33,155
                                    15,126
                                     480.5
EC-Erie-PA
Battery Combustion Stack (805)
                                    D/F TEQ
                                    35,436
                                    23,744
                                     245.7
EC-Erie-PA
Battery Combustion Stack (805)
                                    D/F TEQ
                                    38,773
                                    26,127
                                     247.9
EC-Erie-PA
Battery Combustion Stack (805)
                                    D/F TEQ
                                    37,797
                                    25,444
                                     250.2
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                    D/F TEQ
                                    178,713
                                    93,871
                                      387
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                    D/F TEQ
                                    183,768
                                    96,109
                                      394
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                    D/F TEQ
                                    180,255
                                    95,591
                                      388
CC-Middletown-OH
Combustion Stack
                                      HCN
                                    123,062
                                    80,559
                                      288
CC-Middletown-OH
Combustion Stack
                                      HCN
                                    125,023
                                    69,752
                                      360
CC-Middletown-OH
Combustion Stack
                                      HCN
                                    116,407
                                    63,312
                                      380
CC-Burnsharbor-IN
Coke Battery No. 2 Underfire Stack
                                      HCN
                                    218,408
                                    100,594
                                     454.7
CC-Burnsharbor-IN
Coke Battery No. 2 Underfire Stack
                                      HCN
                                    217,541
                                    99,696
                                     455.5
CC-Burnsharbor-IN
Coke Battery No. 2 Underfire Stack
                                      HCN
                                    218,067
                                    100,278
                                     452.6
CC-Monessen-PA
Battery Combustion Stack #2
                                      HCN
                                    32,138
                                    16,492
                                     432.4
CC-Monessen-PA
Battery Combustion Stack #2
                                      HCN
                                    34,774
                                    15,740
                                      526
CC-Monessen-PA
Battery Combustion Stack #2
                                      HCN
                                    34,617
                                    15,035
                                     546.3
EC-Erie-PA
Battery Combustion Stack (805)
                                      HCN
                                    35,579
                                    24,512
                                     239.3
EC-Erie-PA
Battery Combustion Stack (805)
                                      HCN
                                    35,503
                                    23,848
                                     247.1
EC-Erie-PA
Battery Combustion Stack (805)
                                      HCN
                                    34,260
                                    23,579
                                     243.5
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                      HCN
                                    181,355
                                    95,470
                                      393
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                      HCN
                                    191,878
                                    97,164
                                      396
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                      HCN
                                    185,778
                                    98,128
                                      390
CC-Middletown-OH
Combustion Stack
                                      Hg
                                    126,975
                                    78,619
                                      298
CC-Middletown-OH
Combustion Stack
                                      Hg
                                    124,885
                                    78,747
                                      292
CC-Middletown-OH
Combustion Stack
                                      Hg
                                    124,885
                                    78,747
                                      292
CC-Burnsharbor-IN
Coke Battery No. 2 Underfire Stack
                                      Hg
                                    202,185
                                    94,466
                                     451.3
CC-Burnsharbor-IN
Coke Battery No. 2 Underfire Stack
                                      Hg
                                    202,974
                                    96,241
                                     450.1
CC-Burnsharbor-IN
Coke Battery No. 2 Underfire Stack
                                      Hg
                                    201,951
                                    96,973
                                     440.9
CC-Monessen-PA
Battery Combustion Stack #2
                                      Hg
                                    32,134
                                    16,490
                                     432.4
CC-Monessen-PA
Battery Combustion Stack #2
                                      Hg
                                    34,769
                                    15,738
                                      526
CC-Monessen-PA
Battery Combustion Stack #2
                                      Hg
                                    34,626
                                    15,035
                                     546.3
EC-Erie-PA
Battery Combustion Stack (805)
                                      Hg
                                    33,951
                                    23,590
                                      230
EC-Erie-PA
Battery Combustion Stack (805)
                                      Hg
                                    35,394
                                    24,651
                                     231.2
EC-Erie-PA
Battery Combustion Stack (805)
                                      Hg
                                    35,296
                                    24,286
                                     236.5
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                      Hg
                                    175,965
                                    92,953
                                      383
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                      Hg
                                    174,627
                                    92,058
                                      381
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                      Hg
                                    174,436
                                    91,955
                                      387
CC-Middletown-OH
Combustion Stack
                                 PM Filterable
                                    126,975
                                    78,619
                                      311
CC-Middletown-OH
Combustion Stack
                                 PM Filterable
                                    125,146
                                    78,311
                                      302
CC-Middletown-OH
Combustion Stack
                                 PM Filterable
                                    124,623
                                    79,182
                                      281
CC-Burnsharbor-IN
Coke Battery No. 2 Underfire Stack
                                 PM Filterable
                                    202,185
                                    94,466
                                     451.3
CC-Burnsharbor-IN
Coke Battery No. 2 Underfire Stack
                                 PM Filterable
                                    202,974
                                    96,241
                                     450.1
CC-Burnsharbor-IN
Coke Battery No. 2 Underfire Stack
                                 PM Filterable
                                    201,951
                                    96,973
                                     440.9
CC-Monessen-PA
Battery Combustion Stack #2
                                 PM Filterable
                                    32,134
                                    16,490
                                     432.4
CC-Monessen-PA
Battery Combustion Stack #2
                                 PM Filterable
                                    34,769
                                    15,738
                                      526
CC-Monessen-PA
Battery Combustion Stack #2
                                 PM Filterable
                                    34,626
                                    15,035
                                     546.3
EC-Erie-PA
Battery Combustion Stack (805)
                                 PM Filterable
                                    33,951
                                    23,590
                                      230
EC-Erie-PA
Battery Combustion Stack (805)
                                 PM Filterable
                                    35,394
                                    24,651
                                     231.2
EC-Erie-PA
Battery Combustion Stack (805)
                                 PM Filterable
                                    35,296
                                    24,286
                                     236.5
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                 PM Filterable
                                    175,965
                                    92,953
                                      383
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                 PM Filterable
                                    174,627
                                    92,058
                                      381
USS-Clairton-PA
Battery B Combustion Stack (S012)
                                 PM Filterable
                                    174,436
                                    91,955
                                      387
Average

