Control of Volatile Organic Compounds Emissions from Manufacturing

attery-limit costs and do' not include any provisions for br ingi ng
utilities, services, or roads to the site, or for amy backup facilities,
land, research and development required, or for any process piping and '
instrumentation interconnections that may be required within the process
generating the waste gas. Since RACT will affect existing plants, the
control equipment instal 1 ation factors incl ude cost adjustments for
retrofit instal 1 ations. Typical cost adjustments for control equipment
Installations given in the GARD ~anual2 are presented in Table 5-1. The
installation factors and retrofit cost adjustments assumed for the
various process control devices are presented in Table 5-2. Actual
direct and indirect cost factors depend upon the plant specific conditions
and may vary with the size of the system. The annualized costs consist
of the direct operating and maintenance costs, including labor, utilities,
fuel, and materials for the control system, and indirect costs for
overhead, taxes, insurance, admini stration, and the capital recovery
charges. The utilities considered include natural gas and electricity.
The annualized cost factors that are used to analyze all of the process
VOC control systems are summarized in Table 5-3.
The following sections outline the design and costing procedures
developed for-flares, thermal incinerators, catalytic incinerators,
and condensers. Details of these procedures are given in Appendix E.
This section presents an overview of the procedures and their important
features. The results of the cost analyses for the various control
device and model plant combinations are also presented.
5.1.1 Thermal Incinerator Design and Cost Basis
I
For costing purposes thermal incinerator designs were based on heat
and mass balances for combustion of the waste gas and any required
auxil iary fuel , considering requi rements of total combustion ai r.
Associated piping, ducting, fans, and stacks werd a1 so costed.
5.1.1 -1 Thermal Incineration Design. Designs of thermal incineration
systems for the various combinations of waste gas streams were developed
using a procedure based on heat and mass balances and the characteristics
of the waste gas in conjunction with some engineering design assumptions.
For the purpose of the cost analyses in this report, thermal incinerators
were designed to maintain a 0.75 second residence time at 870°C (1600°F).3
The design procedure is outlined in this section.
5-2
I