon steel, unlined, uninstalled stacks under 100'. These
represent the size and range of stacks normally encountered in industrial
applications. Figure 4-43 contains installed prices for large diameter stacks
over 200 Feet in height with liners and insulation. These stacks are
primarily used for large municipal installations such as power plants and
incinerators. Cost details are contained in reference 158.
4-72
-------
10,000 p
cc
a.
Q
UJ
on
CD
<:
o
9,000
8,000
7,000
6,000
§ 5,000
4,000
3,000
2,000
1,000
1. Plate Thickness: 1/4 inch.
= 2. Includes: flange, stack, cables,
clamps, and surface coating.
3. Cables are stainless steel;
qty.: 4.
4. Source: Ref. 160
WEIGHT OF 1/4" STACK
Diameter Weight (Ibs)
200 + 66 H
240 + 82 H
270 + 98 H
340 + 114 H =
385 + 130 H 5
tt
450 + 146 H 3,
470 + 162 H 1
50 60
H, STACK HEIGHT, FT
Figure 4-41 FABRICATED CARBON STEEL STACK PRICE VS. STACK HEIGHT & DIAMETER FOR 1/4 INCH PLATE
4-73
-------
a:
o.
s
4,000
3,000
2,000
40 50 60 70
H, STACK HEIGHT, FT
Figure 4-42 FABRICATED CARBON STEEL STACK PRICE VS. STACK HEIGHT & DIAMETER FOR 5/16" & 3/8" PLATE
4-74
-------
4000
3000
2000
jiisigffisa^S^^
;gŁShf%| p*SŁsŁ2E 40 F
:J: fi: fcjjit: ^j±E5ffi ^HS^iitd:|i
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"" " "*" ^ *^" \, ! IT' 7" Ti *"^ "^^T "^ ^^ ^ — * """"
4- X '4-14 ^--i- " 1 tt, —. 4 } j 1 1 J-L . , > . ! — ~ -*-r-4 t i . . — .4.
±: ::: SI* g S Effl S |: 1:: || g
1 |i|||iii iii i;;i;;lg 15 J"g
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|J^^:-^::::::^J:H^|^-^
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^^*|^S ^s|§Sip30 Ft I.D. Stai
^j|^^-:^g;g^s ^§SfS^§::i:
ffi^g^gSgg gSgl 20 Ft.
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1 li'slii l^silsailgiliili!!!!
|:i[|S J| 15 Ft. I.D
ilHSi E;giislȤfi!^g;S^p
fiSii :SBBB3a**8":BIE^i
|:: :|: i|; ;;:; loading, minimal seis
1000
0
100
200
600
300 400 500
HEIGHT, FT
Figure 4-43 PRICES FOR TALL STEEL STACKS, INSULATED AND LINE.D
700
4-75
-------
Section 5
CONTROL DEVICES
The following description of the control devices is designed to provide
the user with the basic concept of the operation of the device, the parameters
required to size and cost it, and the required auxiliary equipment necessary
for proper operation of the gas cleaning system. The equipment cost of the
control device is based on flange-to-flange costs. The cost of the auxiliary
equipment has already been discussed in the preceeding Section 4. In this
section, the description of the control devices and the integration of the
auxiliary equipment will be discussed so that the user can develop the capital
and operating costs of a control system for any particular application.
5.1 High Voltage Electrostatic Precipitators
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
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
5-1
-------
dislodge the participate, 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 hi-gh; 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-
ters (baghouses) and space requirements are an important factor in the layout
and design of the facilities.
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:
5-2
-------
E = 1 - e '
where E = collection efficiency
w = drift velocity, fps
o
A ~ plate area, ft
Q = flow rate, acfs
The Deutsch equation, though adequate for "scope" cost estimates, furnishes
only an approximate method to estimate plate area.
The electrical characteristics of the dust, quantified by the drift
velocity, as shown in the Deutsch equation, have a large effect on the collect-
tion 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.
5-3
-------
These factors are additive costs to the basic collector pri.ce 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.
Figure 5-1 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. A heat
exchanger or wasteheat boiler may also be used to cool the gases before
entering the precipitator. 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, ductwork 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 temperatures,
The ducting, like the capture device, should be water cooled, refractory or
stainless steel for hot processes and carbon steel for gas temperatures below
approximately 1150°F (duct wall temperatures <800°F). The ducts should be sized
for a gas velocity of approximately 4000 fpm for the average case. Normally,
radiant U-tube coolers would not be required unless the gas stream temperature
to the precipitator was above approximately 700°F. Even in these cases it may
be prudent to use a spray chamber for cooling since the addition of moisture
5-4
-------
HOOD
DUCTWORK
en
en
DIRECT EXHAUST-
RADIANT COOLER
SPRAY COOLER
STACK
PRECIPITATOR
L a A a *?** *• * **rm
\
SCREW CONVEYOR
MECHANICAL COLLECTOR
CONTROL DEVICE AND TYPICAL AUXILIARY EQUIPMENT
Figure 5-1 ELECTROSTATIC PRECIPITATOR CONTROL SYSTEMS
-------
will enhance the precipitation process. Spray chambers may also be required
for cold processes where the addition of moisture will improve precipitation.
For combustion processes where the exhaust gases are below approximately 700°F,
cooling would not be required and the exhaust gases can be delivered directly
to the precipitator.
A backwardly-curved centrifugal fan located on the clean air side (down-
stream of the precipitator) would be a typical selection for a precipitator
application handling high concentrations of dust. A mechanical collector in
this case may be used to reduce the dust loading on the precipitator if an
appreciable portion of the dust is larger than 20 microns in size. The selec-
tion and type of auxiliary equipment which must be integrated with the control
device to develop a workable control system should be based on engineering
judgement.
Prices for dry type (mechanical rapper or vibrator) precipitators are
contained in Figure 5-2 . Prices are a function of, net plate area, which are
calculated using the Deutsch equation:
(1) n = i . e(-wA/Q)
or
(2) A = -Q In (l-n)/w
where n is efficiency
w is drift velocity, f/s
A is net plate area, ft2
Q is flow rate, cfs
exp. is e, the Naperian log base
5-6
-------
QL
D.
o:
p
«c
H-1
o.
t—t
LU
Q.
Based on data from
JOY/WESTERN PRECIPATION DIV
10
Figure 5-2 DRY TYPE
A, PLATE AREA, SQ. FT.
ELECTROSTATIC PRECIPITATOR PURCHASE PRICES VS. PLATE AREA
5-7
-------
As an 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 (l-.99))/(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.
The cost of wet electrostatic precipitators is very difficult to estimate
because of the variety of designs and materials of construction. These devices
are used to collect particulate and mists which are difficult or sometimes
impossible to collect with a dry precipitator. The operation is similar except
in the method of cleaning the plate area. Instead of rappers or vibrators,
water is used to flush the plate area and remove the collected material. Under
these conditions, corrosion becomes a major factor in the design of the units
and stainless steel and other corrosion resistant materials are frequently
used. As a rough estimate, the cost of wet precipitators can be considered to
be approximately 2.5 times the cost of a dry precipitator in the range of
20,000 sq.ft. of plate area. At 50,000 sq.ft., the cost ratio reduces to
approximately 2.0(ref. 172). Caution should be used in applying these factors
since materials of construction have a large influence on costs. For instance,
lead lined plates are used in the collection of acid mists in wet precip-
itators. The comparative costs of these units is approximately 10 times
the cost of a dry precipitator.
5-8
-------
5.2 Venturi Scrubbers
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 agglo-
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.
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.
5-9
-------
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 centerline 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
of 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"2 and S03 in municipal power plant flue
gases.
5-10
-------
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. As the volume flow rate and/or pressure drop increase, the metal
wall thicknesses must also be increased to prevent buckling. 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 superficial 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 of the separator will
determine the diameter of the trays for an internal gas cooler.
The auxiliary equipment normally associated with venturi scrubber systems
is shown schematically in Figure 5-3. These include a capture device and duct-
•
work, a quencher, dust removal and treatment, fan, and a stack.
Prices for venturi scrubbers are contained in Figures 5-4 through 5-8.
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 5-4. For example, at
100,000 ACFM the price is approximately $39,000.
5-11
-------
HOOD
DUCTWORK
DIRECT EXHAUST
QUENCHER
I
ro
FAN
SEPARATOR/
COOLER
SCRUBBER
STACK
TO TREATMENT
CONTROL DEVICE AND TYPICAL AUXILIARY EQUIPMENT
Figure 5-3 VENTURI SCRUBBER CONTROL SYSTEMS
-------
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1!!! !
iiii ;
:::::: : : :;t: "j
i: i: : oil i
i$ttf
See Figure
x 3.20
x 2.3 2
$3450
$6350
Add 15% of
for 1/8" (
Steel Sen
to total
•!i •. u: :;: :if
-f-}-| . > U it...
:{Hr!!; ; ii
ft:
5-
pr
:ar
jbb
3ri
t
t-
5
ic
bo
er
ce
P
B
n y
—
140 160 180 2(
V, WASTE INLET GAS VOLUME, 1000 ACFM
Figure 5-4 1/8" THICK CARBON STEEL FABRICATED SCRUBBER PRICE VS. VOLUME
-------
1,000
o
CM
CŁ
r>
oo
LlJ
O.
O
UJ
o
«s
Q.
10
V, WASTE INLET GAS, 1000 ACFM
Figure 5-5 METAL THICKNESS REQUIRED VS. VOLUME AND DESIGN PRESSURE
5-14
-------
cr
o
§
to
i
-------
3,000
tn
i
cr>
cr
to
«=c
LU
o:
LU
O
«=c
Lu
CŁ
13
to
2,000 :i;l
1,000
Scrubber Internal Surface Area ii;
Ventun
Elbow
Separator
**"* °--W
B-Jkitafell
Source: Ref. 160 , Fuller Co.
Do not extrapolate beyond range
60 80 100 120 140
V, WASTE INLET GAS, 1000's OF ACFM
200
GO
n>
•o
Oi
o>
o
— i.
fu
ro
-s
co
fD
-o
Oi
CO
Figure 5-7 SCRUBBER INTERNAL SURFACE AREA AND SEPARATOR DIAMETER AND HEIGHT
VS. WASTE INLET GAS VOLUME
-------
50,000
LU
O
i-^
Of.
O.
40,000
30,000
20,000
10,000
" Source-Ref 160,
0
0 • 5
Figure 5-8 INTERNAL
10 15 20 25
D, SEPARATOR DIAMETER, FT.
GAS COOLER BUBBLE TRAY COST VS. SEPARATOR DIAMETER
5-17
-------
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 5-5. For 100,000 ACFM and 30",
the required metal thickness is 1/4" plate (always round up to the next
standard plate thickness).
C. From Figure 5-6, find the price adjustment factor for the design inlet
volume and the material thickness found in Step B. For 100,000 ACFM and
1/4" plate, the factor is approximately 1.6. Thus, the carbon steel
scrubber price is now $39,000 x 1.6 = $62,400.
D. If stainless steel construction, rubber or fiberglass lining, or variable
venturi section is to be included, refer to Figure 5-4 and adjust price
accordingly. For 304 stainless steel construction, the adjusted price
would be $62,400 x 2.3 = $143,520. If rubber linings are required, refer
to Figure 5-7 to determine total square footage.
E. If an internal gas cooler is to be used, determine the number of trays
required based on an average of 5 Ibs of wateV* removed per sq.ft. of tray
area with an outlet gas temperature of approximately 40°F above the inlet
water temperature (this is valid for typical scrubber outlet gas tempera-
tures of 200°F or less, water spray temperatures of approximately 70°F,
and superficial gas velocities of 600 fpm). The total water to be removed
is determined from the difference between the absolute humidities of the
inlet and outlet gas conditions. Determine the diameter of each tray from
the separator diameter of Figure 5-7. Read the price per tray from
Figure 5-8. For 100,000 ACFM the separator diameter is approximately
13.5 ft.; thus, the price for one tray is $14,000. This price includes
the cost of the tray plus the cost of additional separator height needed
to contain the tray.
5-18
-------
NOTE: Radial tip fans are commonly used with scrubbers.
5.3 Fabric Filters
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
state 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 particulate may be retained on either the inside or
the outside 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 and frequency of bag cleaning. These methods of
cleaning 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
the compartment are activated with the subsequent shaking of the bags to
remove 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
• -i
of cleaning mechanisms. For this reason, shaker type cleaning is used in
conjunction with heavier and more durable fabric materials.
5-19
-------
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 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 indefinitely 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.
5-20
-------
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 baghouse, 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, usually located at ground level, and a stack
is normally required to vent the gas from the fans.
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
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
constant 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
5-21
-------
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 bag cleaning mechanism to be used in the baghouse. Usually, felted
fabrics use pulse jet cleaning whereas woven fabrics use mechanical 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 suitable fabrics
for a specific application. Because of the violent agitation of mechanical
shakers, spun or staple yarn fabrics of heavy weight are usually used with this
type of cleaning. 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 as follows (ref. 20):
5-22
-------
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 baghouse
(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 filtering fabric will also dictate the
range of air-to-cloth ratios to be used in a particular application. For in-
stance, 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.
5-23
-------
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.
The typical auxiliary equipment associated wrth fabric filter systems is
shown schematically in Figure 5-9. This equipment includes the capture device,
ductwork, radiant coolers, spray chambers, dilution air ports, mechanical
collectors, dust removal equipment, fans, and stack.
Prices for mechanical shaker, pulse-jet, reverse-air, and custom fabric
filters (baghouses) are contained in Figures 5-10 through 5-.14. 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 2.2).
2
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 $176,000. For stainless steel construction, insulation, and suction-type
5-24
-------
in
i
ro
Ul
DIRECT EXHAUST
FABRIC FILTER
V. n 0 O na
DUST REMOVAL
MECHANICAL COLLECTOR
CONTROL DEVICE AND TYPICAL AUXILIARY EQUIPMENT
Figure 5-9 FABRIC FILTER CONTROL SYSTEMS
-------
U1
I
ro
CXI
35
30 i
25
20
o
o
a 15
OC
Q.
Basic Baghouse Price =3.351 +1.84 x An
Stainless Steel Add On = 2.74
1.12 x An
m
1. Bags not included
2. Baghouse price in
W 3. Net cloth area (An) in
1000 sq. ft.
-4 nil :^'i ::i ittrtt 1:1: ::::
t? Insulation Add On
IT+ 0.84 x A
Source: Ref
Fuller Cu.
S-Cuction Add On = 1.382 + .12 x A
0
24 6 8 10 12
NET CLOTH AREA, 1000 SQ. FT.
Figure 5-10 INTERMITTENT, PRESSURE, MECHANICAL SHAKER BAGHOUSE VS. NET CLOTH AREA
-------
r\>
-vj
o
o
o
Stainless Steel Add On =1.65 + 5.0 x An
Basic Bagnouse Price
5.37 + 7.6
1. Bags not included
2. Baqhouse price in $1000 ;;
3. tlet cloth area (An) in -^
1000 sq. ft. ' '
Source: Ref 160
:Fullsr Co.
Insulation Add On = 4.91 + 2.4 x An
6 8 10 12 14
NET CLOTH AREA, 1000 SQ. FT.
Figure 5-11 CONTINUOUS, SUCTION OR PRESSURE, PULSE JET BAGHOUSE PRICES MS. NET CLOTH AREA
-------
01
I
ro
oo
O
O
O
O
I—I
Q.
Stainless Steel Add On
1.9xAn
| Basic Baghouse Price =
I 6.66 + 3".5 x An
1. Bags not included}]
2. Baghouse price in]
$1000
3. Net Cloth area
i (AJ in 1000
1 sqn Ft.
ms
Insulation Add On = 2.28 + 1.77
x An
Suction Baghouse Add On = 2.26 + .25
Source: Ref 160^
NET CLOTH AREA, 1000 SQ. FT.
Figure 5-12 CONTINUOUS, PRESSURE, MECHANICAL SHAKER BAGHOUSE PRICES VS. NET CLOTH AREA
-------
ro
10
SffiSMiK- ;:H
Basic Baghouse Price = 25.68 + 3.0
x An
Stainless Steel Add On = 11.620+ 1.79
1. Bags not included
re 2. Baghouse price in $1000
3. Net cloth area (An) in
1000 sq. ft.
Insulation Add On = 11.2
x An
Suction Add On = 1.69 + .32
x A
Source: Pef 160!
40 50 60 70
NET CLOTH AREA, 1000 SQ. FT.
Figure 5-13 CONTINUOUS, PRESSURE, REVERSE AIR BAGHOUSE PRICES VS. NET CLOTH AREA
-------
on
i
O
O
O
UJ
en
o_
1. Bags not included
2. Baghouse price in $1000
3. Net cloth area (An) in
1000 sq. ft.
4. Designed for continuous oper-
ation and reverse air cleaning
BAGHOUSE PRICE
101.6 + 2.7 x An
INSULATION ADD ON = 38.0 + 1.4 x A
if STAINLESS STEEL ADD ON « 50.0 + 1.4 x An
150 200 250
NET FABRIC AREA, 1000 SQ. FT.
Figure 5-14 CUSTOM PRESSURE OR SUCTION BAGHOUSE PRICES VS. NET CLOTH AREA
-------
design, the total price without bags would be:
Baghouse $176,000
SS 100,000
Insulation 94,000
Suction 18,OOP
Total $388,000
The prices for bags may be determined from Tables 5.1 and 5.2. From
Table 5.2 obtain factor to calculate gross cloth area (at 50,000 ft2 the
factor is 1.11) and from Table 5.1 obtain the price per square foot for the
appropriate cloth and baghouse type. The price of glass bags for the example
is thus: •) 0
50,000 ft* x 1.11 x $.45/ft* = $24,975
Baghouse prices are flange-to-flange, 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 so prices do not differentiate between
pressure or suction. Custom baghouses are designed for continuous operation and
normally use reverse air cleaning. All baghouses except custom baghouses are
assumed to be factory assembled.