                                    115,438
                                    61,286
                                      381

Development of Unit Costs for Ductwork for BTF Controls for ByP Battery Combustion Stacks

      The ductwork cost model from the Ferroalloy NESHAP RTR (EPA, 2015) was used to develop unit costs for ByP battery combustion stacks using specific data available for the coke industry. Table C-14 shows the ductwork unit costs for coke ByP battery combustion stacks.

Table C-14. Ductwork Unit Costs for BTF Controls for ByP Battery Combustion Stacks
                                  Parameters
                                   ByP Value
                               Source/Reference
DUCTS: COST BASE DATE:  GDP 1993
                                    68.877
BEA, 2023
COST ESCALATION: GDP 2022
                                    126.45
BEA, 2023
-- Inlet stream flowrate (acfm):
                                    115,438
Coke oven test data
-- Duct velocity (ft/min):
                                     3,800
Ferroalloy (EPA, 2015)
-- Duct length (ft):
                                      150
Engineering judgement
-- Material of construction:
                                 Sheet-galv CS
Ferroalloy (EPA, 2015)
-- Insulation thickness (in.): (text input)
                                       0
Ferroalloy (EPA, 2015)
-- Duct design:
                             Circular-longitudinal
Ferroalloy (EPA, 2015)
-- Cost equation parameters:

          a:
                                     2.03
Ferroalloy (EPA, 2015)
          b:
                                     0.784
Ferroalloy (EPA, 2015)
-- Cost equation form:
                                       1
Ferroalloy (EPA, 2015)
-- Control system installation factor:
                                       0
Ferroalloy (EPA, 2015)
   (if no system, enter '0')

-- Fan-motor combined efficiency (fraction):
                                      0.6
Ferroalloy (EPA, 2015)
DESIGN PARAMETERS

-- Duct diameter (in.):
                                      76
Ferroalloy (EPA, 2015)
-- Pressure drop (in. w.c.):
                                       0
Ferroalloy (EPA, 2015)
CAPITAL COSTS

Ductwork Cost ($)--base:
                                    $9,081
Ferroalloy (EPA, 2015)
Ductwork Cost ($)--escalated:
                                    $16,672
Ferroalloy (EPA, 2015)
Purchased Equipment Cost ($):
                                    $18,006
Ferroalloy (EPA, 2015)
Retrofit Adjustment (25%)
                                    $22,507
Ferroalloy (EPA, 2015)
Total Capital Investment ($):
                                    $33,761
Ferroalloy (EPA, 2015)
ANNUAL COST INPUTS

Operating factor (hours/year):
                                     8760
Coke oven test data
Electricity price ($/kWhr):
                                     0.067
Ferroalloy (EPA, 2015)
Annual interest rate (fractional):
                                     0.075
FRED, 2023
Ductwork economic life (years):
                                      20
Ferroalloy (EPA, 2015)
Capital recovery factor (system):
                                  0.098092192
Ferroalloy (EPA, 2015)
Taxes, insurance, admin. factor:
                                     0.04
Ferroalloy (EPA, 2015)
Labor, $/hr
                                    $29.44
BLS, 2023
ANNUAL COSTS

Item
                                  Cost ($/yr)

Electricity
                                    $3,389
Ferroalloy (EPA, 2015)
Taxes, insurance, administrative
                                    $1,350
Ferroalloy (EPA, 2015)
Capital recovery
                                    $3,312
Ferroalloy (EPA, 2015)
Labor
                                    $2,438
Ferroalloy (EPA, 2015)
Overhead
                                    $1,463
Ferroalloy (EPA, 2015)
Total Annual Cost
                                    $11,952
Ferroalloy (EPA, 2015)

Development of Unit Costs for ACI for BTF Controls for ByP Battery Combustion Stacks

