Proyecciones de los precios.

Plant Open or closed Primary control Secondary control

Roof monitor opacity limit

Acme Steel, Riverdale, IL Open ESP Baghouse 20%, 3 minute average

AK Steel, Ashland, KY Closed Scrubber Baghouse 20% except for 3 min/hr

AK Steel, Middletown, OH Closed Scrubber None Covered under “bubble”

Bethlehem, Burns Harbor, IN (3 vessels in 1 shop) Open(2) Closed(1) Scrubber None Scrubber 40%, 6 minute average; <60% for 15-min in 6 hr Bethlehem, Sparrows Point, MD Open Scrubber None 3-day roll avg of 15% (6-min

avg), except 3 min/hr Geneva Steel, Orem, UT Closeda _{Scrubber Baghouse 10%, 6 minute average}

Gulf States, Gadsden, AL Open ESP None 20%, 3 minute average

Inland Steel, East Chicago, IN (2 shops) Closed Open Scrubber Scrubber Scrubber Baghouse 20%, 3 minute average 20%, 3 minute average LTV, Cleveland, OH (2 shops) Open

Closed

ESP

Scrubber Baghouse

20%, 3 minute average 20%, 3 minute average

LTV, East Chicago, IN Open ESP None 20%, 3 minute average

National, Granite City, IL Open ESP None 20%, 3 minute average

National, Ecorse, MI Open ESP Baghouse 20%, 3 minute average

Rouge Steel, Dearborn, MI Open ESP None 20%, 3 minute average

USX, Braddock, PA Open Scrubber Baghouse Not to equal or exceed 20%

except for 12 readings per hour.

USX, Fairfield, AL Closeda _{Scrubber Baghouse}b _{20%, 6 minute average}

USX, Gary, IN (2 shops) Open

Opena

Scrubber

Scrubber Baghouse

20%, 3 minute average 20%, 3 minute average

USS/Kobe, Lorain, OH Closed Scrubber Baghouse 20%, 3 minute average

WCI Steel, Warren, OH Open ESP None None

Weirton Steel Weirton, WV Open Scrubber None 20%

Wheeling-Pittsburgh, OH Open Scrubber None 20%, 3 minute average

a _{Bottom blown}

b _{Canopy hood baghouse controls emissions from “C” furnace only; new secondary control system under construction.}

6. CONTROL COSTS

6.1 APPROACH

The costs associated with improved emission control are based on what each plant may have to

do with respect to upgrading or replacing emission control equipment. The estimates are worst case or

upper bound estimates because they assume in several cases that plants will have to replace existing

control equipment, when if fact, it may be possible to upgrade existing controls.

The cost estimates are derived from industry survey responses, information from vendors, and procedures

in EPA’s manual for estimating costs.

6.2 BOPF PRIMARY CONTROL SYSTEMS

Two plants were identified as candidates for upgrading or replacing their venturi scrubbers used as

the primary control devices for BOPF. Ispat-Inland’s Number 4 BOPF shop has three venturi scrubbers

that are over 30 years old and were designed with a lower pressure drop (25 inches of water) than most

scrubbers that are currently used. The company had performed an engineering analysis in 1990 to

estimate the cost of replacing these scrubbers with higher pressure scrubbers.1 _{The estimate is based on}

an entirely new emission control system that includes three venturi scrubbers and three new capture hoods

for the BOPF. The capital cost estimates are presented below and are indexed to 1998 dollars:

Item Capital cost (millions of dollars)

Three venturi scrubbers 11

Three new BOPF hoods 6.6

Engineering 0.7

Miscellaneous 0.4

Total ($1990) 18.7

Total ($1998) index = 389.5/357.6 20

The increase in operating cost for the new scrubbers is primarily the cost of increased energy

(electricity) due to operating at the higher pressure drop. A cost function is provided in EPA’s cost

manual2 _{that expresses electricity cost as a function of the volumetric flow rate and pressure drop:} Electricity cost ($/yr) = 0.00018 x acfm x )p x hrs/yr x $/kW-hr

Estimates of electrical costs are given below for pressure drops of 25 and 50 inches of water based on

6-2 )p (in. water) Cost ($ millions/yr)

25 1.4

50 2.8

The increase in operating cost for the higher pressure drop scrubbers is estimated as $1.4 million per year.

Test data indicated that the venturi scrubbers at AK Steel (Middletown, OH) may require a minor

upgrade to improve emission control. These scrubbers were designed with an adequate pressure drop

(50 to 60 inches of water). However, the water supply system may need to be upgraded, and the

scrubbers do not have demisters. Estimates obtained from a vendor (Coastal Technologies, Inc.)

indicated that two demisters for two 72-inch diameter stacks would cost about $7,000 (316 stainless steel

chevrons). The cost of new water supply piping2 _{for venturi scrubbers of this size was estimated as}

$10,600 for a total equipment cost of $17,600. Based on a retrofit factor of 1.3 and an indirect cost

factor (from the cost manual2_{) of 36 percent of the purchased equipment cost, the total installed capital}

cost for the minor scrubber upgrade is estimated as $31,000.

6.3 SECONDARY CAPTURE AND CONTROL SYSTEMS

Capture and control systems are used for fugitive emissions in many blast furnace casthouses and

BOPF shops. Table 6-1 summarizes the capital and operating costs reported by several plants that use a

baghouse as the control device.

Only one plant reported no controls for their casthouse -- Gulf States Steel in Gadsden, Alabama.

This plant may be able to use flame suppression and covered runners to provide adequate control to meet

an opacity limit for the casthouse. However, a worst case approach is used by assuming that a capture

system and baghouse may need to be installed. Based on the cost for such a system as reported by

USS/Kobe Steel in Table 6-1, costs are estimated as an installed capital cost of $3.3 million, an operating

cost of $0.7 million per year, and a total annualized cost of $1.0 million per year (includes capital recovery