5.4 Thermal and Catalytic Incinerator Systems
Gas cleaning by thermal or catalytic incineration is well suited for
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 method 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 more commonly used because of their simplicity and reliability. However,
5-31
-------
Table 5.1 BAG PRICES (S/SQ.FT.) Ref. 160
CLASS
Standard
> " ' ^ wi
Ł > °if '
Custom
TYPE
Mechanical shaker, < 20000ft
Mechanical shaker, >20000ft2
Pulse jet*
Reverse air
'•.••• .•..••,;•;,,•
Mechanical shaker
Reverse air
DACRON
.40
.35
.60
.35
:f;;-r:'::- . •:;:::.:;:
.25
.25
ORLON
.65
.50
.95
.60
',;"•-• ' ' .*•;•
' .' '"*" •: '•'•
.35
.35
NYLON
.75
.70
: .•.;'-.- ' '''••'• -.-. \
.70
'••'•'-•-.'•': •&•'':••.•••'••:';'•'•'
.45
.45
NOMEX
1.15
1.05
1.30
1.05
j&t >
.65
.65
GLASS
.50
.45
.45
.30
.30
POLYPROPYLENE
.65
.55
.70
.55
feH:W/^':
.35
.35
COTTON
.45
.40
:i":U:,;~.-:~*
.40
.40
.40
* For heavy felt, multiply price by 1.5
Table 5.2
APPROXIMATE GUIDE TO ESTIMATE
GROSS CLOTH AREA
01
CO
ro
NET CLOTH AREA
(Sq.ft.)
•j _
4001 -
12001 -
24001 -
36001 -
48001 -
60001 -
72001 -
84001 -
96001 -
108001 -
132001 -
180001 ON
4000
12000
24000
36000
48000
60000
72000
84000
96000
108000
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
-------
catalytic units produce combustion at lower temperatures which can result in
lower fuel costs. In direct-fired thermal incinerators (afterburners), the
contaminated gas stream is delivered to the refractory lined burner area by
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 chamber at lower velocities to
increase residence time and ensure complete oxidation of the combustibles. To
reduce fuel costs, recuperative heat exchangers can be used downstream of the
retention chamber to recover heat from the exhaust gases and preheat the inlet
contaminated gas stream. A second method of recovering heat from the after-
burner 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 concentra-
tion of contaminants in the inlet gases, the operating temperature, 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. Secondary heat recovery may also be used to recover heat
from the exhaust stream for use in the basic process or for other purposes such
as ovens, dryers, vaporizers, etc.
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, recycled gas, etc.. Most units only require basic controls
such as safety pilots and flame failure shut-offs, high temperature shut-offs
5-33
-------
(fan failure), temperature monitors and recorders. The fans used for these
units are usually axial flow or low pressure centrifugal type since pressure
drops for the incinerator alone are low (less than 2 inches W.6.). If a heat
exchanger is included, the pressure drop may increase up to 6 inches W.G.
depending on the configuration of the heat exchanger and the number of passes.
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 lower temperatures
(650-1200°F) than the direct-fired incinerator (850-1800°F) and usually results
in lower fuel costs. One of the limitations of the catalytic incinerator is
its susceptibility to fouling and degradation 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 catafyst 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
5-34
-------
available in packaged units for small volume applications and custom units
for larger applications. The normal pressure drops for catalytic incinerators
can be as high as 6 inches W.G. without a heat exchanger and 10 inches W.G.
with heat exchanger.
The cost of thermal and catalytic incinerators is based on the inlet gas
volume flow rate, factors considering 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 exchanger (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.
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.
Prices for thermal incinerators including refractory linings, are contained
in Figures 5-15 and 5-16. Catalytic incinerator prices are found in Figure
5-17. Residence times for thermal incinerators are based on 0.5 seconds. The
price of a thermal incinerator without heat exchanger for a gas volume of
30,000 SCFM and 0.5 second residence time is $99,000. With a heat exchanger,
the price would be $135,000. The price of a custom catalytic unit with heat
exchange would be $234,000 at 30,000 SCFM. Note, gas volumes are measured at
standard conditions.
5-35
-------
i
u>
CD
o
o
o
Ul
S 80
or
a.
a:
o
60
40
i
20
I
if;
TO
g
Mote:
^5.
6.
Operating temperature of 1500°F
Residence Time for incineration is
0.5 seconds.
Accuracy of this curve is ;f 50%
Price includes incinerator, fan or blower,
controls and instrumentation
Prices will vary as a function of:
a. Retention times
b. Materials of construction
d. Heat content of pollutant
Inlet concentrations of 0-25% LEL light
hydrocarbons.
Process Temperatures of 70-300°F.
Oil fired burners.
Source: Ref. 37, 141, 160, 162
4t
FLOW RATE, 1000 SCFM
Figure 5-15 PRICES FOR THERMAL INCINERATORS WITHOUT HEAT EXCHANGERS
-------
co
o
o
o
LU
a:
O-
150
130
UH
no
y 90
70
50
30
10
tut j
1
I
t;n
w
it
I
Mi
iirt
tir
f
fill
ill:
.1 t'
1
1
'11!
t
in
lit J
rt-
Note:
1. Residence time of 0.5 seconds.
2. Process Temperature is 70 F
3. Operating temperature is 1500°F
4. Curve based on 35% heat recovery
5. Accuracy of this curve is +_ 50%
6. Price includes incinerator, heat
exchanger, fan.or blower, damper
controls, and instrumentation:
7. Prices will vary as a function of:
a. Retention times
b. Materials of construction
c. Special controls
d. Heat content of pollutant.
8. Inlet concentration of 0-25% LEL.
9. Oil fired burners.
10. Source: Ref. 37, 141, 160, 162
1
HI!
FLOW RATE 1000 SCFM
Figure 5-16 PRICES FOR THERMAL INCINERATORS WITH PRIMARY HEAT EXCHANGER
-------
en
CO
oo
o
o
o
UJ
o
o:
o
CUSTOM UNITS WITH 35% HR PRIMARY
HEAT EXCHANGER
CUSTOM UNITS WITHOUT HEAT
EXCHANGER
1. Accuracies of ±50%. '-
2. Inlet concentration up to :
25% LEL Light hydrocarbons :
except packaged units.
3. Operating temperature of
PACKAGED UNITS
4. Price includes incinerator.
fan or blower, stub stack,
controls and instrumentation.
5. Source: ref. 37, 141, 160.
(FOR CONCENTRATIONS UP
TO 6% LEL)
40
0
FLOW RATE, 1000 SCFM
Figure 5-17 CATALYTIC INCINERATOR PRICES
-------
Reference 37 should be consulted for design and cost details of inciner-
ators having different residence times. A thorough discussion of the difference
in costs of materials is also included. Longer residence time requires longer
residence chambers and consequently higher costs. The type and temperature
limits of the refractory linings will also affect the cost of the incinerator.
For approximation purposes, a reduction in residence time from 0.5 seconds to
0.2 seconds will result in a cost reduction of 25 percent. Increasing the
residence time to 1 second will increase the costs by approximately 25 percent.
Secondary heat recovery may be added through the use of a waste heat boiler or
a secondary heat exchanger. The cost of secondary heat recovery is difficult
to estimate because of the variety of devices used for this purpose. If a
secondary air-to-air heat exchanger is used downstream of an incinerator with
primary heat recovery, the added costs can be estimated to be 25 percent of
the incinerator/primary heat exchanger costs.
The cost curves for thermal incinerators are based on an operating temper-
ature of 1500°F. The cost of incinerators operating at other temperatures can
be determined by adjusting the inlet gas flowrates to account for the tempera-
ture difference as follows.
Flowrate (SCFM) at t t + 460
(SCFM) at t
(SCFM) at t
Flowrate (SCFM) at t t + 460
where: t = new temperature, °F
tb = baseline temperature, 1500°F
5.5 Adsorbers
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.
5-39
-------
The process can be described 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. Regeneration 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 adsorp-
tion systems are the result of solids in the process gas stream. Particulate
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 regeneration. 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
s
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
5-40
-------
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).
The capital cost for a carbon adsorber is based on the gross weight of
carbon required for the application. The amount of carbon is determined by the
ventilation rate, the type and mass emission rate of the pollutant, the length
of the adsorption and regeneration cycle, and the carbon adsorption capacity at
operating conditions. The key design parameters that determine the size of the
carbon adsorber are the face velocity and the bed depth. The desired face
velocity is approximately 80 to 100 feet per minute for most commercial and
industrial applications involving solvent recovery and the depth of the beds
may vary from 6 inches to 30 inches. For air purification systems where the
concentration of pollutants is in the order of 1 ppm or less, the desired face
velocity is reduced to approximately 40 fpm with bed depths of 0.5 to 3 inches.
For a given ventilation rate in acfm, the face velocity and bed depth determine
the working bed volume and consequently the weight of carbon.
For design purposes, the working bed volume for a selected cycle time can
be determined from the adsorption isotherm for the particular adsorbent and
adsorbate. The adsorption isotherm is a plot of the adsorption capacity at
constant temperature as a function of the vapor pressure or the relative partial
pressure of the adsorbate in the gas stream. Normally, the adsorption capacity
of an adsorbent increases with increased vapor pressure and decreases with
increased temperature. Using the appropriate adsorption isotherm, the adsorption
capacity in pounds adsorbed per pound of adsorbent can be obtained for the
desired operating conditions. The adsorption capacity is then multiplied by a
5-41
-------
design factor of between 0.1 and 0.5 to determine a working capacity. From
discussions with manufacturers, a design factor of 0.25 is adequate for prelim-
inary sizing of most applications (Ref 151). The weight of carbon for each bed
is then determined by multiplying the emission rate in pounds per hour by the
adsorption time in hours and dividing by the working capacity in pounds adsorbed
per pound of adsorbent. For example, assume that toluene vapors at 70°F are to
be recovered from a source at a rate of 6.15 Ib/min. and the inlet concentration
to the adsorber is to be maintained at 25% of the lower explosive limit (LEL).
The LEL for toluene in air is 1.29% or 3.07 lbs/1000 cu.ft.; hence, 25% of the
LEL would be 0.32% or 0.768 lbs/1000 cu.ft.. The flow rate through the adsorber
is determined by dividing the recovery rate (6.15 Ibs/min) by the concentration
_3
(0.768 x 10 Ibs/cu.ft.) to obtain a gas volume rate of 8000 cfm. The vapor
pressure of the toluene in air at a total pressure of 760mmHg is determined
by multiplying the concentration (0.0032) by the operating pressure (760 mm Hg)
to obtain a pressure of 2.4mm Hg. Using the adsorption isotherm in Figure 5-18,
the adsorption capacity in percent by weight at this vapor pressure is 35% or
0.35 Ibs of toluene per Ib. of carbon. Note that the adsorption isotherm is
for operating temperatures of 21 °C (70°F) and operating pressures of 760mm Hg
with a carbon adsorbent having a density of 27 Ibs/cu.ft.. A working capacity
of 8.75% is obtained by multiplying the adsorption capacity from Figure 5-18
by a design factor of 0.25. If the adsorption period is one hour per bed, then
369 Ibs of toluene (6.15 Ibs/min x 60 min/hr) will be recovered per bed. The
carbon requirements per bed will be 369 Ibs/hr divided by 0.0875 Ibs toluene/
Ib carbon or approximately 4200 Ibs per bed.
Adsorption isotherms for other hydrocarbons are available from handbooks
and manufacturers literature. These isotherms are developed for particular
5-42
-------
•sf.
a.
CO
o
m
a:
Pressure: 760 mm Hg
Carbon: 27 Ibs/FP
Source: Ref. 161
0.01
TOLUENE VAPOR PRESSURE (mn Hg at 21°C)
Figure 5-18 ADSORPTION ISOTHERM FOR TOLUENE
5-43
-------
adsorbents operating at certain pressures and temperatures. Experimental work
has also been done by carbon adsorber manufacturers and others to determine
working bed capacities for various hydrocarbon emissions at a temperature of
100°F and a flow rate of 200 acfm per 100 Ibs carbon (see Table 2.3). The value
of 200 acfm per 100 Ib. carbon represents the approximate combination of 80
feet per minute and a bed depth of 1.5 feet. These values are based on
empirical data and caution should be exercised in their use.
Prices for carbon adsorbers are presented in Figures 5-19 and 5-20, as a
function of total pounds of carbon in the unit. The total or gross number of
pounds is determined by the adsorption rate and the regeneration rate of the
carbon for the emission being controlled. A carbon adsorber will normally be a
dual system with one bed on-line adsorbing while the second bed will be off-line
regenerating. A likely estimate of regeneration time for almost all applications
would be between 30 minutes and an hour. The variation in regeneration time is
due to the type of solvent being desorbed and any drying and cooling requirements
Normally, one hour is the longest expected regeneration time. The adsorption
phase generally requires one hour also; particularly where working bed capacity
may be low and the mass emission rate is high. For some operations, such as
dry-cleaning and solvent metal cleaning where working bed capacity is high, a
longer adsorption phase may be desired. This is likely if steam capacity for
desorption is not always available during a typical operating day.
Figure 5-19 represents packaged units for automatic operation in commercial
and industrial applications. Commercial applications cover dry-cleaning and
solvent metal cleaning. Industrial applications include lithography and petro-
chemical processing. Industrial requirements would increase costs 30 percent
over commercial requirements. Industrial requirements would include heavier
5-44
-------
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80
70
60
50
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30
20
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1, „ mrHHmm ,
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- ' '-'I ':'.': '•"•• • ' : ' ''• • ' , ^''[ '- • ! -:
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ffl|j|tnm}[nij}|{|S^lllfffl^
NOTE: 1. These prices are for basic
} If including adsorber, carbc
| or fan, controls, and st
;;. f- -: F |f
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Tt tbi d:i : : i :
:t J.i|t tl'i : ' :;
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systems , J
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earn *
i '•'•'•" \ '•$ '"• " regenerator. Special requ i r-anen us r:
I,.: :: .'.':: maV dOLlhlP thf> CO«it ;*!
r . : . ^ f j
: : 1 fT 2. These prices are for commer
: : .'., -. . ;.iiLti annl i rat i nn AHH Tn^l fnr
.:: ^ |; tions involving stringent
1 • \t •'• industrial standards.
' f i j ||||||j ffi|| ^ . ^niirrp; Rpf. 6Q , 160V 161
i j - - i
pltl^T ::^
HI fmltillt}f^iti[{iiij|fffif||ml^ ' j|]|^:lllllillitiiill I' [j (I
45678
•cial ~
app 1 1 Ca- ...
166 A
t.
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9 1(
Figure 5-19 PRICES FOR PACKAGED
WEIGHT OF CARBON, 1000 IBS.
STATIONARY BED CARBON ADSORPTION UNITS WITH STEAM REGENERATION
-------
en
i.
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CT>
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INSTRUMENTATION AND
CONTROLS INCLUDED.
Source: RUf. 40, 160, 161, 162
0
60 80
TOTAL WEIGHT OF
100 120 140
CARBON, 1000 LBS.
Figure 5-2Q PRICES FOR CUSTOM CARBON ADSORPTION UNITS
-------
materials for high steam or vacuum pressure designs and more elaborate controls
to assure safety against explosions and prevent hydrocarbon breakthrough.
Figure 5-20 presents custom units, mostly for industrial applications where the
gas flow rate exceeds 10,000 acfm. Table 5.3 is provided to estimate annualized
control cost requirements for steam, cooling water, maintenance, electricity,
and carbon replacement. These values and assumptions represent the composite
of information provided by EPA contractual reports and in-house files. To use
the values in Table 5.3 the required inputs are the pollutant emission rate,
recovery efficiency, annual operating hours, exhaust gas rate, and the purchase
price. The carbon weight used to determine the purchase cost can also be used
to estimate the carbon replacement cost.
In Table 5.3, the steam consumption is based on the energy necessary to
heat the bed and vessel from the operating temperature ( 100°F) to the solvent
boiling temperature plus the energy required to evaporate the solvent from the
bed. The heat of evaporation is directly proportional to the quanity of solvent
present, however, the sensible heat added to the bed and vessel depends on the
amount of carbon and the design of the bed. Some sources have related the steam
usage to the quanity of carbon (0.3 Ibs steam per Ib carbon, Ref. 161), however,
for study estimates, a value of 4 Ibs steam per Ib. solvent desorbed is reason-
ably accurate and acceptable. The cooling water requirement varies directly
with the steam consumption rate in that it represents the heat removed in con-
densing and subsequent cooling of low pressure saturated steam. The electrical
requirement is based on a pressure drop of 20 inches W.G. using a bed depth of
1.5 feet of 8-14 mesh carbon. The pressure drop through a carbon bed is a
function of the carbon granule size, the size distribution, the packing of the
bed and flow velocity. Given a specific carbon bed, the pressure drop through
the bed will be proportional to the square of the superficial face velocity.
5-47
-------
in
i
*>
00
TABLE 5.3 TECHNICAL ASSUMPTIONS FOR ESTIMATION OF DIRECT OPERATING COSTS
Item Assumption Reference
Steam Consumption 4 Ib per Ib. pollutant recovered MSA, DOW, STAUFFER, VIC
Cooling Water 12 gal per 100 Ibs. steam SHAW
Electricity 5 HP per 1000 ACFM STAUFFER, MSA
Maintenance 5% of equipment purchase cost Compromise between DOW and MSA
Carbon Replacement Replace original carbon every five years STAUFFER, MSA
MSA - "Hydrocarbon Pollutant Systems Study" by MSA Research Corp., EPA Contract EHSD 71-72, January, 1973.
DOW - "Study to Support New Source Performance Standards for Solvent Metal Cleaning Operations", EPA
Contract 68-02-1329, Dow Chemical Co., June, 1976.
STAUFFER - Private communication from J. J/"Harte, Stauffer Chemical Co. to Richard Schippers, EPA,
April 11, 1977 on subject of carbon adsorber costs for control of ketones and toluene.
VIC - Private communication from J. W. Barber, Vic Manufacturing Co., to F. L. Bunyard, EPA, June 3, 1977.
SHAW - "Carbon Adsorption/Emission Control Benefits and Limitations", paper presented at Surface Coatings
Industry symposium, April 26, 1979.
-------
Since many adsorption applications involve recovery of a re-useable
solvent, a by-product credit should be included in determining the annualized
costs of control. This credit can have a substantial effect on the amortiza-
tion rate of the capital costs of the equipment. For instance, in the previous
example of an adsorber recovering toluene at a rate of 369 Ibs per hour, the
control device cost based on a unit having two beds (8400 Ibs carbon total)
is $66,500 (see Figure 5-19). The addition of taxes and freight at 8 percent
from Table 3.3 results in a purchased equipment cost of approximately $72,000.