      The ACI cost model from the Ferroalloy NESHAP RTR (EPA, 2015) was used to develop unit costs for ByP battery combustion stacks using specific data available for the coke industry. Table C-15 shows the ACI unit costs for BTF controls for ByP battery combustion stacks.
 Table C-15. ACI Unit Costs for BTF Controls for ByP Battery Combustion Stacks
                                  Parameters
                                     Value
                               Source/Reference
Annual Operating Hours, hr/yr (H)
                                     8760
Coke oven test data
Exhaust Gas Flow Rate, acfm (Qa)
                                    115,438
Coke oven test data
Exhaust Gas Flow Rate, dscfm (Q)
                                    61,286
Coke oven test data
Operating Labor Rate, $/hr (LR)
                                    $29.44
BLS, 2023
Activated Carbon Cost, $/lb (ACC)
                                     $0.75
Ferroalloy (EPA, 2015)
Dust Disposal Cost, $/Ton (DDC, Non-Hazardous)
                                    $40.00
Ferroalloy (EPA, 2015)
Dust Disposal Cost, $/Ton (DDC, Hazardous)
                                    $400.00
Ferroalloy (EPA, 2015)
Capital Recovery Factor (CRF)
                                  0.098092192
CRF calculated assuming 20-year equipment life and 7.5% interest (FRED, 2023)
GDP, 2022
                                    126.45
BEA, 2023
GDP, 2008
                                    94.419
BEA, 2023
GDP, 1991
                                    65.783
BEA, 2023
ACI Adjustment Factor (AF)
                                     0.95
Calculated control efficiency
ACI Injection Rate (lb/MMacf)
                                      2.0
Ferroalloy (EPA, 2015)
Total Capital Investment, $ (TCI)
                                    $81,498
Calculated using algorithm 4,500 x (Q/1,976)0.6 x (1.2 retrofit factor) x CEPCI Adj.
Direct Annual Cost, $/yr (DAC)

Operating Labor
                                    $8,059
Calculated using (0.25 hr/8-hr shift) x H x LR
Supervisory Labor
                                    $1,209
Calculated using 0.15 x Operating Labor
Maintenance
                                    $16,300
Calculated using 0.2 x TCI
Activated Carbon
                                    $91,011

Dust Disposal (Non-Hazardous)
                                    $2,403
Calculated using ACI injection rate, 99% capture efficiency, and non-hazardous disposal cost
Dust Disposal (Hazardous)
                                    $24,027
Calculated using ACI injection rate, 99% capture efficiency, and hazardous disposal cost
Indirect Annual Cost, $/yr (IAC)

Overhead
                                    $15,341
Calculated using 0.6 x (Labor + Maintenance)
Property Tax, Insurance, & Admin
                                    $3,260
Calculated using 0.04 x TCI
Capital Recovery
                                    $7,994
Calculated using CRF x TCI
Total Annual Cost (Non-Hazardous)
                                   $145,576
Sum of DAC + IAC
Total Annual Cost (Hazardous)
                                   $167,201
Sum of DAC + IAC

Development of Unit Costs for WAS for BTF Controls for ByP Battery Combustion Stacks

      The WAS cost model from the Portland Cement NESHAP (EPA, 2010) was used to develop unit costs for ByP battery combustion stacks using specific data available for the coke industry. Table C-16 shows the WAS unit costs for BTF controls for coke ByP battery combustion stacks.

 Table C-16. WAS Unit Costs for BTF Controls for ByP Battery Combustion Stacks
                                 Capital Costs
Parameter
                                     Value
                               Source/Reference
Gas flowrate (dscfm)
                                    61,286
Coke oven test data
GDP 2010
                                    96.166
(BEA, 2023)
GDP 2022
                                    126.45
(BEA, 2023)
CC = Capital ($2022)
                                  $14,112,933
Portland Cement (EPA, 2010)
                                 Annual Costs

Parameter
                                     Value
                               Source/Reference
COSTKWH ($2022/kWhr)
                                  0.095199759
Portland Cement (EPA, 2010)
Annual interest rate (fraction):
                                     0.075
(FRED, 2023)
Control system life (years):
                                      20
Portland Cement (EPA, 2010)
CRF = Capital recovery factor:
                                  0.098092192
Portland Cement (EPA, 2010)
                                   Facility
                                    Source
                                 Type of Coke
                              Coke Production TPY
                           Operating Hours per year
                                      FC
                               SO2 (lb/ton coke)
                                      VC
                                      TAC

                                Coke Oven Data
                                  Coke Oven
                                     Data
                          Portland Cement (EPA, 2010)
                                Coke Oven Data
                Portland Cement (EPA, 2010 & Andover 2009)
                          Portland Cement (EPA, 2010)
ABC-Tarrant-AL
underfiring stack #4, serving batteries #5 and #6
                                    Foundry
                                    148,079
                                     8760
                                   $612,610
                                     0.55
                                    $4,773
                                  $2,001,752
ABC-Tarrant-AL
underfiring stack #1, serving battery #1
                                    Foundry
                                    377,606
                                     8760
                                   $648,852
                                     0.22
                                    $10,530
                                  $2,043,750
BLU-Birmingham-AL
underfiring stack of coke batteries no. 3 & 4
                                    Foundry
                                    203,045
                                     8760
                                   $622,639
                                     0.40
                                    $6,152
                                  $2,013,159
BLU-Birmingham-AL
underfiring stack of coke battery no. 5
                                    Foundry
                                    145,668
                                     8760
                                   $612,139
                                     0.56
                                    $4,712
                                  $2,001,220
CC-Follansbee-WV
Battery #1 Combustion
                                 Blast Furnace
                                    36,264
                                     8760
                                   $585,194
                                      49
                                    $23,861
                                  $1,993,423
CC-Follansbee-WV
Battery #2 Combustion
                                 Blast Furnace
                                    36,264
                                     8760
                                   $585,194
                                      49
                                    $23,861
                                  $1,993,423
CC-Follansbee-WV
Battery #3 Combustion
                                 Blast Furnace
                                    36,264
                                     8760
                                   $585,194
                                      49
                                    $23,861
                                  $1,993,423
CC-Follansbee-WV
Battery #8 Combustion
                                 Blast Furnace
                                    453,069
                                     8760
                                   $658,594
                                      3.9
                                    $34,314
                                  $2,077,277
CC-Middletown-OH
Wilputte Coke Oven Battery - Combustion Stack
                                 Blast Furnace
                                    401,752
                                     8760
                                   $652,048
                                      4.2
                                    $31,977
                                  $2,068,393
CC-BurnsHarbor-IN
EU512-08 battery #1 underfire
                                 Blast Furnace
                                    932,178
                                     8760
                                   $709,556
                                      5.2
                                    $86,279
                                  $2,180,203
CC-BurnsHarbor-IN
EU512-16 battery #2 underfire
                                 Blast Furnace
                                    955,975
                                     8760
                                   $711,766
                                      5.1
                                    $86,876
                                  $2,183,011
CC-Monessen-PA
Coke Oven Battery 1B Underfiring (Combustion Stack)
                                 Blast Furnace
                                    222,015
                                     8760
                                   $625,839
                                      1.3
                                    $9,266
                                  $2,019,473
CC-Monessen-PA
Coke Oven Battery 2 Underfiring (Combustion Stack)
                                 Blast Furnace
                                    114,007
                                     8760
                                   $605,627
                                      2.5
                                    $6,557
                                  $1,996,552
CC-Warren-OH
No. 4 Coke oven battery - Oven Underfiring
                                 Blast Furnace
                                    359,281
                                     8760
                                   $646,372
                                      4.9
                                    $31,962
                                  $2,062,703
EES-RiverRouge-MI
Battery Heating Stack
                                 Blast Furnace
                                    981,765
                                     8760
                                   $714,137
                                      1.8
                                    $47,574
                                  $2,146,079
USS-Clairton-PA
Coke Oven Battery 1 Underfiring
                                 Blast Furnace
                                    217,224
                                     8760
                                   $625,041
                                      1.2
                                    $8,754
                                  $2,018,164
USS-Clairton-PA
Coke Oven Battery 2 Underfiring
                                 Blast Furnace
                                    217,224
                                     8760
                                   $625,041
                                      1.2
                                    $8,754
                                  $2,018,164
USS-Clairton-PA
Coke Oven Battery 3 Underfiring
                                 Blast Furnace
                                    217,224
                                     8760
                                   $625,041
                                      1.2
                                    $8,754
                                  $2,018,164
USS-Clairton-PA
Coke Oven Battery 13 Underfiring
                                 Blast Furnace
                                    225,724
                                     8760
                                   $626,451
                                      1.1
                                    $8,968
                                  $2,019,788
USS-Clairton-PA
Coke Oven Battery 14 Underfiring
                                 Blast Furnace
                                    225,724
                                     8760
                                   $626,451
                                      1.1
                                    $8,968
                                  $2,019,788
USS-Clairton-PA
Coke Oven Battery 15 Underfiring
                                 Blast Furnace
                                    225,724
                                     8760
                                   $626,451
                                      1.1
                                    $8,968
                                  $2,019,788
USS-Clairton-PA
Coke Oven Battery 19 Underfiring
                                 Blast Furnace
                                    424,307
                                     8760
                                   $654,964
                                     0.60
                                    $13,948
                                  $2,053,280
USS-Clairton-PA
Coke Oven Battery 20 Underfiring
                                 Blast Furnace
                                    424,307
                                     8760
                                   $654,964
                                     0.60
                                    $13,948
                                  $2,053,280
USS-Clairton-PA
Coke Oven B Battery Underfiring
                                 Blast Furnace
                                    718,216
                                     8760
                                   $688,550
                                     0.35
                                    $21,319
                                  $2,094,238
USS-Clairton-PA
Coke Oven C Battery Underfiring
                                 Blast Furnace
                                    880,570
                                     8760
                                   $704,683
                                     0.29
                                    $25,391
                                  $2,114,443
Where:
CC = Capital ($2022) = 14,398*(DSCFM)[0.6]
Fixed costs (FC) include labor (operating, supervisory, and maintenance), maintenance materials, replacement parts, taxes, insurance, etc.:
FC = 38 * TPY[0.6] + 0.04 * CC
Variable costs (VC) include consumption of limestone, power, and water plus generation of scrubber slurry:
VC = (0.000844 * TPY * COSTKWH) + (0.013 * TPY * SO2) + (TPY * 0.025)
Total annualized cost (TAC) includes fixed annual costs, variable annual costs, and capital recovery interest rate, 20‐year lifetime, and a capital recovery factor:
TAC = FC + VC + CRF * CC

BTF Costs per Facility for ByP Battery Combustion Stacks

      It was assumed that the coke facilities will duct each ByP battery combustion stack to one APCD configuration. The unit APCD costs were multiplied by the required number of APCD configurations to calculate the total BTF costs for ByP battery combustion stacks per facility. The total BTF costs are shown in Table C-17.