The total installed cost for a typical installation (Table 3.3) is 1.61 x
$72,000 or approximately $116,000. The total annualized cost can be determined
based on the following assumptions: 1) 5800 hours annual operation,
2) 10-year equipment life, 3) 10% annual interest rate, 4) annual maintenance
cost of 5 percent of capital costs, 5) a value of $0.10 per pound for the
recovered product, and 6) operating labor requiring 360 man-hours per year at
$7.87/man-hour. The cost basis is developed from Table 3.4 and the annualized
cost breakdown is as follows:
1) Operating labor ..... ---- ...................... ---------- $~ 2,800
(360 m-h x $7.87/m-h)
2) Maintenance --------- ..... ------------------------------- $~ 5,800
(0.05 x $116,000)
3) Carbon replacement at 5 year life ----------------------- $~ 1,400
(84g°Jb C x $0.85/lb C)
a yr
4) Steam ----------- .......................... -------------- $~ 43,200
(369 Ib/hr x 5800 hrx'41b/lb x
5) Electricity ----------- ..... - ................ - ........... $- 7,500
(SOOOcfm x gj cfm x °'74jLkwh x 5800 hr x $0.0432/kwh)
5-49
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6) Cooling water •» $~ 6,200
/12 gpm 1476 1b steam 60 min ,.ftnn , $0.10 \
(T001b steam x h? x HF^ x 580° hr X 1000 gal'
7) Capital charges @ 22% -- - — $~ 25,500
(based on 10 yr. life, 10% interest & 5.725% for taxes,
insurance, admin., etc.)
8) By-product credit - ($-214,000)
TOTAL $-121,600
The annualized costs for this example is a negative $121,600 indicating
a decided cost advantage to solvent recovery for this application.
5.6 Absorbers
Gaseous pollutants in a process stream can be removed or reduced through
absorption using a solvent having a high gas solubility to dissolve or chemically
combine with the solute. The combined solvent and solute can then be further
processed by stripping or desorbing to remove the solute and recover the solvent
s
for reuse. In some cases the combined product may be returned to storage without
separation as in the case of hydrocarbon recovery in oil or gasoline. Although
absorption is used as a basic process in the chemical industry for the manufac-
ture of acids and other chemical compounds, it is also used as an air pollution
control device for the removal of gaseous contaminants such as sulfur dioxide
and hydrogen sulfide from waste gas processes or the recovery of hydrocarbons
from bulk storage and transfer operations.
The fundamental concept in the design of an absorber is the provision for
good contact between the gas and the liquid. To achieve this, absorbers have
been developed by the various manufacturers with specific proprietary design
features. Each design, however, can be categorized by the type of construction
5-50
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and the method of contact employed. These are typically identified as packed
tower, spray chamber, tray tower and venturi absorbers.
Packed towers and tray towers are the most common absorbers used today
and the design considerations for each are amply covered in Reference 88.
Packed towers consist of a vertical column filled with irregular-shaped
packing, gas-liquid distributors, support plates for supporting the packing,
liquid sprays, and entrance and exit ports for the liquid and gas streams.
The gas and liquid flow through the column can be either concurrent or counter-
current, the latter being most often used. In the countercurrent tower, the
gas enters the bottom of the column, passes through the packing material and
exits at the top of the column. The liquid solvent is delivered to a manifold
of sprays or other devices at the top of the column and is sprayed over the
packing to wet the entire surface. The liquid solvent trickles down through
the packing countercurrent to the gas flow rising through the column. To
preclude channeling through the tower, particularly with long columns, distri-
butors are located at intervals to redistribute the liquid over the cross-
section of the column. These distributor plates have selective openings for
both the gas and liquid. Support plates are also required at intervals to
support the packing. These plates which may provide a dual function of both
a support plate and a distributor plate, should have a larger open area than
the column area with packing so that they do not substantially affect the
overall pressure drop.
In the design of a packed tower, four basic parameters establish the size
and operating characteristics of the unit. These include column diameter,
pressure drop, number of transfer units and the height of the transfer unit.
5-51
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To determine column- diameter, the gas and liquid flow rates, gas and liquid
densities, type of packing, and the liquid viscosity must be known or estimated.
The superfical gas velocity and column diameter are determined from empirical
graphs which estimate the pressure drop correlation and generalized flooding
condition for various packings. The flood condition is a point at which
increased gas flow will result in excessive pressure drop and liquid entrain-
ment in the gas stream. Normally, design velocities for a packed tower are
based on a certain percentage of the superficial gas velocity at the flooding
condition. This percentage is based on the orientation and type of packing
material.
The performance of the tower is predicted from experimental data in two
forms: 1) the required number and height of transfer units, and 2) the gas
and liquid film mass transfer coefficients. The use of either system is a
matter of choice and usually depends on the units in which the operational and
equilibrium data are presented. A thorough description of the development of
S
the design criteria for a packed tower absorber using the transfer unit system
is contained in Reference 88, "Air Pollution Control Manual" AP-40 and therefore
that system of units will be used in this discussion. The transfer unit concept
offers the advantage of the characteristics of the packed tower being expressed
as a number of units with a corresponding height in feet. The number of trans-
fer units is related to the efficiency of the absorption process itself, while
the height of the units is concerned with the geometric and flow characteristics.
Using the transfer unit method of design, the column height can be deter-
mined from:
column height = H x N + h
5-52
-------
where: H = height of transfer unit
N = number of transfer units
h = added height for vapor/liquid separation, cleaning, etc.
The value, h , depends on the specific application, although it normally
becomes less significant as H „ and N increase. The height of the transfer
og og
unit, H , can be determined from:
og
0.5
(Ref. 88)
where: a.e.y are packing constants (see Ref. 88)
2
G = superficial gas mass flow rate through column (Ib/hr-ft )
2
L = superficial liquid flow rate through column (Ib/hr-ft )
VG = gas viscosity (Ib/hr-ft)
PQ = gas density (lb/ft3)
D6 =• gas diffusivity (ft2/hr)
Although the above equation (obtained from Ref. 88) neglects the effect of the
liquid film resistance, it is sufficiently accurate for study estimate designs.
The number of transfer units, N , can be approximated by the following:
mg y - mx '"G
NOQ = ln [(1- -r)(Y1 -»"x2) + r^
s m 2 2 m
•"G
where m = slope of the solute/solvent equilibrium curve
2
G = superficial molar gas. flow rate (Ib-mole/hr-ft )
L = superficial molar liquid flow rate (Ib-mole/hr-ft2)
5-53
-------
Y, Y? = mole fraction of solute in gas stream at concentrated and
dilute ends of countercurrent tower, respectively
X2 = mole fraction of solute in liquid stream at dilute end
of tower.
This equation for N is based on the work of Col burn (Ref. Trans. AICHE,
og
35,216 (1939) and is duscussed further in Reference 164. It is only applicable
to those systems where the equilibrium curve is linear or where the solute
concentration is less than 3 percent by volume. This encompasses most air
pollution control applications.
An example problem illustrating the method of determining tower diameter,
height and type of packing, flow rates and pressure drop for a packed tower
absorber is contained in Reference 88. This design process must be completed
to establish the equipment cost criteria for this type of absorber.
Tray towers are similar in many respects to packed towers. Instead of a
gas-liquid interface on the surface of the packing, the gas is bubbled through
the liquid contained in a tray. Several trays are arranged in a vertical column
and the liquid cascades downward from one tray to the next. The trays are
usually designed to permit vertical gas flow through bubble caps or perforations
while the liquid level in the trays is maintained by a weir. Overflow from each
tray cascades to the next lower tray and is removed from a sump at the bottom of
the tower. The gas flow enters the bottom of the tower and passes upward
through the openings of each tray, through the liquid held in each tray, and
finally exits at the top of the tower. Theoretically, as the gas passes through
each tray, it is assumed that the gas mixes with liquid of uniform composition
and is in perfect equilibrium with the liquid. Even if perfect equilibrium is
5-54
-------
assumed, the absorption efficiency would not necessarily be 100 percent. The
absorption efficiency is limited by the solute concentration in the solvent and
the gas stream, the temperature, and other variables. However, perfect equil-
ibrium cannot be obtained on an actual plate and therefore it is necessary to
introduce a performance factor, known as the plate efficiency, to express the
relation between the actual and an ideal plate. A discussion of the development
of the design criteria for tray towers is also included in References 88 and 164.
For a given application, the tower diameter, type and number of trays, and
operating characteristics are needed to develop equipment and operating costs.
A simpler type of absorber is the spray chamber which provides gas-liquid
contact without the use of packing material or trays. These devices are also
used to cool hot gas streams or add moisture to the gas (see section 4).
Typically, a spray chamber consists of an empty vessel equipped with a
series of nozzles which spray liquid over the cross-section of the chamber
while the gas passes through the sprays. The size of the droplets depends on
the type and size of nozzles and the pressure of the liquid supply. Nozzles
can be selected to provide a nominal droplet size, however, in the spraying
process, some drops agglomerate while other disintegrate into smaller drop-
lets. The fine droplets have a tendency to be entrained and carried away in
the gas stream while the large droplets traverse the gas stream and collect on
the walls of the chamber. This combined with the short contact time reduces
the efficiency of the absorption process as such. One advantage of spray
chambers is that both particulate and gaseous contaminants can be removed from
a gas stream. This is of particular importance with gases that also produce
solid deposits when reacted with the liquid solvent. Another advantage of spray
chambers is the. possibility of cooling gas streams at high temperatures where
5-55
-------
the packing material in a packed tower might be affected by these high temper-
atures. Spray chambers are used primarily where the absorbed gases have a
high solubility and only a few transfer units are required for the absorption
process. To reduce the carry-over or entrainment of small droplets, the gas
velocity in a spray chamber must be low. As a result, the diameter of the
chamber, and hence the cost, become rather large as the design flow rate is
increased. To compensate for this, cyclonic spray chambers have been developed
where the gas enters the chamber through a tangential opening and the liquid
is injected at the axis through a row of nozzles. The cyclonic action assists
the separation of the'liquid droplets from the gas and permits higher gas
velocities, The cost of spray chambers is related to the type and thickness
of construction materials used, such as stainless steel, rubber-lined steel,
etc., and the configuration of the vessel in terms of diameter, height, and
tangential or axial inlet.
Venturi absorbers are similar to spray chambers in that they too can be
used for gaseous and particulate removal. As described in Section 5.2, the
venturi scrubber/absorber achieves contact between the gas and the liquid in
the throat of the venturi where the gas is accelerated to high velocities at the
point where the liquid is injected. The shearing action of the high velocity
gas on the liquid stream or droplets produces a fine mist and good dispersal.
The relative velocity between the gas and liquid droplets insures good contact.
However, the contact period is short and the number of transfer units that
can be expected is similar to that obtained with a spray chamber. As a
result of the high velocities in the venturi and the fine droplets generated,
the carry-over or entrainment is considerable and therefore a mist eliminator
is generally required downstream to remove this liquid from the gas stream.
5-56
-------
To provide the high gas velocity, a substantial amount of energy must be dis-
sipated in the venturi in the form of pressure loss and this represents high
power costs at the fan. Maintenance costs are also increased due to the
abrasion at the venturi and fan caused by the impact of liquid in the gas
stream.
The costs of spray chambers and venturi scrubbers are covered in Sections
4.3 and 5.2. The cost of absorption towers is shown in Figures 5-21 through
5-24. The cost of these towers depends on the size, thickness, and materials
of construction of the vessel since these units are basically custom designed
for individual processes and applications. To develop the design parameters,
the design sequence demonstrated in Reference 88 should be followed to deter-
mine the tower diameter, pressure drop, and the number and height of transfer
units for the specific application. Figure 5-21 illustrates the fabricated
cost of a carbon steel vessel shell in dollars per linear foot plus the cost
of two semi-elliptical heads. The height of the vessel is determined by
multiplying the number of transfer units by the height of the transfer units
plus some additional heinht for vapor/liquid separation at the top of the tower
and cleanout at the bottom.(typically 2-3 ft plus 25% of the diameter, ref. 38).
The shell thickness is determined from Table 5.4 for the expected internal
operating pressures and temperatures. In many cases a corrosion allowance of
1/8-1/4 inch is also added to the minimum thickness for carbon steel constru-
tion. The cost of the fabricated vessel alone, therefore, includes the cost
of the shell plus the cost of two heads. The fabricated cost of a skirt which
is provided for support of the vessel and flange-type nozzles for shell
penetrations must also be added to the vessel cost. Figure 5-22 reflects the
cost of skirts which include a base plate, anchors, an 18-inch diameter access
opening, two reinforced pipe openings and a vent hole. The thickness of the
5-57
-------
10,000
t/5
O
O
O
O
o
ac.
-------
00
CO
CO
4600
4400
4200
4000
3800
3600
3400
3200
3000
2800
2600
2400
2200
o
g 2000
CO
1800
1400
1200
1000
r
±k
0
4ii
L
i L/
"
r
Source: Ref. 160, 165, 166
2345678
SHELL DIAMETER (FT)
10 11 12 13
14
Figure 5-22 SKIRT AND SUPPORT COSTS FOR CARBON STEEL VESSEL
5-59
-------
1800 i - -^L
1700 b=pi
1600 ^r-^
1500 ~^-—
| ; ' ''II
1400 H^
1300 HIE;
1200 ^=Ł
i ' ' "T •
— 1100
*~ 1 1 \'< ' 1 ; i ' ' 1
g 1000 =^i±S
o i i
UJ -l-r j--*— *•
W 900 H^
O i--14" -H — r
UJ 1
Ł 800 =5EJ|
i -I--1-1 — — r
Ul ---.131
i ;:1^;
< 700 ;|P?;
U. :S:::+:
600 ;=Ł=+;
500 :i;=g
400 || H
300 1 II | I ' I
200 Unffifji
i r*n " t iit- "
100 7, -^T
0 Ł::±:::
0 2
= :150 PSI
Ł3:4 Flanqe-T
-rj-*- ' ' ' ' j|ii i i i i
1 T "T •' •"*"[ *"T"T * I !
----i- ,iji i | i -I--J-.-
i ,.i . . j 1 ; -tit i . ( 1
pi-i-. — i-_*. | , | . — TJ;^
i=li?:g
Bjtj*-Ł— Ijtf
Rai
ype
4r^i-
i' ! i I
^rrr
4-> )-(..
Ill
t i t •
-p-H-
F
-rV
i 1 1
4-4-*-
, . j.. -
sed-Face G^t-^^ii-^.---^
Nozzles la-^f--.-^^^
-J-j t i- --i-j-- -f tJ4 t t i ~- . 1 ; i *-.*•-- | i-i-*- -i i-i- -r-
^: 5:: ^ ^ -Si 3si -*: itti ^
:gi;l;l^ilgg:i|i
Fm!' :: : fi
li!4.jEEE±SEEEi;EEiEEEEEc 2)
iU_ ttt . r ii iiil lU . ^ i . i_L
:S: J:::!:^:3^:^:^:*::::^::
rrn. Ł IE - -r-4- • -4-h- t ; * • ^ — ._-_ -
|jl!!|l|j|||ji|||Tl[|iii |![|i|l|| ||llj||-
EEE!|EEE Source: Ref: 160, 165, 166 :;:;:;:;;:
4 6 8 10 12 14
J_. Xj.t J ;.l -,. jili 4-4-1 j- -J-T--1- ^j 1 i i-l-i j t |4-
._— ,i_p, 4 Tj. i * . i . , i I J , ! > : i , , 1 ,
i -I- .. J_i ! ! I . iiil ii|.{ 1 . ; ; | , r 1_
1-4- - .Ml j . IJ. 4- -4-- -j-i--.t -|-i r!^ -1-4 t j- ; r i ! 1 . ) [
H-- -H--J- : 1 - 1 - J--- j j I 4- 41 -M--J- -4--*- 1 ! i -
For manways and Handholes
50% for cost of blind fla
gaskets, hinges or davit.
For stainless steel
TYPE COST ADJUSTMENT
304 2.0 •
316 2.3
[ 1 1 ' ' ' [1 1 1 1 ' 1 1 1 1 1 1 1 ' 1 H 1 1 1 [ 1 1 | i 1 1 1 ' | • | | • ; *
16 18 20 22 ;
i t i
^rr
.; a. . .,-
TIT
i ri T i
TT4
-tt-
T'PT
1 ' i
, i i i
add
nge
•"'"T
24
H
TT1-'
H
tfr
i , i I-
i I
"TJ+
^.4 J j .
:±r:
/
±±tt
"^5
^-H
•H-1-
*"^"M~
- — H-
±3=r
— "T4"
>6
^rt
id
—
M
2
INSIDE NOZZLE DIAMETER (INCHES)
Figure 5-23 COST OF NOZZLES
5-60
-------
3800
3400
3000
2600
LU
UJ
I— QC
o: o
os:
o.
2200
GO
a: CM
o
=3
2
a: co
S< 1800
>- or
er LU
2 a.
LUO
0.0
1400
1000
600
200
FOR TRAYS ONLY
COST PER TRAY MUST BE MULTIPLIED
BY COST ADJUSTMENT FACTOR
20
COST ADJUSTMENT FACTOR
304
TAILLESS
TRAY
CARBON STEEL
DISTRIBUTOR
CARBON STEEL TRAY
CARBON STEEL SUPPORT PLATE
FOR STAINLESS STEEL
SUPPORT PLATE OR DISTRIBUTOR
ITEM: COST FACTOR
SUPPORT PLATE 1.8
DISTRIBUTOR 1.3
10
Source: Ref:'160, 165, 166
4 68 10 12
SHELL DIAMETER (FT)
Figure 5-24 COST OF TRAY, SUPPORT PLATE OR DISTRIBUTOR
14
5-61
-------
skirt should be approximately equal to the thickness of the shell. Figure 5-23
reflects the fabricated cost of nozzles for typical shell penetrations such as
those required for the inlet and outlet for the gas and liquid, relief valve
connections, pumpout alternates, spray inlets, and manways.