     Table C-17. BTF Costs per Facility for ByP Battery Combustion Stacks
                                   Facility
                            No. APCD Configurations
                            Total Capital Cost ($)
                             Total Annual Cost ($)

                                   Ductwork
                                     ACI
                                     WAS
                                    Total
                                   Ductwork
                                     ACI
                                     WAS
                                    Total
ABC-Tarrant-AL
                                       2
                                    $67,522
                                   $162,995
                                  $28,225,867
                                  $28,456,384
                                    $23,904
                                   $334,401
                                  $4,045,502
                                  $4,403,807
BLU-Birmingham-AL
                                       2
                                    $67,522
                                   $162,995
                                  $28,225,867
                                  $28,456,384
                                    $23,904
                                   $334,401
                                  $4,014,379
                                  $4,372,684
CC-Follansbee-WV
                                       4
                                   $135,044
                                   $325,990
                                  $56,451,734
                                  $56,912,768
                                    $47,807
                                   $668,803
                                  $8,057,545
                                  $8,774,155
CC-Middletown-OH
                                       1
                                    $33,761
                                    $81,498
                                  $14,112,933
                                  $14,228,192
                                    $11,952
                                   $167,201
                                  $2,068,393
                                  $2,247,546
CC-BurnsHarbor-IN
                                       2
                                    $67,522
                                   $162,995
                                  $28,225,867
                                  $28,456,384
                                    $23,904
                                   $334,401
                                  $4,363,214
                                  $4,721,519
CC-Monessen-PA
                                       2
                                    $67,522
                                   $162,995
                                  $28,225,867
                                  $28,456,384
                                    $23,904
                                   $334,401
                                  $4,016,025
                                  $4,374,330
CC-Warren-OH
                                       1
                                    $33,761
                                    $81,498
                                  $14,112,933
                                  $14,228,192
                                    $11,952
                                   $167,201
                                  $2,062,703
                                  $2,241,855
EES-RiverRouge-MI
                                       1
                                    $33,761
                                    $81,498
                                  $14,112,933
                                  $14,228,192
                                    $11,952
                                   $167,201
                                  $2,146,079
                                  $2,325,232
USS-Clairton-PA
                                      10
                                   $337,610
                                   $814,976
                                 $141,129,335
                                 $142,281,920
                                   $119,518
                                  $1,672,007
                                  $20,429,098
                                  $22,220,623
Industry Total

                                   $844,024
                                  $2,037,439
                                 $352,823,337
                                 $355,704,800
                                   $298,795
                                  $4,180,016
                                  $51,202,939
                                  $55,681,750

BTF Emission Reductions for ByP Battery Combustion Stacks

      Baseline emissions for ByP battery combustion stacks were estimated from coke oven CAA section 114 requests data. The coke oven stack test data were used to develop industry average Hg, PM, Non-Hg metal HAP, AG, and HCN lb/ton coke default values per coke produced type, which were used to estimate emissions for the units that were not tested, as shown in Table C-18.

              Table C-18. ByP Combustion Stack Default Baseline
             Emission Factors (lb/ton coke) by Coke Type Produced
                                   Pollutant
                                 Blast Furnace
                                 (lb/ton coke)
                                   Foundry
                                 (lb/ton coke)
Hg
                                   1.19E-05
                                   4.99E-06
PM
                                   4.14E-01
                                   1.00E-01
Non-Hg Metal HAP
                                   4.27E-04
                                   4.39E-04
AG
                                   2.57E-02
                                   8.56E-03
HCN
                                   1.54E-03
                                   3.77E-03

      In addition, the coke oven stack test data for similar units at the test facilities were used as "surrogate" data, where appropriate. The lb/ton coke emission factor developed for each battery combustion stack source (i.e., coke oven test data, similar unit, or default emission factor) were multiplied by each source's corresponding battery coke production value (TPY), as shown in Table C-19, and then divided by 2,000 to calculate TPY emissions.