The cost of internal tower equipment such as support plates, trays, and
distributors is shown in Figure 5-24. The indicated prices apply to both tray
towers and packed towers and represent the installed cost per item. The cost
of trays is based on quantities of 20 or more. For quantities less than 20,
the unit tray cost must be multiplied by the cost adjustment. The cost per
cubic foot of internal packing is shown in Table 5.5.
The summation of these costs represent the fabricator's shop costs. Added
to this must be the fabricator's cost of engineering, administration costs,
and profit as determined from Table 5.6.
As an example, the design calculations for a carbon steel packed tower as
outlined in the illustrative problem of Reference 88 indicate that the tower
diameter should be approximately 2 feet with a tower height of approximately
15 feet. The inlet gas flow rate is 520 cfm and the liquid flow rate is 3 gpm.
The tower packing is to be 1-inch carbon steel raschig rings and the absorber
is to be operated at ambient conditions of temperature and pressure.
Under these conditions, a 1/4-inch place thickness for the shell may be
selected which would provide adequate allowance for corrosion. A suitable
inlet gas velocity for this absorber would be approximately 1800 fpm which
would require a gas inlet and outlet of approximately 8-inch diameter. A
suitable liquid inlet and outlet pipe for 3 gpm would be approximately one inch.
A manway of 18 to 24 inch diameter would normally be provided at the top and
bottom for larger diameter towers, however, for this small diameter tower, a
5-62
-------
Table 5.4 MINIMUM SHELL THICKNESS AT AMBIENT TEMPERATURE (CARBON STEEL)
Shell Diameter* (Ft)
Internal Pressure:
Atmospheric
25" WG
50" WG
100" WG
10 PSIG
100 PSIG
200 PSIG
2
1/8"
1/8"
1/8"
1/8"
1/8"
1/8"
1/4"
4
1/8"
1/8"
1/8"
1/8"
1/8"
1/4"
1/2"
6
1/8"
1/8"
3/16"
3/16"
1/4"
3/8"
3/4"
8
1/8"
1/8"
3/16"
1/4"
3/8"
1/2"
1"
10
1/8"
3/16"
1/4"
5/16"
7/16"
3/4"
1-1/4"
12
1/8"
3/16"
1/4"
5/16"
1/2"
3/4"
1-1/2"
* For corrosion allowance add minimum of 1/8 inch.. Thicknesses are for
ambient temperatures and temperatures up to 600°F. Thickness correction
factors for higher temperatures are: 1.04 for 700F; 1.14 for 750F;
1.35 for 800F (Ref. 165).
Table 5.5 COST OF TOWER PACKING (Ref. 160, 165, 166)
Type and Material
Pall Rings:
Carbon Steel
304 Stainless
Polypropylene
Intalox Saddles:
Polypropylene
Porcelain
Raschig Rings:
Carbon Steel
Porcelain
1 Inch
($/Ft3)
19
54
14
15
12
17
8
1-1/2 Inch
($/Ft3)
15
43
-
-
-
14
7
2 Inch
($/Ft3)
13
35
8
10
9
9
6
3 Inch
($/Ft3)
-
-
-
5
8
-
-
3-1/2 Inch
($/Ft3)
-
-
-
-
-
-
-
5-63
-------
Table 5.6 ADDITIONAL COSTS FOR FABRICATOR'S ENGINEERING, PURCHASING,
ADMINISTRATION AND PROFIT (Ref. 160, 166)
Total Cost of Fabricated Vessel
Less than $ 5,000
$ 5,000 to $10,000
$10,000 to $20,000
$20,000 to $30,000
$30,000 to $50,000
$50,000 to $80,000
Over $80,000
Cost Factor
0.25
0.23
0.20
0.19
0.18
0.17
0.16
5-64
-------
12-inch hand hold can be provided at each end of the tower. A drain in the
bottom head of the tower should also be provided for draining, flushing and
cleanout.
Using Figure 5-21 the cost of the basic vessel is $420 for the heads plus
$52 per foot of shell or $1200. The cost of the skirt, as determined from
Figure 5-22, is $1140. The installation of nozzles for the various vessel
penetrations results in a cost of $2580 for three liquid nozzles at $120 each,
two gas inlet/outlet nozzles at $330 each, and two hand holes with blind
flanges at $780 each.
The tower internals would consist of a packing support plate and two
distributors spaced at 5 foot intervals plus the internal packing material.
The cost of the support plate and distributors, as determined from Figure
5-24, is estimated to be $1220. The volume of packing required for a 15-foot
tower with a 2-foot diameter is approximately 47 cubic feet and the estimated
cost of the packing, as determined from Table 5.5, is approximately $800.
The total fabricated cost of the packed tower is therefore $6940. The
fabricator's sell price including engineering, administration costs, and
profit, but less taxes and freight, is determined from Table 5.6 to be
$6940 x 1.23 or $8540.
5.7 Refrigeration
Removal of gaseous contaminants in a process stream can be accomplished
by cooling the gas stream to condense and remove the contaminants. Refrigera-
tion may be used alone or be combined with other processes for the removal or
recovery of gaseous pollutants. For instance, in the removal and recovery
of hydrocarbon vapors from the transfer operations at teminals and bulk plants,
5-65
-------
refrigeration can be used singly to condense the vapors at atmospheric pressure
or it can be used in conjunction with a compressor for condensation and/or
absorption of the vapors at higher pressures and more moderate temperatures.
In absorption systems, refrigeration can be used to condition the solvent by
increasing its gas solubility characteristics at lower temperatures, thus
permitting both the solute and solvent to be the same product but in different
phases, i.e., gas and liquid.
Vapor recovery systems utilizing refrigeration alone at atmospheric
conditions usually consist of a refrigeration unit, a heat exchanger/evaporator,
storage tanks for the chilled and defrost brines, and a vapor condenser. For
low temperature applications, the refrigeration unit is normally a compound or
cascade multistage system providing temperatures to as low as -250°F- In
general, compound systems are used for systems requiring temperatures to
approximately -100°F and cascade systems are used for temperatures below -100°F.
The recovery of hydrocarbons typically found in the transfer operations of
petroleum products require temperatures of approximately -110°F and cascase
refrigeration systems are normally used. In the cascade system, shown in Figure
5-25,the condenser of one refrigeration stage acts as the evaporator for the
second stage to produce these lower temperatures. The evaporator for the
final stage of refrigeration is the heat exchanger/evaporator where a chilled
brine is circulated and cooled. A storage tank is provided for the chilled
brine as a low temperature reservoir of coolant for the vapor condenser. The
gas stream mixture of air and hydrocarbon vapors enters the vapor condenser
where the hydrocarbons having boiling temperatures above approximately -100°F
are condensed and collected at the bottom of the vapor condenser. In the
condensing process, moisture in the gas stream is also collected as frost on
5-66
-------
in
Air- Cooled
Condenser
Compressor
Air
Reclaim
Heat
From Refrigeration
Compressors
Vapor/Ai r
In
Air Out
Cold
Brine
Reservoir
Defrost
Brine
Reservoi r
Hydrocarbon
Out
Condensed
Water
Vapor
Source: Edwards Engineering Corp,
Figure 5-25 Cascade Refrigeration System for Vapor Recovery
-------
the condensing surface and periodically the condenser must be defrosted. This
is accomplished by passing a defrost brine through the vapor condenser for a
short time period. The defrost brine acts as a heat exchange medium by removing
heat from the refrigeration unit and transferring it to the vapor condenser. A
separate storage tank is used as a warm brine reservoir. For continuous vapor
recovery, two vapor condensers can be used; one condensing while the second is
defrosting.
Refrigeration can also be used as an intermediate stage in a combined
process to remove hydrocarbon vapors. Systems utilizing refrigeration in this
capacity are the Compression-Refrigeration-Condensation systems (CRC) and the
Compression-Refrigeration-Absorption systems (CRA). In the compression-
frigeration-condensation process, the gas stream containing hydrocarbon vapors
is first passed through a saturator with recovered product to saturate the gas
stream beyond the flamability range. The saturated gas stream is then passed
through the first stage of a two stage compressor where the gas is compressed.
An intercooler and liquid/gas separator are provided between stages to cool
s
and condense some of the more volatile vapors before the gas stream is
delivered to the second compressor stage. The gas leaving the compressor
passes through a condenser where it is cooled to permit subsequent condensa-
tion of the remaining vapors. This^condensate together with the condensate
from the intercooler are returned to storage tanks or to the saturator as
recovered product.
In the Compression-Refrigeration-Absorption system, the flow scheme is
essentially the same with the exception of the replacement of the condenser
with an absorber. The absorber in this process, however, is the primary unit
and the remaining components serve to condition the liquid and vapor entering
the absorber. The vapor-laden gas is first passed through a saturator to
5-68
-------
saturate and maintain the gas mixture above the flamability level before it is
delivered to the compressor. A single stage compressor and aftercooler are used
to precondition the gas stream for absorption. The gas then enters the absorber
where it is sprayed by liquids chilled in a refrigeration unit. The absorp-
tion of the vapors by the liquid is promoted by moderate pressures and lower
temperatures so that the remaining gases are essentially free of hydrocarbons
and can be vented to the atmosphere.
The CRC and CRA systems are proprietary systems which have been custom
designed and fabricated for specific applications. These systems are not
actively marketed at this time. Systems using only refrigeration can be
adapted to many applications and the efficiency or vapor recovery capability
of these systems depends on the vapor pressure and temperature characteristics
of the pollutants and the gas stream. Refrigeration systems are particularly
well suited for applications such as the recovery of hyrdrocarbon vapors from
gasoline marketing operations. These systems are sold as packaged units con-
taining all the piping, controls, and components and are usually provided
skid-mounted with an appropriate weather enclosure. The auxiliary equipment
required to provide a complete vapor collection and recovery system might con-
sist of a gas holder, liquid storage tanks, pumps, and piping between the
pollutant source and the storage tanks. The size and subsequently the cost
of a vapor recovery unit will depend on the operational schedule, process
flow rate, level of hydrocarbon emissions and the gas and liquid storage capac-
ities.
The costs of refrigeration vapor recovery systems are shown in Figure
5-26. The cost of the unit includes a complete skid mounted package containing
the refrigeration unit, brine storage, two condensing units, and pumps, valves
5-69
-------
o
o
•*>«>•
s-
o
Q.
(T3
O
'43
(O
O)
250
200
150
100
50
:i Re
;; Ou
:: IIHtllJ
i;:;;:
-Note
i 1}
i 2)
1 3)
|;:; 1
UttlM
imtJIl
trfttilm
!ill!!U!![l!
iliiii
illii
i^iiill i
• •••Hill *Ml
iiiiiiiliH-ii
Kmmm'itm «••
,.:;s:!:: :32
ts»:::!uiM
iiiiiMi!
lili
•:=;:;i:(imi
•••••••••••ill
•••••••••••Sin
friqeration Vapor Recovery Systems with - • •••••
tlet Condenser Temperatures to -110°F ;:; ;:; ;j
^HUfHHUItHrilltit-HiHIIIIIIIIIItlltlllllllltlllllllllltritUtt tt t
illlllllllliitltll'MllllilllllllllllllllllllFlllltillilllllllilllf l'rf 1 1
TBiiilSiii
i:. I T :
Normal power requirements include ^mffl|fm^li[||{ffl
brine pumps, compressor, condenser jMrnmlmffllBiflHlffl]
fan, controls & instrumentation. igm»||Mwff
For explosion proof units, multiply \ I ^ (,\(
by 1.2. •;;;;;:{* * ^.
' } f O-*.^t i '
Source: Edwards Engineering Corp. IfflifflPrlfffft iirfflfifflffffl
1 Lt 1 j '' 1
flffl||pt{{ti|i jj[p[j|ffijM^
•wimWtiliitH
illii llgiiiyillp:liilH^liligiiypHB|
w mmmt i 1
iiiiii !!!!! H Jilii i! jiilil!! II !
iilliiili JJiii ill ill! !,!0
!ii! II P ! !!H!ii H!ii!!0ilili!!!l!!!!!!!!! iilHHi! ! (ii
! piiii !!Hii!i!!iiiiHi!ii! 111!!
SI iii III
:•::..•::.:::: ': :. , . :. . . 1.;
; :: ; ..:.:: *i|ui.
•^•iilP^ Wifiiffll Hi
ii r:;pT J;N^:'':: t
• - ^ ?^^iij ;;; - i *t
»ppr L ^^siii|ii ttpiy
I; r^^t\\'' :! :;:::;;: - - i It
^'S&il Nil! MiiMiii ::: :ift|
^g^^^M|fi|M||!ii|;'!:|
WSiffi^Biiip{i^l Ą"
:•; :;: . Ill i» :: :• •-: ;;. It H it t-i vn :f
r-i viiii ' +- t- - •- :f fffi ^T- }f T -ip tm
: : :i :1 : ; : i Ifflti *L = Jii
IfiBBBiiBli11 iiiPiji|
^^^^^BHwwii
MlPliliilllliPfiil1'!^^
m^ ISiffilii^^
!»(i!!::ijsj HnHninn i» inuig : ny m n m tmmai
i*2-«Jii«IiiM» ••• ••••••Iii* i • i ii •! * • t HI IHH*H
ssju:»!!ius. u: sscutn uiJut ir i u in{B
liiijipjyq iii'iiljliljnin il!| IJIP ifflHIUffiffi
••••i«3iiii* ••• ••• MB ii •••**•••! •!• 1 U EfUHBHIHM
:::!:!}[:«:• iinii- ijiii i|"ii!:::::«:ia jiimjj [fiilSJBiD
: ::: i:i:::i:::n: ;;;:! n!HI!"!»::!:!!» !li!l» !« ! < I!-HI
i::n i!ii!li:i:!:i !l:i: !!:!'!h!i::i:::i:Ji 1 Hiiiii lit hlUH!
i!|:; iiHUSiHiii ii:;:iijiiij:j;:;;;;;;i;;;::j iiijilHliigi i S iHiii
iii:: ::::;::::;::::;i:i:::::::;:::::n:::::;t:::i::::::;ii:{:::: r: : ::ii
•••••••••••••••• ••••••••••••••••••••«••••••**(••••»••**• •••Jiiiiitf>»i »•••
!••••• •••••••••••»•«•••••••••••••••••••••••••• ••••••« fiiiii*i*i st til*! •••
••«•!••• ••••••••ii|f •••••••••••••••••••• •••••••••« illl9|li*i|ii! 11111 •••
ipfMll Illii ••••••••••••••••••t •••»•• •••••••••• •••••If •••••••••••I iiiil •••
300
200
100
0
100 200 300
Figure 5-26 Refrigeration Vapor Recovery Units
400 500 600
Flow Rate (CFM)
700
800
(U
O
z
(U
to
to
-M
CL>
O)
I
DL
(O
S-
o
-------
and controls. These units are priced according to the continuous gas flow
rate in cfm which is processed. In transfer operations, this represents the
displaced volume of gas corresponding to the maximum continuous flow rate of
product pumped; or, in terms of cfm, one cfm is equal to 7.48 gpm. The
condensing temperature for these units is approximately -100 to -110 F which
is sufficient to condense most of the heavier hydrocarbons.
For gasoline vapor recovery, the units have the capacity of recovering
a minimum of 90% of the hydrocarbon vapor when the vapor entering the condenser
consists of 35% gasoline hydrocarbon by volume; and of recovering 70% of the
hydrocarbon vapor when the vapor entering the condenser consists of 15% gasoline
hydrocarbon by volume. At all feed conditions the partial pressure of the
hydrocarbons in the vapor leaving the vapor recovery units is approximately
0.38psia. The recovery rate of other hydrocarbons, such as benzene or toluene,
will depend on the partial pressure of the hydrocarbons in the feed stream and
the corresponding vapor pressure of the hydrocarbons at the outlet temperature
of approximately -HOOF
The pressure drop through the vapor condensers ranges from approximately
1 inch W.G. when the condenser is free of frost to 4 inches W.6. when the
condenser is ready for defrosting. The estimated normal power consumption for
the units excluding fan/blower power costs for the gas stream and pump power
requirements, if any, for the recovered product, is also shown in Figure 5-26.
The average service and maintenance costs for these units are estimated to be
approximately $150 per month based on an optional oreventative maintenance ser-
vice provided by the manufacturers. The cost of this service is the same for
all units.
5-71
-------
The costs shown in figure 5-26 are specifically for refrigeration vapor
recovery units used to recover hydrocarbons from gas streams. These systems
include vapor condensers, defrost equipment, and other ancillary components re-
quired for these applications. The cost of industrial vapor compression refrig-
eration systems used for cooling other products are shown in figure 5-27. These
costs represent the complete system fully installed including the compressor,
condenser, evaporator, controls, foundations and all auxiliaries except the
piping runs for product or cooling lines. These systems are rated in tons of
refrigeration (12,000 Btu per hour per ton of refrigeration) at various evapor-
ator temperatures. As the evaporator temperature is lowered, the capacity of
a given refrigeration unit decreases. In air cooling systems similar to the
solven recovery units shown in figure 5-25, the approximate relationship be-
tween gas flow rate and tons of refrigeration is given by
Tons refrigeration = 4.5 Q U.24 + 0.45 W) AT + 1076AVJ]
12,000
where Q = gas flow rate, SCFM
W = humidity ratio, Ib water/1 b dry air ^
AT = inlet air temperature minus evaporator
temperature, °F
5.8 Flares
Flares are used predominantly in refineries and in the petrochemical
industry to burn waste gases which normally are not economically recoverable.
In many cases flares are used in the event of a process upset or some other
emergency condition where excess gases and vapors must be vented immediately.
Under these circumstances, flares are normally used intermittently with pos-
sible long periods of disuse.
5-72
-------
10,000,000,
(A
O
O
c
•^*
Q.
«^-
0.
•p
O
3
•o
O
D.
c
•I—
a.
a.
O
O
O
W)
I/)
0)
o
O
TJ
OJ
10
•p
(O
-P
O
1,000,000,0 :±tiia
100,000,
10,000,
3 4 t, 6 7 « 9 10
Tons of Refrigeration
Figure 5-27 Installed Cost of Industrial Vapor Compression
Refrigeration Systems
5-73
-------
Flares are generally categorized as either ground or elevated flares.
By elevating the flare, the open flare can be removed from potentially dangerous
ground areas and the products of combustion can be dispersed above the working
areas to reduce the effects of noise, smoke, and objectionable odors. As in all
combustion processes, an adequate air supply and good mixing are required to
produce complete combustion and minimum smoke. In the design of flares, this
is accomplished by injecting steam or water into the combustion zone to produce
turbulence for mixing and to induce air into the flame. Other techniques are
employed which rely on a blower assisted air supply instead of steam, however,
these are used to a lesser degree than the steam assisted flares. The flaring
process, by itself, produces some undesirable products and emissions such as
noise, light, smoke, SO , NO , and CO, however, by proper design these can be
X A
minimized. Shields and mufflers are sometimes provided to limit light and noise
and by proportioning the steam flow rate to the gas flow, smoke can be reduced
to invisible levels.
The elements of an elevated flare generally consist of the stack, burner,
seal, pilot, ignition system and controls. Many different configurations are
available and the differences between each are due primarily to the method and
location of the air or steam injection and the design of the burner. Included
in the stack of most flares is a flare seal to prevent air entering the stack
due to wind or the thermal contraction of stack gases, and to reduce the amount
of purge gas that may be needed to expel combustibles when the flared gas is
lighter than air. Water seals may also be used as a seal and as a means of
directing the gas flow to alternate flares. In addition, a knock-out drum is
provided as a separator for any liquid that may be entrained in the gas stream.
The knock-out drum and water seal are usually incorporated into the same vessel,
Elevated flares can be free standing, guyed, or structurally supported by a
5-74
-------
derrick. Free standing flares provide ideal structural support. However, for
very high units the costs increase rapidly and the foundation and nature of
the soil must be considered in both the static/dynamic and cost analysis.
Derrick supported flares can be built as high as required since the system
load is spread over the legs of the derrick. This design provides for differ-
ential expansion between the stack, piping and derrick. The guy supported
flare is the simplest of all the support methods. However, a considerable
amount of land is required since the guy wires are widely spread apart. In
addition the waste gases must be near ambient temperature since any expansion
or contraction due to temperature differences will change the tension in the
guy wires and cause structural damage.
Some flares are provided with auxiliary fuel to oxidize hydrocarbon vapors
when the gas stream falls below the flammability range or can no longer sustain
a flame. Control of the auxiliary fuel is automatic, and this type of system
is ideal for processes with large fluctuations of hydrocarbon gas compositions.
Ground flares are used to dispose of waste liquids and gases. These flares
may contain several nozzles or burners and combustion can occur inside a
refractory chamber or in an open pit. Ground flares and elevated flares can
be used together in an integrated system whereby excess waste gases can be
diverted from ground flares to an elevated flare.
Elevated flare diameters are normally sized to provide vapor velocities
at maximum throughput of about 20 percent of the sonic velocity in the gas.
The maximum pressure drop for a flare is limited to approximately 2 psig
(60 inches WG). The height of a flare is based on the ground level limitations
of luminosity, thermal radiation, noise, height of surrounding structures and
the dispersion of the exhaust gases. A discussion of these items can be found
5-75
-------
in References 88 and 138. Self supporting flares should be used for flare
tower heights of up to 50 feet, guyed towers to 100 feet, and derrick towers
above 100 feet. The operating costs for a flare will depend on the quantity
of purge gas and steam required and a discussion of these requirements is
given in Reference 138. For general consideration, the quantity of steam
required can be assumed to be 0.4 pounds of steam per pound of hydrocarbon.
For specific applications, Reference 138 should be consulted. The use of
steam as a smoke suppressant for elevated flares can represent 92 to 98 percent
of the operating costs.
The capital cost of flares depends on the degree of sophistication desired
and the amount of appurtenances selected such as knock-out drums, seals,
controls, ladders, platform, etc. The basic structure and support of the flare,
the size and height, the flow rate, and the auxiliary equipment are controlling
factors in the cost of the flare. The capital investment will also depend on
the availability of utilities such as steam and natural gas, the variations in
the composition of the waste gases, and the frequency of flaring. Typical
costs for elevated flares range between $30,000 and $100,000 (Ref. 138).
Ground flares can be as much as ten times the cost of an elevated flare for the
same capacity range. Blower assisted flares (force'd draft flares) are between
two to three times the cost of an equivalent conventional elevated flare
(Ref. 138).
Figure 5-28 shows typical costs of elevated flares (self-supporting,
guyed, and derrick) versus gas flow rates. The gases are assumed to have an
average molecular weight of 42. For comparison purposes, a 12-inch diameter
flare (Figure 5-28) would be designed for an approximate gas flow of 70,000
Ibs/hr, an 18-inch diameter for 200,000 Ibs/hr, and a 30-inch diameter for
600,000 Ibs/hr. The cost of ground level flares in shown in Figure 5-29.
5-76
-------
o
O
QŁ
«t
UU
_J
LU
U_
to
O
u
200
180
160
140
120
100
80
60
40
20
''Nfir*
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E§iSg: Note:
EijJtTil:; 1) Cost incl
:|iirMitfcy and steam-
g| idj. si tjfi Łr t-fj: g ^ ±H| ^
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r= rttt r= ^fa
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100. 200
GAS FLOW,
300 400 500 600
1000 LBS/HR 0 MOL. WT. OF 42
Figure 5-28 COST OF ELEVATED FLARES
5-77
-------
400
360
320
280
o
o
o
GO
LLJ
OL
O
cr:
CD
1/5
O
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240
200
160
120
80
40
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Note :
1) Cost i
with s
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enclos
2) Source
i. ^_ri jit^. ilii iUi. . . .4- *— ~ * «-**
*T ITT 7 'i ' ' 1 1 IT * I M" 7*"T ^7 i '' ' Tf" tTtT
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±^H---:|^H?i:— rti*jt-»:aa
ncludes knockout dn
eals, pilot and igm
1 instrumentation, s
1 instrumentation, a
ure for protection.
: Ref. 170
1
m
tion
taged-
nd
20 40 60 80 100
GAS FLOW 1000 LBS/HR. 9 MOL. WT. 42
Figure 2-29 COST OF GROUND LEVEL FLARES
120
5-78
-------
Section 6
SAMPLE COST ESTIMATES AND SYSTEM COST COMPARISON
To illustrate use of the manual, a case study on rotary kiln air
pollution control is presented here. Since this manual provides very little
guidance regarding the design of air pollution control systems, it is essen-
tial that the user have prepared in advance an engineering design for
control of the pollutant source. Care should be taken in the design because
a poor design is likely to result in unrealistic costs. There may be many
system configurations that will satisfy the technical requirements, but only
one or two will cost the least. In the example presented here, the engineer-
ing 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).
Lime (CaO or CaO-MgO) is the product of the calcination of limestone
(CaCOg or CaCOg-MgCO.,). 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
6-1
-------
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 10y 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:
o A typical 250 TPD rotary kiln to be controlled at 1000 ft elevation.
o Required control efficiency of 99+%.
o Exhaust gas from kiln: 30,000 SCFM or 88,300 ACFM @ HOOF. *
o Control device to be located 200' from source.
o Direct exhaust from kiln.
o Duct velocity - 4000 fpm to prevent fallout
o Surrounding terrain does not impose unusual constraints on system
design and stack height (50').
CASE A - OUTLINE OF ENGINEERING CALCULATIONS FOR 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.
Composition: N2-60%, C02-24%, H20-15%, 02-1% (by volume),
6-2
-------
Figure 6-1 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 = ?? , F 2
4000 fpm
Hence, 64" duct (22.3 ft ) may be used, giving:
88300 AC™ • 3960 fpm
22.3 ft*
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:
88300 ACFM
1.767 ft /tube X 5000 fpm
10 pairs of tubes in parallel
From engineering calculations for 40' high tubes, the
temperature drop for two tubes in series is 500F. Thus
exit temperature is 600F and gas volume is 60000 ACFM.
Pressure drop is 2.1" W.G. Estimated length of cooler
is 30 feet based on tube spacing of 18" (see sketch).
-^•10 pairs of 2 tubes
^> (r^^f (units) each
(cfc^
18" tube spacing
Heat transfer calculation methods may be found in the EPA publication AP-40.
See Appendix C, reference 88.
6-3
-------
Sc.rew 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
j
52"
-2.1"
3
30,000
530 F
56,000
52"
-2.7"
4
30,000
500 F
54,300
52"
-8.7"
5
38,600b
100 Fb
40,800b
52"
-
6
30,000^
68,600b
500 Fj
275 FD
54,300*
95,100b
Neglect
-
7
30,000*
68,600b
500 F?
275 Fb
54,300*
95,100b
Neglect
-14.7"
a - glass bag
b - polyester bag
Figure 6-1 FABRIC FILTER SYSTEM DESIGN
-------
From Chapter 3 of ref. 88, the quantity of heat removed from
the cooler is determined by: Q = w( Ah) where w is in Ibs/hr
or scfh and Ah is in Btu/lb or Btu/scf. The overall heat
transfer coefficient (U) is determined by calculating the inside
and outside film coefficients for an 18-inch diameter tube with
a velocity of 5000 fpm. The log mean temperatures difference
( Tm) is calculated using an assumed ambient temperature of
100°F and an inlet temperature of 1100°F and an outlet temperature
of 600 F. The total surface area required is then determined
by: A = Q/U( ATm). Since there are 10 pairs of tubes (units)
in parallel, the developed length of each will be:
L = A/10 ir D where D is the diameter (1.5 ft). The height
of the cooler is calculated by dividing the developed length
L of each pair by the number of vertical columns in each pair.
For pressure drop calculations, also see Chapter 2 of Ref. 88.
b. Determine carbon steel duct diameter
60000 ACFM
4000 fpm
= ,,
I0
2
Hence 52" duct (14.7 ft ) may be used, giving:
60000 AC™ . 4080 fpm
14.7 fr
Stage 3. Cooling of gas will take place over 200-30 = 170 ft. of duct.
The calculations used in stage 2 to determine the size of the
U-tube cooler are applied again. The surface area of a 52"
duct, 170 ft long is calculated to be 2314 sq. ft. The overall
heat transfer coefficient is determined using a velocity of
4080 fpm and a duct diameter of 52". An outlet temperature at
6-5
-------
the end of the duct must first be assumed to determine the log
mean temperature difference. If the calculated and assumed
temperatures differ significantly, the procedures must be
reiterated until both temperatures are approximately the same.
For gas temperatures about 600°F and a velocity of 4000 fpm, a
temperature drop of 0.4 degrees per ft. is a reasonable
assumption. Using the overall heat transfer coefficient,
assumed log mean temperature difference, and the surface area,
the total heat transferred can be calculated. The outlet
temperature is determined from the change in enthalpy of the
gas stream. In this case, the outlet temperature is found
to be 530 F. This is reasonably close to the assumed temperature.
The pressure drop through 170' of duct can be determined from
the friction charts in chapter 2 of reference 88, corrected for
the difference in density. The pressure drop is found to be
approximately 0.6" W.G. The new ACFM at the end of the duct is:
S
60000 ACFM X -r- = 56000 ACFM
I UOU K
Expansion joints are usually provided between major components
such as coolers, mechanical collectors, etc.; therefore, two
expansion joints are required, one 52", the other 64".
Stage 4. Select two mechanical collectors in parallel to handle 28000
2
ACFM each. For 6" pressure loss, the inlet area is 8.5 ft and
the critical parti cal size is 24 microns. Mechanical collectors
also provide some degree of cooling. Manufacturers usually
supply the expected heat losses for specific applications. For
gas temperatures at 500 F, a temperature drop of approximately
6-6
-------
30 F can be assumed. Thus, the new gas volume after the
mechanical collectors is:
56000 ACFM X -- = 54,300 ACFM
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 95,100 ACFM @ 275F for
polyester bags, and is 54,300 ACFM @ 500F for glass bags.
The baghouse is sized as follows:
a. For glass bags:
= 27150 ft2 net cloth area.
b. For polyester bags:
= 3170° f*2 net cloth area
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.
6-7
-------
Size fans for 54,300 ACFM and 95,100 ACFM for glass and polyester
bags respectively. Assuming a stack height requirement of 50'
and a cesign exit stack velocity of 4000 fpm, select stack
diameters of 50" and 66" respectively. Dust storage is also
assumed to be at or near the collection site so that 50' of 9"
screw conveyor is adequate for dust removal.
COST ESTIMATE OF FABRIC FILTER SYSTEM
a. (1) 64" carbon steel elbow, 1/4" thick (Figure 4-10) - $ 2,200
b. (20) units of 18" carbon steel radiant cooler 40' high
(Figure 4-24) - 71,000
c. (170) feet of 52" carbon steel duct 3/16" thick
(Figure 4-7) - 11,900
d. (2) carbon steel, 10 Ga., mechanical collectors with
inlet area = 8.5 ft2 - 19,240
Collector (Figure 4-17) $ 4,360
Support (Figure 4-19) 2,960
3/16" Hopper (Figure 4-20) 86o
Scroll (Figure 4-21) 1,500
Total Each $ 9,620
e. (1) 3/16" transition to mechanical collector
(Figure 4-10) - 800
(2) expansion joints, one 52" one 64" (Figure 4-12) - 7,300
Sub-Total $112,440
(Filter with glass bags)
f. (1) 52" carbon steel dilution air port, 3/16" thick
(Figure 4-25) - $ 6,200
6-8
-------
g. (1) 27,150 ft net cloth area, continuous, reverse
air, insulated baghouse (Figure5-13) - 162,000
h. Suction add-on (Figure 5-13) - 10,000
i. (1 set) 27J50 X 1.17 = 31,765 sq ft gross area
glass bags (Table 5.1) - 14,300
j. (1) 54,300 ACFM backwardly curved Class IV fan at
14.7" U.G. actual (29" standard) (Figure 4-33) - 7,000
k. (1) 1,800 RPM, 180 HP drip proof motor
(Figure 4-34) - 3,000
1. (1) Magnetic starter with circuit breaker
(Figure 4-34) - 1,800
m. (1) 50" diameter, 50' high stack, 1/4" thick
(Figure 4-41) - 5,200
n. (50) feet of 9" screw conveyor (Figure 4-26) 3,900
Sub-Total $213,400
(Filter with polyester bags)
f. (1) 66" carbon steel dilution air port, 1/4" thick
(Figure 4-25) - $ 8,600
2
g. (1) 31,700 ft net cloth area, continuous,
mechanical shaker baghouse (Figure 5-12) - 116,000
h. Suction add-on (Figure 5-12) - $ 10,000
i. Insulation add-on (Figure 5-12) - 58,000
j. (1) set 31,700 X 1.17 = 37,089 sq ft gross
area Dacron bags (Table 5.1) - 12,980
k. (1) 95,100 ACFM backwardly curved Class IV fan
at 14.7" WG actual (29" standard) (Figure 4-33) - 10,000
6-9
-------
1. (1) 1,800 RPM, 300 HP, drip-proof motor (Figure 4-34) - 4,800
m. (1) magnetic starter with circuit breaker
(Figure 4-34) - 3,000
n. (1) 66" diameter, 50' high stack, 1/4" thick
(Figure 4-41) - 6,400
o. (50) feet of 9" screw conveyor (Figure 4-26) - 3,900
Sub-Total $233,680
Total capital and annualized costs for the fabric filter system are
summarized below; see Section 3 for installation, maintenance and operating
cost factors with no cost adjustment.
CAPITAL COSTS
Item Glass bags Polyester bags
Auxiliary equipment and control device $325,840 $346,120
Instruments and Control (10%) 32,580 34,610
Taxes and freight (8%) 26,070 27,690
Purchased Equipment Cost $384,490 $408,420
Direct and indirect installation costs
(117% of equipment costs) 449,850 477,850
Total Installed Cost $834,340 $$886,270
6-10
-------
ANNUALIZED COSTS
(8000 hrs/yr. or 1000 shifts)
Item Glass bags Polyester bags
Operating labor (2 hr/shift) $18,100 $18,100
General maintenance (1 hr/shift Smat'l.) 34,640 34,640
Replacement bags (life 1.5; 2 years) 9,530 6,490
labor for replacement bags 9,530 6,490
Electricity (1.08 M - 1.79 M kwh) 46,660 77,330
Overhead 28,340 28,340
Property tax, insurance, and administration
Ł 4% 33,370 35,450
Capital charges @ 0.11746 @ 10%, 20 yrs. 98,000 104,100
Credits - assume negligible credit for
recovered product
Total Annualized Costs $287,170 $310,940
CASE B - OUTLINE OF ENGINEERING CALCULATIONS FOR ELECTROSTATIC PRECIPITATOR
Establish overall engineering design as follows:
a. Drift velocity - .21 fps. (average)
b. Insulated precipitator
c. Inlet gas temperature of 700F for good resistivity
d. Spray chamber next to source
Figure 6-r2 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.
6-11
-------
Spray
chamber
\/
Screw conveyer
l\3
DESIGN PARAMETER
SCFM
TEMPERATURE
ACFM
DUCT DIAMETER
STATIC PRES. (" WG)
1
30,000
1100 F
88,300
64"
Kiln
Draft
2
32,770
800 F
77,900
60"
3
32,770
690 F
71,100
60"
-1.0"
4
32,700
690 F
71,100
Neglect
-1.5"
Figure 6-2 ELECTROSTATIC PRECIPITATOR SYSTEM DESIGN
-------
Stage 2. For preliminary design purposes, assume spray cooling to 800 F
with water at 60 F. The water requirements are determined by
the change in enthalpy of the gas stream from 1100 F to 800 F
divided by the sensible heat gain and latent heat of evaporation
per Ib of water from 60 F to 800 F. The total water requirement
is 129 Ibs per min or 15 gpm based on an assumed total pressure
of 280 ft including 230 ft for spray nozzles. The added gas
volume of 129 Ibs per min of water vapor is 2770 scfm. The
length of the spray cooler is assumed to be 35 ft. The gas
volume after the cooler will be:
32770 SCFM X p = 77900 ACFM
Calculate duct diameter:
77900 ACFM _ ,Q , f.2
"4000 " 19'5 ft
Hence 60" duct (19.6 ft2) may be used.