   Table C-19. Annual Coke Production Values by Facility and Emission Source
                                   Facility
                               Emission Source
                              Coke Production TPY
ABC-Tarrant-AL
underfiring stack #4, serving batteries #5 and #6
                                    148,079
ABC-Tarrant-AL
underfiring stack #1, serving battery #1
                                    377,606
BLU-Birmingham-AL
underfiring stack of coke batteries no. 3 & 4
                                    203,045
BLU-Birmingham-AL
underfiring stack of coke battery no. 5
                                    145,668
CC-Follansbee-WV
battery #1 combustion
                                    36,264
CC-Follansbee-WV
battery #2 combustion
                                    36,264
CC-Follansbee-WV
battery #3 combustion
                                    36,264
CC-Follansbee-WV
battery #8 combustion
                                    453,069
CC-Middletown-OH
Wilputte coke oven battery - combustion stack
                                    401,752
CC-BurnsHarbor-IN
EU512-08 battery #1 underfire
                                    932,178
CC-BurnsHarbor-IN
EU512-16 battery #2 underfire
                                    955,975
CC-Monessen-PA
coke oven battery 1b underfiring (combustion stack)
                                    222,015
CC-Monessen-PA
coke oven battery 2 underfiring (combustion stack)
                                    114,007
CC-Warren-OH
no. 4 coke oven battery - oven underfiring
                                    359,281
EES-RiverRouge-MI
battery heating stack
                                    981,765
USS-Clairton-PA
coke oven battery 1 underfiring
                                    217,224
USS-Clairton-PA
coke oven battery 2 underfiring
                                    217,224
USS-Clairton-PA
coke oven battery 3 underfiring
                                    217,224
USS-Clairton-PA
coke oven battery 13 underfiring
                                    225,724
USS-Clairton-PA
coke oven battery 14 underfiring
                                    225,724
USS-Clairton-PA
coke oven battery 15 underfiring
                                    225,724
USS-Clairton-PA
coke oven battery 19 underfiring
                                    424,307
USS-Clairton-PA
coke oven battery 20 underfiring
                                    424,307
USS-Clairton-PA
coke oven b battery underfiring
                                    718,216
USS-Clairton-PA
coke oven c battery underfiring
                                    880,570

      The baseline PM and HAP emissions for all ByP battery combustion stacks at each facility were summed to produce a facility total for ByP battery combustion stacks. Table C-20 shows the baseline ByP battery combustion stack emissions for each facility.

Table C-20. Baseline PM and HAP Emissions from ByP Battery Combustion Stacks Before BTF Controls
                                   Facility

                      Baseline PM and HAP Emissions (TPY)

                                      PM
                                      Hg
                               Non-Hg Metal HAP
                                      AG
                                      HCN
                                   Total HAP
ABC-Tarrant-AL
                                      26
                                    0.0013
                                     0.12
                                     2.250
                                     0.99
                                      3.4
BLU-Birmingham-AL
                                      17
                                    0.00087
                                     0.077
                                     1.493
                                     0.66
                                      2.2
CC-Follansbee-WV
                                      116
                                    0.0033
                                     0.12
                                     7.23
                                     0.43
                                      7.8
CC-Middletown-OH
                                      248
                                    0.00084
                                     0.079
                                     12.27
                                     0.61
                                      13
CC-BurnsHarbor-IN
                                      309
                                     0.030
                                     1.11
                                     15.44
                                      2.3
                                      19
CC-Monessen-PA
                                      3.9
                                    0.00065
                                     0.013
                                     1.743
                                     0.087
                                      1.8
CC-Warren-OH
                                      74
                                    0.0021
                                     0.077
                                     4.622
                                     0.28
                                      5.0
EES-RiverRouge-MI
                                      203
                                    0.0058
                                     0.21
                                     12.63
                                     0.75
                                      14
USS-Clairton-PA
                                      132
                                     0.013
                                     0.113
                                     28.53
                                     0.32
                                      29
Industry Total
                                     1,132
                                     0.059
                                      1.9
                                     86.2
                                      6.4
                                      95

      Table C-21 shows the control efficiencies of each APCD that were used to calculate the BTF emission reductions as shown in Table C-22.

        Table C-21. Pollutants, APCD, Control Efficiency for BTF Controls
                                   Pollutant
                                     APCD
                              Control Efficiency
Hg
                                      ACI
                                      95%
PM
                                      WAS
                                      95%
Non-Hg Metal HAP
                                      WAS
                                      95%
AG
                                      WAS
                                     99.9%
HCN
                                      WAS
                                      95%

Table C-22. Reductions in PM and HAP Emissions for ByP Battery Combustion Stacks due to BTF Controls
                                   Facility
                   BTF PM and HAP Emission Reductions (TPY)

                                      PM
                                      Hg
                               Non-Hg Metal HAP
                                      AG
                                      HCN
                                   Total HAP
ABC-Tarrant-AL
                                      25
                                    0.0012
                                     0.11
                                     2.248
                                     0.94
                                      3.3
BLU-Birmingham-AL
                                      17
                                    0.00083
                                     0.073
                                     1.491
                                     0.62
                                      2.2
CC-Follansbee-WV
                                      111
                                    0.0032
                                     0.11
                                     7.22
                                     0.41
                                      7.7
CC-Middletown-OH
                                      236
                                    0.00080
                                     0.075
                                     12.26
                                     0.58
                                      13
CC-BurnsHarbor-IN
                                      294
                                     0.029
                                     1.05
                                     15.43
                                      2.2
                                      19
CC-Monessen-PA
                                       4
                                    0.00062
                                     0.012
                                     1.742
                                     0.083
                                      1.8
CC-Warren-OH
                                      71
                                    0.0020
                                     0.073
                                     4.617
                                     0.26
                                      5.0
EES-RiverRouge-MI
                                      193
                                    0.0055
                                     0.20
                                     12.62
                                     0.72
                                      14
USS-Clairton-PA
                                      126
                                     0.013
                                     0.108
                                     28.51
                                     0.31
                                      29
Industry Total
                                     1,076
                                     0.056
                                      1.8
                                     86.1
                                      6.1
                                      94

      The remaining emissions (TPY) shown in Table C-23 were calculated by subtracting the emission reductions (TPY) from the baseline emission values (TPY) per pollutant.