Stage 3. a. Cooling through the duct is determined again by the method
shown in chapter 3 of ref. 88. The length of the duct is
200 ft - 35 ft for the spray cooler or 165 ft. The final
temperature is 690 F at the end of the duct and the new gas
volume at the preci pita tor is:
77900 ACFM X 4i|2-4 = 71100 ACFM
I &OU K
Two expansion joints will be needed as for baghouses. The
pressure drop is assumed to be 0.6" WG for the duct and 0.4" WG
for the spray chamber.
b. Size preci pi tator as follows:
A = -71,100 ACFM ln(l-.993)/(0.21 fps x 60 s/min)
A = 28,000 ft2
6-13
-------
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 71,100 ACFM. Select a 50' high stack 57" diameter
Fifty feet of screw conveyor 9" in diameter will be required.
COST ESTIMATE OF ELECTROSTATIC PRECIPITATOR SYSTEM
a. (1) 64" carbon steel elbow, 1/4" thick
(Figure 4-10) - $ 2,200
b. (1) spray chamber @ 88,300 ACFM (Figure 4-22) - 62,500
c. (165) feet of 60" carbon steel duct 3/16" thick
(Figure 4-7 ) - 13>500
d. (2) expansion joints, one 60" and one 64"
(Figure 4-12) - 7,800
e. (1) 28,000 ft2 precipitator, insulated
(Figure 5-2 ) - s 300,000
f. (1) 71,100 ACFM backwardly curved Class I fan
at 1.5" W.G. actual (3.4" standard) (Figure 4-33) - 9,000
g. (1) 600 RPM, 50 BHP drip-proof motor (Figure 4-34) - 3,000
h. (1) magnetic starter with circuit breaker
(Figure 4-34) - 500
i. (1) 57" diameter, 50' high stack, 1/4" thick
(Figure 4-41) - 5,400
j. (50) feet of 9" screw conveyor (Figure 4-26) - 3,900
Total $407,800
6-14
-------
The capital and annual!zed costs for the electrostatic precipitator
system are summarized as follows.
CAPITAL COSTS
Item Cost
Auxiliary equipment and control device $407,800
Instruments and controls (10%) 40,800
Taxes and freight (8%) 32,600
Purchased Equipment Costs $481,200
Direct and indirect installation costs (124% of
equipment costs) 596,700
Total Installed Costs $1,077,900
ANNUALIZED COSTS
(8000 hrs/yr or 1000 shifts)
Item Costs
Operating labor (0.5 hrs/shift) $ 4,530
General maintenance (0.5 hr/shift & mat'l) 8,660
Utilities:
Electricity - fan and pump (2801 head for pump) 13,400
precipitator (1.5 watt/sq.ft.) 14,500
Water 1,800
Overhead 7,090
Property tax, insurance and administration @ 4% 43,100
Capital charges @ 0.11746 126,610
Credits - same as Case A
Total Annualized Costs $ 219,690
6-15
-------
CASE C - OUTLINE OF ENGINEERING CALCULATIONS FOR VENTURI SCRUBBERS
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 6-3 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.
Stage 2. a. The quencher is sized to cool 30,000 scfm gas from 1100 F
to 220 F which requires heat transfer of approximately
510,000 Btu/min. The quantity of water required is
approximately 55 gpm based on an inlet water temperature
of 60 F. Since quenchers are normally supplied excess
water, assume a water rate of 60 gpm. The pressure head
for the quencher is assumed to be 100 ft (43 psig). The
quencher is estimated to be approximately 30 ft long. The
new gas volume after the quencher is:
gas: 88,300 ACFM X |j = 38,500 AC FM
water vapor: 60 gpm X 8.33 Ib/gas X |fŁ4 X 21.1 cu ft/lb
OoU K
= 13500 ACFM
total: 38,500+13500 = 52,000 ACFM
b. Required duct size is:
52,000 ACFM _ 17 n f+2
4,000 fpm " IJ'U Tt
Hence a 48" (12.57 ft ) duct may be used giving:
5LOOOIACFM .
12.57 ft*
6-16
-------
Quencher \/
Water treatment
I
«>J
DESIGN PARAMETER
SCFM
TEMPERATURE
CFM
DUCT DIAMETER
STATIC PRES. (" WG)
1
30,000
1100 F
88,300
64"
K1ln
Draft
2
40,200
220 F
52,000
48"
3
40,200
190 F
49,700
48"
-1"
4
40,200
170 F
48,200
Neglect
-16"
Figure 6-3 VENTURI SCRUBBER SYSTEM DESIGN
-------
Step 3. Using the heat transfer calculations of ref. 88, the gas
temperature will be 190 F after 170 ft of duct. The new gas
volume will be:
52,000 ACFM X |^-| = 49,700 ACFM
The pressure drop through the duct is 0.6" WG and a pressure
drop of 0.4" WG is assumed for the quencher.
Step 4. The scrubber is sized for 49,700 acfm and will be constructed
of 3/16" steel to allow for corrosion. The pressure drop
through the scrubber is estimated to be 15" WG (typical average
for lime'kilns, ref 19). The recirculating pump horsepower is
estimated to be 20 hp based on 10 gpm per 1000 cfm gas flow and
an assumed head of 100 ft. Some sensible cooling occurs in the
scrubber and this depends on the inlet water conditions. In
this case, a temperature drop of 20 F is estimated; therefore,
the fan is sized for:
49,700 ACFM X f|Ł4 = 48,200 ACFM
DOU K S
A 48" stack is selected for an approximate exit velocity of
4000 fpm.
COST ESTIMATE OF VENTURI SCRUBBER SYSTEM
a. (1) 64" carbon steel elbow, 1/4" thick
(Figure 4-10) - $ 2,200
b. (1) quencher @ 88,300 ACFM (Figure 4-23) - 28,000
c. (1) quencher pump for 60 gpm (Figure 4-29) - 800
d. (170) feet of 48" carbon steel duct, 3/16" thick
(Figure 4-7 ) - 11,900
6-18
-------
e. (2) expansion joints, one 48" and one 64"
(Figure 4-12) - 7,300
f. (1) 49,700 ACFM scrubber, 3/16" thick
(Figure 5-4 ) - 31,200
g. (1) 48,200 ACFM radial-tip fan at 16" W.G. actual
(20" standard) (Figure 4-37). - 10,000
h. (1) 900 RPM, 225 HP drip-proof motor (Figure 4-34) - 8,000
i. (1) magnetic starter with circuit breaker
(Figure 4-34) - 2,000
j. (1) 48" diameter, 50' high stack, 1/4" thick
(Figure 4-41) - 5,000
Total $106,400
The capital and annualized costs for the venturi scrubber system are
summarized as follows.
CAPITAL COSTS
Item Cost
Auxiliary equipment and control device $106,400
Instruments and controls (10%) 10,640
Taxes and freight (8%) 8,500
Purchased Equipment Costs $125,540
Item Cost
Direct and indirect installation costs 114,240
(91% of equipment costs)
Total Installed Costs $239,780
6-19
-------
ANNUALIZED COSTS
(8000 hrs/yr or 1000 shifts)
Item Cost
Operating labor (2 hrs/shift) $18,100
General maintenance (1 hr/shift + mat'l) 34,640
Utilities:
Electricity - fan power 1.34 Mkwh 57,890
pump power (100 head) 6,080
Water - 10 gpm/1000 acfm + quencher (at cost of
0.-10 $/1000 gal. treated) 26,880
Waste disposal - Cost of waste treatment system is not
*
considered.
Overhead 28,340
Property tax, insurance, and administration @ 4% 9,590
Capital charges,0.16275 @ 10%, 10 yrs. 39,020
Credits
s
Total Annual!zed Costs $220,540
SUMMARY OF SYSTEM COSTS FOR THREE METHODS OF CONTROL
Item Filter Precipitator Scrubber
Capital Costs $ 834,340 $ 1,077,900 $ 239,780
Annual!zed Costs $ 287,170 $ 219^690 $ 220,540
The cost of wastewater treatment facilities can be established from
ref. 128. Water pollution and treatment are beyond the scope of this
manual.
6-20
-------
Section 7
UPDATING COSTS TO FUTURE TIME PERIODS
7.1 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
1977 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
7-1
-------
for labor productivity changes not found in other cost indexes. Further
information is available regarding the make-up of the indexes and it is pos-
sible to modify the indexes to suit particular needs (see Arnold, T. H. and
Chi 1 ton, 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 farbackas 1957. Figure 7-1 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
s
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:
7-2
-------
I
CO
X
UJ
o
o
o
58 59
60 61 62 63 64 65 66 67 68 69 70 71
YEAR
72 73 74 75 76 77 78
Figure 7-1 CHEMICAL ENGINEERING PLANT COST INDEX
-------
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
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 elevatoVs
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%
7-4
-------
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
07 1967 Rubber and Plastic Products B-4
10130246 ' 1967 A-36, Carbon Steel Plates B-5
7-5
-------
Code No.
10130247
10130262
10130264
1141
11450133
1147
11730112
11730113
11730119
11750781
135
13520111
13520131
13520151
1392
Base Year=100
1967
1967
1967
1967
1967
1967
1967
1967
1967
1967
1967
1967
1967
Dec/1974
1967
Commodi ty
Stainless Steel Plate
Carbon Steel Sheet
Stainless Steel Sheet
Pumps, Compressors, and
Equipment
V-Belt Sheaves
Fans and Blowers, Except
Portable
10 HP, AC Motors
250 HP, AC Motors
50 HP, AC Motors
75 HP, 440 volt, AC Starters
Refractories
Fire Clay Brick, Super Duty
High Alumina Brick, 70 Pet.
Castable Refractories
Insulation Materials
Table No.
B-6
B-7
B-8
B-9
B-10
B-ll
B-12
B-13
B-14
B-15
B-16
B-17
B-18
B-19
B-20
7.2 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:
1/2 (BLS #1392 factor) + (CE Fabricated Equipment Factor).
Venturi Scrubbers
Use CE Fabricated Equipment index. For rubber liners use BLS #07 on
the liner cost only.
7-6
-------
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.
Absorbers
Use CE Fabricated Equipment index
Refrigeration
Use CE Process Equipment index
Flares
Use CE Fabricated Equipment index
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.
7-7
-------
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.
Dust Removal Equipment
For screw conveyors, use the CE Fabricated Equipment index. For water
treatment equipment, use the appropriate CE or BLS index, depending on
the equipment component.
7-8
-------
APPENDIX A
COMPOUND INTEREST FACTORS
-------
Table A-l 1% COMPOUND INTEREST FACTORS
Single Payment
Present
Worth
Factor
n P/F
1 0.9901
2 0.9803
3 0.9706
4 0.9610
5 0.9515
6 0.9420
7 0.9327
8 0.9235
9 0.9143
10 0.9053
11 0.8963
12 0.8874
13 0.8787
14 0.8700
15 0.8613
16 0.8528
17 0.8444
18 0.8360
19 0.8277
20 0.8195
21 0.8114
22 0.8034
23 0.7954
24 0.7876
25 0.7798
26 0.7720
27 0.7644
28 0.7568
29 0.7493
30 0.7419
31 0.7346
32 0.7273
33 0.7201
34 0.7130
35 0.7059
40 0.6717
45 0.6391
50 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
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
0.9804
0.9612
0.9423
0.9238
0.9057
0.8880
0.8/06
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
Uniform Series
0.
0.
.6598
,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
Capita]
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
,942
.884
.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
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
0.9709
0.9426
0.9151
0.8885
0.8626
0.8375
0.8131
0.7894
0.7664
0.7441
0.7224
0.7014
0.6810
0.6611
0.6419
0.6232
0.6050
0.5874
0.5703
0.5537
0.5375
0.5219
0.5067
0.4919
0.4776
0.4637
0.4502
0.4371
0.4243
0.4120
0.4000
0.3883
0.3770
0.3660
0.3554
0.3066
0.2644
0.2281
Capita]
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 s
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
20.3b9
20.766
21.132
21.487
23.115
24.519
25.730
A-3
-------
1
2
3
4
5
6
7
8
L>
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.
0.
.4388
.4220
0.4057
0.3901
0.3751
0.3607
0.3468
0.3335
0.3207
0.3083
0.2965
0.2851
.2741
,2636
0.
0.
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
,5303
,5051
0.
0.
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
0.0&870
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
-------
1
2
3
4
5
6
7
8
9
10
11
ir
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-6 6% COMPOUND INTEREST FACTORS
Single Payment Uniform Series
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
0.07179
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
-------
Table A-7
Single Payment
Present
Worth
Factor
n P/F
1 0.9346
2 0.8734
3 0.8163
4 0.7629
5 0.7130
6 0.6663
7 0.6227
8 0.5820
9 0.5'439
10 0.5083
11 0.4751
12 0.4440
13 0.4150
14 0.3878
15 0.3624
16 0.3387
17 0.3166
18 0.2959
19 0.2765
20 0.2584
21 0.2415
22 0.2257
23 0.2109
24 0.1971
25 0.1842
26 0.1722
27 0.1609
28 0.1504
29 0.1406
30 0.1314
31 0.1228
32 0.1147
33 0.1072
34 0.1002
35 0.0937
40 0.0668
45 0.0476
50 0.0339
7% COMPOUND INTEREST FACTORS
Uniform Series
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
10.0-j9
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.&J2
12.6*7
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
-------
Table A-9 10% COMPOUND INTEREST FACTORS
Single Patient Uniform Series
Present
Worth
Factor
n P/F
1 0.9091
2 0.8264
3 0.7513
4 0.6830
5 0.6209
6 0.5645
7 0.5132
8 0.4665
9 0.4241
10 0.3855
11 0.3505
12 0.3186
13 0.2897
14 0.2633
15 0.2394
16 0.2176
17 0.1978
18 0.1799
19 0.1635
20 0.1486
21 0.1351
22 0.1228
23 0.1117
24 0.1015
25 0.0923
26 0.0839
27 0.0763
28 0.0693
29 0.0630
30 0.0573
31 0.0521
32 0.0474
33 0.0431
34 0.0391
35 0.0356
40 0.0221
45 0.0137
50 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 S
0.11401
0.11257
0.11130
0.11017
0.10916
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
6.614
7.1J3
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
9.5i:6
9.569
9.609
9.644
9.779
9.863
9.915
A-9
-------
Table A-10 12% COMPOUND INTEREST FACTORS
Single Payment Uniform Series
Present
Worth
Factor
n P/F
1 0.8929
2 0.7972
3 0.7118
4 0.6355
5 0.5674
6 0.5066
7 0.4523
8 0.4039
9 0.3606
10 0.3220
11 0.2875
12 0.2567
13 0.2292
14 0.2046
15 0.1827
16 0.1631
17 0.1456
16 0.1300
19 0.1161
20 0.1037
21 0.0926
22 0.0826
23 0.0738
24 0.0659
25 0.0588
26 0.0525
27 0.0469
28 0.0419
29 0.0374
30 0.0334
31 0.0298
32 0.0266
33 0.0238
34 0.0212
35 0.0189
40 0.0107
45 0.0061
50 0.0035
Capita]
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
17
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.
4.
.784
.160
4.487
4.772
5.019
,234
.421
.583
5.724
5.847
5.
5.
5.
5.
6.
,954
.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. b91
, 600
,609
6.
6.
6.617
6.642
6.654
6.661
A-ll
-------
Table A-12 20% 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
0.8333
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
Uniform Series
0.
0.
.0541
.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
1978
ANNUAL
JAN FEB MAR
APR MAY JUN
JUL AUG SEP
OCT NOV DEC
CE Plant Index
Engineering &
Supervision
Building
218.8
161.9
213.7
210.6 213.1 214.1
159.2 159.6 159.9
207.0 210.5 210.3
215.7 216.9 217.7
160.3 160.6 161.0
211.1 212.8 214.0
219.2 221.6 222.8
161.6 162.0 162.3
215.0 214.3 216.3
223.5 224.7 225.9
162.6 165.4 168.2
217.2 217.8 218.1
Construction Labor
Equipment, Machinery
Supports
Fabricated Equipment
185.8
240.6
238.6
182.8 181.1 182.0
229.6 233.8 234.9
226.6 233.0 233.6
180.7 183.1 183.4
237.9 238.8 239.8
237.1 237.3 237.4
186.6 188.2 191.0
240.9 244.2 244.9
238.6 243.3 243.2
190.8 190.3 190.5
246.0 247.6 249.0
243.8 244.1 245.2
Process Machinery
Pipe, Valves &
Fittings
Process Instruments &
Controls
228.3
269.4
216.0
218.1 221.6 222.7
256.0 262.2 264.0
209.8 211.0
224.3 225.5 226.8
266.0 .267.0 268.4
212.1 214.2 214.6
228.6 231.0 232.5
269.1 273.1 274.9
217.2 218.3 218.6
234.1 235.8 237.8
276.5 278.1 277.9
219.5 221.7 223.7
Pumps & Compressors
Electrical Equipment
& Materials
Structural Supports
Insulation & Paint
257.5
167.8
249.1
248.4 250.3 250.6
162.5 162.9 162.8
235.5 236.8 240.7
254.2 256.3 258.2
164.6 166.4 167.9
246.6 247.4 250.1
258.6 258.8 259.1
168.7 169.5 170.0
250.5 253.6 254.7
260.9 266.6 268.1
170.5 173.5 174.1
256.1 258.0 258.7
SOURCE: Chemical Engineering, Economic Indicators
-------
Table B-l CHEMICAL ENGINEERING PLANT COST INDEXES
INDEX
1977
ANNUAL
JAN FEB MAR
APR MAY JUN
JUL AUG SEP
OCT NOV DEC
CE Plant Index
Engineering &
Supervision
Building
204.1
162.1
199.1
198.7 198.5 199.3
158.3 159.0 159.7
194.0 193.6 195.3
200,3 201.4 202.3
160.4 161.0 161.7
196.7 197.3 197.2
204.7 206.4 208.8
162.4 163.1 163.8
199.0 201.0 204.2
209.0 209.4 210.3
164.4 165.1 165.8
203.6 203.5 204.1
Construction Labor
Equipment, Machinery
Supports
„>
Fabricated Equipment
178.2
220.9
216.6
178.5 176.3 175.7
213.2 213.6 214.8
208.3 208.3 208.9
175.6 175.9 176.8
216.2 217.7 218.8
210.2 211.9 212.8
177.1 178.1 180.8
222.3 224.3 226.8
219.8 222.1 223.9
181.5 180.9 181.2
226.9 227.7 228.7
222.9 224.4 226.2
Process Machinery
Pipe, Valves &
Fittings
Process Instruments &
Controls
211.6
247.7
203.3
205.8 206,1 207.1
236.3 238.1 241.0
199.5 199.6 200.1
207.8 209.0 210.1
244.6 246.5 247.3
200,8 201.5 201.5
212-:3 213.8 215.0
248.2 251.9 254.1
202.5 203.1 204.3
216.0 217.4 218.3
255.0 254.1 254.9
207.8 209.1 209.9
Pumps & Compressors
Electrical Equipment
& Materials
Structural Supports
Insulation & Paint
240.2
159.0
226.0
234.6 234.3 234.4
154.0 154.9 156.4
219.3 219.2 220.7
234.4 237.2 238.8
157.2 158.0 159.2
221.3 221.7 223.6
241.8 241.9 244.0
160.6 160.3 161.3
225.2 226.2 235.4
245.4 247.9 248.0
161.8 161.9 162.4
233.2 233.0 233.5
SOURCE: Chemical Engineering, Economic Indicators
-------
Table B-l CHEMICAL ENGINEERING PLANT COST INDEXES
INDEX
1976
ANNUAL
JAN FEB MAR
APR MAY JUN
JUL AUG SEP
OCT NOV DEC
CE Plant Index
Engineering &
Supervision
Building
192.1
150.8
187.4
187.3 187.5 188.4
147.9 148.5 149.1
182.6 182.9 184.4
188.9 190.2 191.1
149.6 150.2 150.7
185.2 186.0 185.3
192.0 193.9 195.6
151.2 151.7 152.1
186.5 188.3 190.8
196.3 196.4 197.4
152.6 153.0 153.5
191.4 192.0 192.9
Construction Labor
Equipment, Machinery
Supports
Fabricated Equipment
174.2
205.8
200.8
172.8 171.3 172.5
199.5 200.3 200.9
196.2 196.3 196.6
171.3 173.4 172.9
202.1 203.3 205.0
196.0 197.0 198.5
174.3 174.6 176.5
205.6 208.5 210.2
198.9 203.7 205.3
177.1 176.9 177.0
211.0 211.0 212.5
205.9 206.5 208.3
Process Machinery
Pipe, Valves &
Fittings
Process Instruments &
Controls
197.5
232.5
193.1
191.6 192.9 193.1
222.9 223.0 223.9
188.2 189.6 190.0
193.8 194.9 196.9
229.0 231.9 235.1
190.4 191.3 192.5
198.0 199.0 200.7
235.8 236.9 238.0
193.2 193.3 195.3
201.7 202.8 204.5
239.1 236.8 237.3
197.1 197.5 198.7
Pumps & Compressors
Electrical Equipment
& Materials
Structural Supports
Insulation & Paint
220.9
148.9
209.7
211.5 217.7 218.0
145.0 145.6 146.1
202.6 202.3 204.9
219.5 219.4 221.2
146.9 147.3 147.6
205.5 206.5 206.7
221.3 222.6 223.9
147.6 148.9 150.6
207.5 213.3 216.8
223.2 223.7 228.7
153.8 153.9 153.4
216.8 216.4 217.0
SOURCE: Chemical Engineering, Economic Indicators
-------
Table B-l CHEMICAL ENGINEERING PLANT COST INDEXES
CD
I
INDEX
CE Plant Index
Engineering &
Supervision
Building
Construction Labor
Equipment, Machinery
Supports
:abr1cated Equipment
Process Machinery
Pipe, Valves &
Fittings
'rocess 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
179.4 179.5 180.7
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
177.6 177.8 177.7
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 DFC
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 19C-?
221.6 222.6 223.3
186.3 186.6 187. Ł
209.1 209.1 209.0
143.1 143.7 143.3
200.7 200.7 201.2
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
s
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 1B9.6 197.1
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 PFi
176.0 177.4 177.8
138.2 138.7 139.1
170.5 172.1 172.'-
165.8 166.9 165.6
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 1S2.4
03
I
(Tt
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
1973
ANNUAL
144.1
122.84
150.6
157.9
141.9
142.5
137.6
151.3
147.1
139.5
104.2
140.9
JAN FEB MAR
140.8 140.4 141.5
112.0 112.0 122.3
146.5 146.9 148.3
158.9 155.8 154.8
138.3 138.8 140.7
140.0 140.0 140.9
134.3 134.5 135.1
146.1 146.1 149.2
145.0 144.9 145.8
137.0 137.0 138.4
100.6 100.6 102.1
137.2 137.2 140.0
APR MAY JUN
141.8 142.4 144.5
122.4 112.5 129.8
150.3 151.1 150.4
155.0 155.4 155.6
140.9 141.7 142.2
141.7 142.6 143.0
137.1 137.6 137.9
150.1 151.1 151.7
146.1 146.9 146.9
138.4 138.4 141.3
103.9 104.5 105.2
141.2 142.0 141.8
JUL AUG SEP
144.6 145.0 146.4
130.1 130.1 130.1
149.8 150.4 153.0
156.3 156.3 161.8
142.1 142.0 142.6
143.0 143.0 143.4
137.9 138.5 139.1
151.8 151.8 151.8
147.0 147.4 147.9
140.9 140.9 140.9
105.1 105.1 105.1
141.2 141.2 141.2
OCT NOV DEC
146.7 147.5 148.2
130.7 130.8 131.3
150.9 154.7 155.0
161.7 161.6 162.0
143.5 144.3 145.2
143.7 144.1 144.8
139.6 140.3 142.0
153.9 156.6 157.3
148.1 148.8 150.4
140.8 141.4 142.4
105.3 106.0 107.2
141.5 143.5 142.8
00
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
•f
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 DlC
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
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
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
128.2 129.1 129.9
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
1.28.6 130.0 130.0
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 DFC
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./
141.2 141.1 141.5
133.7 132.4 132.4
98.3 97.7 97.7
131.9 131.9 132.0
DO
I
oo
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
CO
I
ID
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 ANNUAL 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
116.3 112.1 108.7
123.1 117.4 113.0
126.1 120.9 115.2
119.6 115.2 111.3
92.8 91.4 90.1
112.5 105.7 102.1
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
101.7 101.6 100.1 101.2
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 195;
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 98.1
103.3 98.8 97.9
102.9 100.4 96.7
102.5 100.0 97.5
101.0 100.6 98.4
101.6 100.4 98.0
CD
O
SOURCE: Chemical Engineering, Economic Indicators
-------
MONTH
ANNUAL
Table B-2
WHOLESALE PRICE INDEXES
FOR COTTON BROADWOVEN GOODS,
BLS 1 0312, 1967=100
1971
1972
1973
1974
110.6 122.3
144.3
1975
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
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
195.3
199.6
177.8 175.4
1976
1977
Discontinued
MONTH
ANNUAL
Table B-3 WHOLESALE PRICE INDEXES
FOR MANMADE FIBER BROADWOVEN
GOODS, BLS #0334, 1967=100
1971
1972
1973
1974 S1975
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
149.8
149.6
101.5
116.9 144.5 161.7 140.6
1976
1977
Discontinued
B-ll
-------
MONTH
ANNUAL
1971
Table B-4
1972
WHOLESALE PRICE INDEXES FOR
RUBBER AND PLASTIC PRODUCTS
BLS # 07, 1967=100
1973
1974
1975
1976
1977
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
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
151.8
151.9
152.3
154.1
155.5
156.7
157.1
157.1
158.3
161.1
163.9
164.6
164.8
164.7
164.6
164.2
164.6
165.7
166.3
167.5
168.9
169.3
169.5
170.2
170.2
170.0
109.2 109.3 112.4 136.2 150.2 159.2 167.6
MONTH
ANNUAL
Table B-5
1971
1972
WHOLESALE PRICE INDEXES FOR
CARBON STEEL PLATES, A36
BLS # 10130246, 1967=100
1973
1974 1975
1976
132.3
141.0 146.7 181.6 213.2 228.2
1977
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
218.8
218.8
219.8
219.8
219.8
219.8
219.8
219.8
219.8
240.2
240.2
240.2
240.2
240.2
240.2
240.2
240.2
240.2
240.2
240.2
256.5
256.5
256.5
256.5
256.5
256.5
248.4
B-12
-------
MONTH
ANNUAL
Table B-6
WHOLESALE PRICE INDEXES FOR
STAINLESS STEEL PLATE
BLS # 10130247, 1967=100
1971
1972
1973
1974 1975
1976
JAN
FEE
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
206.3
206.3
206.3
206.3
206.3
206.3
206.3
206.3
206.3
206.3
201.5
201.5
206.3
206.3
206.3
144.6 128.1 132.8 166.9 198.5 205.5
MONTH
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL
Table B-7 WHOLESALE PRICE INDEXES FOR
CARBON STEEL SHEET,
BLS #10130262, 1967=100
1971
1972 1973
1974 S1975 1976 1977
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
197.0
197.0
197.0
197.0
197.0
197.0
197.0
209.1
209.1
209.1
209.1
209.1
209.1
220.9
222.6
222.6
222.6
222.6
222.6
222.6
237.4
237.4
237.4
237.4
237.4
237.4
123.5 133.6 135.3 167.6 189.3 205.0 230.0
B-13
-------
MONTH
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL
Table B-8 WHOLESALE PRICE INDEXES FOR
STAINLESS STEEL SHEET
BLS # 10130264, 1967=100
1971
1972 1973
1974 1975
1976
1977
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
156.9
156.7
162.6
162.6
164.2
164.2
164.2
164.2
164.2
174.4
176.3
176.3
176.3
176.3
185.0
186.6
186.6
186.6
200.1
203.4
205.6
205.6
202.7
202.7
200.3
200.3
135.0
126.4 122.1 157.1 165.3 168.8 197.1
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
1976
1977
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
191.3
191.1
192.2
194.9
195.8
196.2
195.9
197.4
197.5
198.5
199.6
200.9
201.4
203.6
205.5
205.3
206.4
206.6
209.2
210.3
212.9
213.7
215.1
216.0
218.5
219.1
121.6 124.0 127.5 153.0 187.4 197.8 211.6
B-14
-------
MONTH
JAN
FEB
MAR
APR
MAY
JUN
OUL
AUG
SEP
OCT
NOV
DEC
ANNUAL
Table B-10 WHOLESALE PRICE INDEXES FOR
V-BELT SHEAVES
BLS * 11450133, 1967=100
1971
1972 1973
1974
1975 1976 1977
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
175.6
175.6
175.6
175.6
175.6
179.7
179.7
184.4
184.4
184.4
184.4
184.4
180.7
180.7
180.7
192.3
192.3
192.3
210.1
210.1
210.1
210.1
213.7
213.7
213.7
213.7
117.6
123.6 126.8 150.2 174.5 180.8 204.4
MONTH
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL
Table B-ll WHOLESALE PRICE INDEXES FOR
FANS AND BLOWERS, EXCEPT PORTABLE
BLS # 1147, 1967=100
1971
1972 1973
1974
1975
1976 1977
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
206.6
206.5
206.5
207.1
210.1
213.9
214.1
214.2
216.0
216.0
216.1
221.7
221.7
221.9
224.7
226.4
226.8
224.1
224.8
228.8
230.5
231.1
233.7
233.9
233.9
234.4
123.8
129.0 135.2 168.3 202.8 214.9 229.4
B-15
-------
MONTH
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL
Table B-12 WHOLESALE PRICE INDEXES FOR
MOTORS, INTEGRAL HORSEPOWER, A.C., 10 HP
BLS # 11730112, 1967=100
1971
1972 1972
1974
1975 1976 1977
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
186.1
186.1
192.2
193.6
193.6
193.6
193.6
193.6
195.7
197.8
202.1
204.4
204.4
204.4
204.4
204.4
211.4
207.9
207.9
211.4
218.5
218.5
218.5
218 5
218.5
218.5
105.6
104.7 118.8 151.5 185.9 197.4 213.2
N/A = Not Available
MONTH
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL
Table B-13 WHOLESALE PRICE INDEXES FOR
MOTORS, INTEGRAL HORSEPOWER, A.C., 250 HP
BLS # 11730113, 1967=100
1971
1972 1973
1974 1975
N/A =
128.3 127.8
Not Available
136.3 142.8 N/A
1976
N/A
1977
123.9
123.9
123.9
125.6
129.0
129.0
130.7
130.7
130.7
130.7
130.7
130.7
125.1
.125.1
125.1
127.8
127.8
127.8
127.8
129.5
129.5
129.5
129.5
129.5
129.5
129.5
131.9
136.3
136.3
136.3
139.3
139.3
139.3
139.3
139.3
139.3
142.0
143.9
143.9
141.3
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
B-16
-------
MONTH
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL
Table B-14 WHOLESALE PRICE INDEXES FOR
MOTORS, INTEGRAL HORSEPOWER, A.C., 50 HP
BLS * 11730119, 1967=100
1971
1972 1973
1974 1975 1976 1977
115.1
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
99.6
101.5
105.6
105.6
105.6
105.6
105.6
105.6
111.5
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
123.5
126.1
126.1
140.7
152.4
160.9
163.1
164.3
172.8
172.8
172.8
178.0
180.6
184.9
184.9
. 184.9
184.9
184.9
184.9
184.9
184.9
184.9
184.9
186.6
190.1
191.9
191.9
191.9
191.9
191.9
194.5
200.6
200.6
200.6
200.6
200.6
200.6
200.6
200.6
200.6
204.1
216.3
216.3
216.3
216.3
216.3
216.3
98.3
104.7 117.6 149.9 184.0 194.4 208.7
MONTH
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL
Tabl* B-15 WHOLESALE PRICE INDEXES FOR
A.C. STARTERS, 75 HP, 440 VOLTS
BLS #11750781, 1967=100
1971
1972 1973
1974
^1975
1976 1977
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
150.3
146.7
152.0
152.0
152.0
150.0
152.0
152.0
152.0
152.0
155.0
163.3
163.3
163.3
163.3
163.2
163.2
163.2
163.2
163.2
163.2
163.2
166.2
173.8
176.3
176.3
108.5
112.4 112.4 128.5 144.9 154.9 166.5
B-17
-------
MONTH
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL
Table B-16 WHOLESALE PRICE INDEXES FOR
REFRACTORIES
BLS # 135, 1967=100
1971
1972 1973
1974 1975
1976
1977
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
161.2
163.3
163.5
163.6
163.7
163.7
163.8
164.0
164.2
164.3
177.0
179.7
179.7
179.7
179.9
180.3
180.2
180.4
180.7
181.2
188.9
191.1
193.0
192.9
193.1
193.2
193.2
193.3
194.3
196.5
197.3
198.5
207.1
208.5
209.3
209.3
126.9
129.0 136.3 143.5 166.0 184.0 199.5
MONTH
Table B-17 WHOLESALE PRICE INDEXES FOR
FIRE CLAY BRICK, SUPER DUTY
BLS # 13520111, 1967=100
1971
1972 1973
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL
N/A =
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
Not Available
129.0
129.0
129.0
N/A
N/A
N/A
129.0
131.0
132.3
N/A
132.3
132.3
130.5
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
1974
1975 1976 1977
134.5
134.5
134.5
134.5
134.5
134.5
135.3
N/A
156.0
164.2
164.2
167.1
144.9
167.1
170.3
170.3
170.3
170.3
170.3
170.3
170.3
170.3
170.3
189.2
194.1
173.6
194.1
194.1
194.1
194.1
194.1
194.1
194.1
195.1
199.8
201.9
206.9
206.9
197.4
207.9
207.9
207.9
207.9
207.9
207.9
209.7
210.8
218.4
220.8
222.3
222.3
212.9
B-18
-------
MONTH
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL
Table B-18 WHOLESALE PRICE INDEXES FOR
HIGH ALUMINA BRICK, 70 PCT.
BLS I 13520131, 1967=100
1971
121.1
1972 1973
1974 1975 1976 1977
119.8
119.8
119.8
119.8
119.8
121.5
121.5
121.5
121.5
122.7
122.7
122.7
122.7
122.7
122.7
N/A
N/A
N/A
122.7
130.4
134.5
N/A
134.5
134.5
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
146.9
146.9
146.9
146.9
146.9
154.6
N/A
170.4
178.7
178.7
181.2
183.4
189.0
189.0
190.1
190.1
190.1
190.1
192.4
192.4
192.4
209.3
211.5
211.5
211.5
212.9
212.9
212.9
212.9
215.5
215.5
219.3
221.1
224.7
224.7
224.7
224.7
224.7
224.7
227.6
229.6
229.6
229.6
240.0
242.6
244.5
244.5
128.1 146.9 158.6 193.3 216.3 232.2
N/A = Not Available
MONTH
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL
Table B-19
1975 1976
WHOLESALE PRICE INDEXES FOR
CASTABLE REFRACTORIES
BLS # 13520151, DEC 1974=100
1977
100.8
100.8
100.8
101.9
101.9
101.9
101.9
102.7
102.7
102.7
105.3
108.6
102.7
109.9
109.9
110.0
110.0
110.0
110.0
110.0
110.8
112.3
113.2
116.2
116.2
111.6
116.9
116.9
116.9
116.9
116.9
116.9
117.6
117.6
123.2
123.2
125.1
125.1
119.4
B-19
-------
MONTH
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL
Table 20 WHOLESALE PRICE INDEXES FOR
INSULATION MATERIALS
BLS #1392, 1967=100
1971
1972 1973
1974
1975 1976 1977
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
201.4
201.4
201.4
201.4
215.7
210.6
210.5
210.5
210.2
210.2
219.1
220.6
220.6
220.6
223.1
223.1
228.2
228:2
228.2
236.4
238.1
238.7
251.7
244.9
245.3
244.5
131.7
136.9 137.4 150.5 192.2 212.6 235.9
MONTH
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL
Table B-21 WHOLESALE PRICE INDEXES FOR
NATURAL GAS
BLS # 05310101, 1967 = 100
1971
112.8
1972 1973
1974 1975 1976
121.0 131.3
1977
109.5
107.9
109.7
110.8
112.2
113.0
113.0
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
236.1
236.1
248.5
257.0
259.8
273,0
279.0
294.1
294.3
356.8
408.1
360.6
331.1
384.2
392.8
405.0
420.2
410.3
N/A
N/A
N/A
N/A
N/A
N/A
155.1 215.3 292.0 N/A
N/A Not Available
B-20
-------
MONTH
JAN
FEE
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL
Table B-22 WHOLESALE PRICE INDEXES FOR
INDUSTRIAL POWER, 500 KWD
BLS # 0543, Dec 1967 = 100
1971
1972 1973
1974
1975 1976 1977
112.7
113.5
115.1
115.5
116.1
116.3
118.0
119.5
119.4
119.3
119.5
122.6 '
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
216.4
217.5
220.8
224.6
224.1
225.1
228.9
231.9
233.8
231.6
233.5
232.3
234.7
241.7
248.2
256.4
257.2
256.0
262.5
269.2
265.9
267.3
262.2
262.3
117.3 123.9 132.6 172.3 209.7 226.7 257.0
MONTH
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
ANNUAL
Table B-23 INDEXES OF AVERAGE HOURLY EARNINGS:
MANUFACTURING
1967 = 100
1971
1972 1973 1974 s 1975 1976 1977
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
178.8
180.0
180.9
181.9
182.5
183.6
185.3
186.6
188.0
188.4
189.8
191.0
192.3
193.4
194.3
195.6
196.9
198.5
200.3
201.2
202.7
204.2
205.4
206.3
129.3
129.0
131.3
127.5 135.4 143.6 156.0 171.5 184.7 199.3
SOURCE: U.S. Dept. of Commerce, Survey of Current Business
B-21
-------
APPENDIX C
GUIDE TO REFERENCES TO THE 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 of 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, 167
24, 36, 117, 167
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, 3;, 63,
64, 72, 82, 90, 112, 117, 167
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, 11
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 , 132, 133, 134,
136, 137, 143, 144, 145, 148
C-l
-------
LIST OF REFERENCES
Source
No.