Table C-23. Remaining PM and HAP Emissions for ByP Battery Combustion Stacks After BTF Controls
                                   Facility
            Remaining PM and HAP Emissions After BTF Control (TPY)

                                      PM
                                      Hg
                               Non-Hg Metal HAP
                                      AG
                                      HCN
                                   Total HAP
ABC-Tarrant-AL
                                      1.3
                                    6.6E-05
                                    0.0058
                                    0.0023
                                     0.050
                                     0.058
BLU-Birmingham-AL
                                     0.87
                                    4.4E-05
                                    0.0038
                                    0.0015
                                     0.033
                                     0.038
CC-Follansbee-WV
                                      5.8
                                    1.7E-04
                                    0.0060
                                    0.0072
                                     0.022
                                     0.035
CC-Middletown-OH
                                      12
                                    4.2E-05
                                    0.0040
                                     0.012
                                     0.030
                                     0.047
CC-BurnsHarbor-IN
                                      15
                                    1.5E-03
                                     0.055
                                     0.015
                                     0.12
                                     0.19
CC-Monessen-PA
                                     0.19
                                    3.2E-05
                                    0.00065
                                    0.0017
                                    0.0043
                                    0.0068
CC-Warren-OH
                                      3.7
                                    1.1E-04
                                    0.0038
                                    0.0046
                                     0.014
                                     0.022
EES-RiverRouge-MI
                                      10
                                    2.9E-04
                                     0.010
                                     0.013
                                     0.038
                                     0.061
USS-Clairton-PA
                                      6.6
                                    6.7E-04
                                    0.0057
                                     0.029
                                     0.016
                                     0.051
Industry Total
                                      57
                                    0.0029
                                     0.10
                                     0.086
                                     0.32
                                     0.51

BTF Cost Effectiveness for ByP Battery Combustion Stacks

      To calculate $/ton cost effectiveness values, annualized costs (shown in Table C-17 above) were divided by the emission reductions (shown in Table C-22 above), as shown in Table C-24. Note, the values presented were calculated from unrounded emissions.

Table C-24. BTF Cost Effectiveness for ByP Battery Combustion Stacks due to BTF Controls
                                   Facility
                          Cost Effectiveness ($/Ton)

                                   PM w/ WAS
                                   Hg w/ ACI
                            Non-Hg Metal HAP w/ WAS
                                   AG w/ WAS
                                  HCN w/ WAS
                       Total HAP w/ Ductwork + ACI + WAS
ABC-Tarrant-AL
                                   $161,942
                                 $268,348,778
                                  $36,919,417
                                  $1,797,626
                                  $4,084,754
                                  $1,334,522
BLU-Birmingham-AL
                                   $242,250
                                 $404,535,900
                                  $55,227,864
                                  $2,689,074
                                  $6,110,396
                                  $1,997,575
CC-Follansbee-WV
                                    $72,853
                                 $211,250,772
                                  $70,738,879
                                  $1,114,772
                                  $18,659,499
                                  $1,132,434
CC-Middletown-OH
                                    $8,765
                                 $209,769,848
                                  $27,504,449
                                   $168,611
                                  $3,407,155
                                   $174,124
CC-BurnsHarbor-IN
                                    $14,840
                                  $11,549,337
                                  $4,137,742
                                   $282,551
                                  $1,895,434
                                   $252,527
CC-Monessen-PA
                                  $1,089,924
                                 $542,136,384
                                 $325,126,362
                                  $2,303,642
                                  $46,213,136
                                  $2,381,080
CC-Warren-OH
                                    $29,166
                                  $82,591,175
                                  $28,319,618
                                   $446,288
                                  $7,470,148
                                   $452,492
EES-RiverRouge-MI
                                    $11,105
                                  $30,224,585
                                  $10,782,594
                                   $169,923
                                  $2,844,232
                                   $171,750
USS-Clairton-PA
                                   $162,510
                                 $130,823,571
                                 $189,882,137
                                   $715,952
                                  $63,377,305
                                   $768,024
Industry Total
                                    $47,607
                                  $74,718,217
                                  $28,169,513
                                   $593,933
                                  $7,965,453
                                   $591,704
Note: Total HAP=Hg+Non-Hg Metal HAP+AG+HCN
C.4 HNR HRSG Main Stack BTF Analysis

       For HNR HRSG main stack sources, Hg, PM, AG, and PAH MACT limits were developed, as described above in Section 3.0 and Appendix B. The BTF analysis includes the cost of adding ACI followed by a WAS to each HNR HRSG main stack. Note, HNR HRSG main stacks have existing controls (e.g., flue-gas desulfurization (FGD) and baghouses).

Input Parameters for BTF Controls for HNR HRSG Main Stacks

	The actual and standard exhaust flowrates and stack temperatures (°F) were compiled from the coke oven stack testing of Hg, PM, AG, and PAH at HNR HRSG main stack sources. Overall average exhaust flowrates and stack temperature were calculated from the stack tests to use as inputs for calculating BTF controls for HNR HRSG main stack sources. Table C-25 shows the average stack parameters for the HNR HRSG main stack sources. Copies of the coke oven stack test data are included in the coke oven PQBS docket (Docket ID No. EPA-HQ-OAR-2002-0085).