Title
APT 1C
No.
NTIS
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 Anon,, "Pollution Control Update, 1970", McGraw- 30462
Hill, Modern Manufacturing, July 1970, 6 pp.
11 Vaiga, J., et al., "A Systems Analysis of the 30698
Iron & Steel Industry", Battelle, May, 1969.
12 Walling, I. C., "Cement Plant Dust Collectors", 31538
Pit & Quarry, July, 1971, 64(1):143-148.
13 Cook, C. C., et al., "Operating Experience 31567
With the Alcoa 398 Process for Fluoride
Recovery", Alcoa, Journal of the Air Pollu-
tion Control Assoc., 21(8);479-483. Aug. 1971.
184577
C-2
-------
Source
No.
Title
APTIC
No.
NT IS
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
to 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
200643
200651
200650
34955 200514
35574 2035?2
35581
C-3
-------
Source
No.
Title
APT 1C
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 with 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.
*
38 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
APT 1C
No.
NTIS
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", RTPf
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, s 240573
50 Ibid Item 46, Sulfur Oxide, CCMS 12. 240572
51 "Control Techniques For Particulate Air Pollutants", 190253
USNGW, 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.,
4-5(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.
36286
C-5
-------
Source
No.
Title
APTIC
No.
NTIS
No.
57
58
59
Hayes, C. T., "Cut Industrial Pollution by
Eliminating Gaseous Waste", Automation,
Cleveland 18(3):64-G5, Mar., 1971.
36516
60
61
62
63
64
65
66
67
68
69
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, M. 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.
62:26-31, 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, 1975:
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
APT 1C
No.
NFIS
No.
70 Calvert, Seymour, "Source Control by Liquid Scrubr 30868
bing", In: Air Pollution, Arthur C. Stern (Ed.),
Vol. 3, 2nd Ed., N.Y., Academic Press, 1968.
71 Olds, F. C., "SO, Control: Focusing on New Targets", 31673
Power Eng.. 75(8):24-29, Aug., 1971.
72 Lardieri, N. T., "Present Treatment Practices in 35660
Kraft Mills of Air-borne Effluents", Paper Trade
J.., 142(15):28-33, 14 April, 1958.
73 Taylor, D. H., "Recommendations for Dust Collection 35087
Systems", Metal Progr. 98(6):63, Dec., 1970.
74 Van DeWouwer, R., "Clinker Cooler Dust Collector 35990
Recovers 60 TPD at Inland's Winnepeg Plant", Pit
Quarry. 64(7):104-105, Jan., 1972.
75 Alonso, J. R.F., "Estimating the Costs of Gas 35532
Cleaning Plants", Chem. Eng.. 78(28):86-96.
76 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.
77 Selzler, David R. and Watson, W. D., "Hot Versus S 58903
Enlarged Electrostatic Precipitation of Fly Ash:
A Cost-Effectiveness Study". J. Air Poll. Control
Assoc., 24(2): 115-121, Feb., 1974, 25 Refs.
78 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 6b-02-
0289, Rept. EPA-450/3-73-010, IGCI Rept. 47-173,
724 p., Dec. 1973, 82 Refs.
79 Nichols, Richard A., "Hydrocarbon-Vapor Recovery" 60808
Chem. Eng.. 80(6):85-92, 5 Mar., 1973. Presented
at the Petroleum Mech. Engrg.Conf., New Orleans, La.,
Sept. 17-21, 1972.'
80 Shannon, Larry J.; Gerstle, Richard W.; Gorman, 59566
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.
C-7
-------
Source APTIC NTIS
_Nu^_ 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., Julyr 1971, 13 Refs.
85 Bagwell, F. A., Cox, L. F. and Pirsh, E. A., 58729
"Flue-Gas Filtering Proves Practical on Oil-
F.ired 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.
88 Daniel son, J. A., "Ai'r 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 Killin, A. M., "Engineering and
Cost Study of the Ferroalloy Industry", U. S.
EPA, EPA 450/2-74-008, May, 1974.
90 Hendrjckson, E. R., et al., "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.
C-8
-------
Source APT1C NTIS
No. Title No. 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 Fernandas, J. H., "Incineration Air Pollution Control",
Proceedings of1968 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. s
98 Kreichelt, T. E., et al., "Atmospheric Emissions from
the Manufacture of Portland Cement", U. S. Dept. of
Health, Education, and Welfare, 1967. PBir)23c,
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
NCK
101
102
103
104
105
106
107
10R
109
110
111
APTIC
No.
Title
Coughlin, R.W., et al., "Air Pollution and Its
Control", American Institute of Chemical Engi-
neers, Symposium Series 1972, Volume 68, No. 126.
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.
Anon., "Background Information for Standards of
Performance: Electric Arc Furnaces in the Steel
Industry", Volume 1 - Proposed Standards, October,
1974.
Ibid Item 103, Volume 2 - Test Data Summary,
Report No. EPA-450/2-74-017b.
Anon., "Economic Analysis of the Proposed Effluent
Guidelines for the Integrated Iron and Steel Industry",
February, 1974, Environmental Protection Agency,
Report No. EPA-230/1-73-027, A. J. Kearny, Contract
No. 68-01-1545.
Anon., Municipal Refuse Disposal, Institute for Solid
Wastes of American Public Works Association, 1970,
Public Administration Service, Chicago, Illinois.
Anon., 1968 National Incinerator Conference, New York,
N. Y., Sponsored by ASME Incinerator Division.
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
American Petroleum Inst., Wash. D. C., Committee
on Refinery Environmental Control, Hydrocarbon
Emissions From Refineries. # Pub-928, 64 p.,
July, 1973.
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.
Cheremisinoff, Paul N., "Wet Scrubbers - A Special
Report", Pollution Engineering, May, 1974,
pp. 33-43.
NTIS
No.
PB 237840
PB 237841
59178
61061
C-10
-------
Source APTIC NTIS
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- 224-53f
ment Modules", Vol. I & II, EPA-R5-73-023a & b, July, 224-53t
1973.
120 Liptak, B. 6., Environmental Engineers Handbook, Radnor,
Chi 1 ton 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.
1?7 Rymarz, J. *!. 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 Chilton, C. H., New Index Shows
Plant Cost Trends, Chemical Engineering.
Feb. 18, 1963, pp. 143-149.
131 Economic Indicators, Chemical Engineering, Every Issue.
132 Gorman, P. G., "Control Technology For Asphalt Roofing
Industry", Midwest Research Institute, Kansas City, Mo.,
EPA Contract 68-02-1324, Rept. EPA 600/2-76-120, April 1976.
133 Parsons, T. B., Shirley, T. E., Piana, M. B., "Hydrocarbon
Control Cost Effectiveness Analysis for Nashville, Tenn.,"
Radian!Corporation, Austin, TX., EPA Contract 68-02-2608,
Rept. EPA 904/9-78-003, February, 1978.
134 Burklin, C. E., Colley, S. D., Owen, M. L., "Background
Information on Hydrocarbon Emissions From Marine Terminal
Operations, Volume I, Discussion", Radian Corp., Austin,
TX., EPA Contract 68-02-1319, Rept, EPA 450/3-76-038a,
November, 1976.
135 IBID Item 134, Volume II, Appendices, Rept. EPA 450/
3-76-0385.
136 Pitruzzello, V. J., "The Control of Hydrocarbon Emissions
From Gasoline Marketing Operations," EPA, Proceedings of
Air Pollution Control Association Annual Meeting, June, 1977.
C-12
-------
Source APTIC
No. Title No.
137 Burklin, C. E., Cavanaugh, E. C., Dicker-man, J. C.,
Fernandes, S. R., "A Study of Vapor Control Methods
For Gasoline Marketing Operations: Volume I -
Industry Survey and Control Techniques," Radian Corp.
Austin, TX, EPA Contract 68-02-1319, Rept. EPA
450/3-75-046a, April, 1975.
138 Klett, M. G., Galeski, J. B., "Flare Systems Study",
Lockheed Missiles and Space Co., Huntsvilie, AL,
EPA Contract 68-02-1331, Rept. EPA 600/2-76-079,
March, 1976.
139 Mcllvaine, R. W., Ardell, M., "Research and Develop-
ment and Cost Projections for Air Pollution Control
Equipment," The Mcllvaine Co., Northbrook, IL, EPA
P.O. DA-7-6086A, Rept. EPA-600/7-78-092, June, 1978.
140 Bellegia, F. L., Mathews, J. D., Paddock, R. E.,
Wisler, M. M., "Update and Improvement of the Control
Cost Segment of the Implementation Planning Program",
EPA Contact 68-02-0607, February, 1975.
141 Anon., "Report of Fuel Requirements, Capital Cost
and Operating Expense for Catalytic and Thermal
Afterburners", CE Air Preheater Industrial Gas
Cleaning Institute, Stamford, Conn., EPA Contract
68-02-1473, Rept. EPA 450/3-76-031, September, 1976.
142 Bryan, R. J., Yamada, M. M., Norton, R. L., Kokin, A.,
"Evaluation of Top Loading Vapor Balance Systems For
Small Bulk Plants", EPA Contract 68-01-4140, Rept.
EPA 340/1-77-014, April, 1977.
143 Gammell, D. M., "Emission Control Technology For
Marine Terminals Handling Crudes and Gasoline",
Robert Brown Assoc., Carson, CA., EPA Contract
68-02-2838, March, 1978.
144 Gisser, P., "Benzene Emission Control Costs In
Selected Segments of the Chemical Industry", Booz,
Allen & Hamilton, Inc., Florham Park, N.J., Manu-
facturing Chemists Association, Washington, D.C.,
Rept. PB-283-781, June, 1978
145 Anon., "Control of Volatile Organic Emissions From
Existing Stationary Sources Volume I, Control Methods
For Surface-Coating Operations", Rept. EPA-450/2-76-028
November, 1976.
C-13
-------
Source APTIC NTIS
No. Title No. No.
146 Perry, et al. "Chemical Engineers Handbook,
147 Maxwell, J. B., "Data Book on Hydrocarbons",
Standard Oil Development Company.
148 Anon., "Cost Estimates of Upgrading Participate
Matter Controls on Copper Smelter Reverberatory
Furnaces", Industrial Gas Cleaning Institute,
Stamford, Conn., EPA Contract 68-02-2532,
March, 1977.
149 Cost Engineer's Notebook, American Association of
Cost Engineers.
150 C. H. Chilton, "Cost Engineering in the Process
Industries", McGraw-Hill, 1960.
151 Anon, "Industrial Ventilation" 10th Edition,
American Conference of Governmental Industrial
Hygienist.
152 Hemeon, W.C.L., "Plant and Process Ventilation",
Second Edition, The Industrial Press, New York,
N,Y.
153 Loyal Clarke, "Manual for Process Engineering
Calculations", McGraw-Hill, 1947
154 Anon, "Air Pollution Manual" PartiI Control
Equipment, American Industrial Hygiene Association.
155 Strauss W. "Industrial Gas Cleaning" Pergamon
Press, Second Edition 1975.
156 Bauman, H.C. "Fundamentals of Cost Engineering
in the Chemical Industry" Reinhold 1965
157 Gaylord "Structural Engineering Handbook:
McGraw Hill 1968.
158 Anon, "Capital Costs of Free Standing Stacks"
Vulcan - Cincinnati Inc, EPA Contact #68-02-0299
159 Holland, F.A., et al., "How to Estimate
Capital Costs", Chemical Engineering, April 1,
1974.
160 GARD in-house data.
C-14
-------
APTIC NTIS
No. No.
161 Shaw, N.R., "Carbon Absorption/Emission
Control Benefits and Limitations", Paper
presented at symposium on Volatile Organic
Compound Control in Surface Coating Industries,
April 25-26, 1979 Chicago, 111.
162 Anon "Hydrocarbon Pollutant Systems Study"
MSA Research Corp., EPA contract EHSD 71-72,
January 1973.
163 Private communication with PGST Company and
vendor quote.
164 Norman, W.S., "Absorption Distillation and
Cooling Towers". Wiley Press., New York,
N.Y. 1961
165 Miller, J.S. et. al., "Cost of a Distillation
Column" Chemical Engineering, April 11, 1977
166 Pikulik, A., et. al., "Cost Estimating for
Major Process Equipment" Chemical Engr,
Oct. 10, 1977
167 Steenberg, L.R. "Air Pollution Control
Technology and Costs, Seven Selected Emission
Sources". EPA-450/3-74-060, Dec. 1974 s
168 White, H. J.; "Industrial Electostatic Precipita-
tion", Addison-Wesley Publishing Co., 1963.
169 Horzella, T. I., "Selecting, Installing and
Maintaining Cyclone Dust Collectors", Chemical
Engineering, January 30, 1978.
170 Anon., "Review and Comments on Report Entitled
Capital and Operating Costs of Selected Air
Pollution Control Systems", PEDCo Environ-
mental, Inc., August, 1979.
171 Anon., Building Construction Cost Data, 35th
Annual Edition, Means, 1977.
172 Based on discussions with T. Tarnok of Joy/
Western Precipitation Division.
C-15
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APPENDIX D
GUIDE TO ASSOCIATIONS FOR THE 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. W. 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
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. Portland 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
v. 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. Eastern 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
43. Incinerator Institute of America
2425 Wilson Blvd.
Arlington, Virginia 22201
44. American Public Works Association
1313 East 60th Street
Chicago, Illinois 60637
45. National Solid 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
Gieorge 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
Multiply by
5
1.01325 *
to
pascal (Pa)
joule (J) 1.05506 * 103
joule/metre2 (J/m2) 1.13565 * 104
Btu/pourid -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)
watt (W)
joule/kilogram-
(J/kg)
joule/kilogram-
kelvin (J/kg-K) v
2
watt/metre -kelvin
(W/m2.K)
joule (J)
second (s)
kelvin (k)
degree Celsius
kelvin (k)
metre (m)
o p
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 (V*59.67)/1.8
0.30480
9.29030 * 10"2
2.83168 * 10
metre/second (m/s) 8.46667 * 10
-2
-5
+ The Btu quantity used herein is that based on the International Table.
E-l
-------
To convert from
to
Multiply by
foot/minute (fpm)
foot/second (fps)
foot /minute (cfm)
foot /second (cfs)
gallon (U.S. liquid) (gal)
gallon (U.S. liquid)/day (gpd)
metre/second (m/s)
metre/second (m/.s")
3 3
metre /second (m/s)
metre /second (m /s)
metre (m )
metre /second
(n»3/s)
5.08000 * 10
0.30480
-3
4.71947 * 10
-4
2.83168 * 10
-2
gallon (U.S. liquid)/minute (gpm) metre, /second
•
u-ain \qr)
Horsepower (hp)
NDur (Hr)
•-rich (•''n)
inch2 («n2)
inch of water (60F)
kilowatt-hour (kwh)
minute (min)
parts per million (ppm)
pound-force (Ibf avoirdupois)
o
pound-force/inch (psi)
pound-mass (Ibm avoirdupois)
pound-mass/foot3 (lbm/ft3)
pound-mass/minute (Ibm/min)
pound-mass/second (Ibm/sec)
ton (cooTing capacity)
ton (short, 2000 Ibm)
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).
3
kilogram/metre
(kg/m3)
kilogram/second
(kg/s)
kilogram/second
(kg/s)
Btu/hr
kilogram (kg) •
3.78541 * 10
-3
4.38126 * 10
-8
6.30902 * 10~5
6.47989 * 10"5
7.46000 * 102
3.60000 * 10 3
2.54000 * 10~2
6.45160 * 10~4
2.4884 * 102
3.60000 * 106
60.000
(molecular weight)/24.5
4.44822
6.89476 * 103
0.453592
1.60185 * 101
7.55987 * 10"3
4.53592 * 10"1
1.2000 * 1040
9.07185 * 102
E-2
-------
I I UINICAI '• ''Oil 1 DA I A
1 Imltlii lll>ll\ i"l ; in UN i n it. us/on N i NMI n it MMS
Industrial Emission Sources
CO^LS
Manual
Fabric Filters, Absorbers, Flares,
Scrubbers, Refrigeration
Electrostatic Precipitators
Adsorbers, Incinerators
Cost Estimation
Techniques
Capital Costs
Annualized Costs
Air Pollution Control-
Systems
v.. COSA I I I II-lil/l iliui|'
18. DISrHIBUTIONSTAIEMLNT
Unlimited
in r,r CUMIT Y 1:1 ASS /inn
Unclassified
•jv r.i i-inil ry c.i A'.s iiim /
Unclassified
71. NO. 01 I'ACil '.'.
PHUT
EPA Form 2220-1 19-73)
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