         Table C-25. Average Stack Parameters for HNR HRSG Main Stacks
                                   Facility
                                     Unit
                               Pollutant Tested
                              Flow Actual (acfm)
                           Flow Dry Standard (dscfm)
                             Temp Stack Gas (°F)
SC-Middletown-OH
P901- Coke Oven (Battery A-C) - Main Stack
                                      PAH
                                    390,869
                                    237,659
                                      243
SC-Middletown-OH
P901- Coke Oven (Battery A-C) - Main Stack
                                      PAH
                                    402,815
                                    242,390
                                      244
SC-Middletown-OH
P901- Coke Oven (Battery A-C) - Main Stack
                                      PAH
                                    388,639
                                    238,788
                                      241
SC-Middletown-OH
P901- Coke Oven (Battery A-C) - Main Stack
                                 PM Filterable
                                    382,427
                                    226,979
                                      248
SC-Middletown-OH
P901- Coke Oven (Battery A-C) - Main Stack
                                 PM Filterable
                                    388,162
                                    232,635
                                      247
SC-Middletown-OH
P901- Coke Oven (Battery A-C) - Main Stack
                                 PM Filterable
                                    386,648
                                    227,660
                                      247
SC-Middletown-OH
P901- Coke Oven (Battery A-C) - Main Stack
                                      Hg

                                    226,979
                                      248
SC-Middletown-OH
P901- Coke Oven (Battery A-C) - Main Stack
                                      Hg

                                    232,635
                                      247
SC-Middletown-OH
P901- Coke Oven (Battery A-C) - Main Stack
                                      Hg

                                    227,660
                                      247
SC-Middletown-OH
P901- Coke Oven (Battery A-C) - Main Stack
                                      AG

                                    231,980
                                      247
SC-Middletown-OH
P901- Coke Oven (Battery A-C) - Main Stack
                                      AG

                                    229,410
                                      248
SC-Middletown-OH
P901- Coke Oven (Battery A-C) - Main Stack
                                      AG

                                    229,448
                                      247
Average

                                    389,927
                                    232,019
                                      246

Development of Unit Costs for Ductwork for BTF Controls for HNR HRSG Main Stacks

      The ductwork cost model from the Ferroalloy NESHAP RTR (EPA, 2015) was used to develop unit costs for HNR HRSG main stacks using specific data available for the coke industry. Table C-26 shows the ductwork unit costs for HNR HRSG main stacks.

   Table C-26. Ductwork Unit Costs for BTF Controls for HNR HRSG Main Stacks
                                  Parameters
                                   HNR Value
                               Source/Reference
DUCTS: COST BASE DATE:  GDP 1993
                                    68.877
BEA, 2023
COST ESCALATION: GDP 2022
                                    126.45
BEA, 2023
-- Inlet stream flowrate (acfm):
                                    389,927
Coke oven test data
-- Duct velocity (ft/min):
                                     3,800
Ferroalloy (EPA, 2015)
-- Duct length (ft):
                                      150
Engineering judgement
-- Material of construction:
                                 Sheet-galv CS
Ferroalloy (EPA, 2015)
-- Insulation thickness (in.): (text input)
                                       0
Ferroalloy (EPA, 2015)
-- Duct design:
                             Circular-longitudinal
Ferroalloy (EPA, 2015)
-- Cost equation parameters:

          a:
                                     2.03
Ferroalloy (EPA, 2015)
          b:
                                     0.784
Ferroalloy (EPA, 2015)
-- Cost equation form:
                                       1
Ferroalloy (EPA, 2015)
-- Control system installation factor:
                                       0
Ferroalloy (EPA, 2015)
   (if no system, enter '0')

-- Fan-motor combined efficiency (fraction):
                                      0.6
Ferroalloy (EPA, 2015)
DESIGN PARAMETERS

-- Duct diameter (in.):
                                      76
Ferroalloy (EPA, 2015)
-- Pressure drop (in. w.c.):
                                       0
Ferroalloy (EPA, 2015)
CAPITAL COSTS

Ductwork Cost ($)--base:
                                    $9,081
Ferroalloy (EPA, 2015)
Ductwork Cost ($)--escalated:
                                    $16,672
Ferroalloy (EPA, 2015)
Purchased Equipment Cost ($):
                                    $18,006
Ferroalloy (EPA, 2015)
Retrofit Adjustment (25%)
                                    $22,507
Ferroalloy (EPA, 2015)
Total Capital Investment ($):
                                    $33,761
Ferroalloy (EPA, 2015)
ANNUAL COST INPUTS

Operating factor (hours/year):
                                     8760
Coke oven test data
Electricity price ($/kWhr):
                                     0.067
Ferroalloy (EPA, 2015)
Annual interest rate (fractional):
                                     0.075
FRED, 2023
Ductwork economic life (years):
                                      20
Ferroalloy (EPA, 2015)
Capital recovery factor (system):
                                  0.098092192
Ferroalloy (EPA, 2015)
Taxes, insurance, admin. factor:
                                     0.04
Ferroalloy (EPA, 2015)
Labor, $/hr
                                    $29.44
BLS, 2023
ANNUAL COSTS

Item
                                  Cost ($/yr)

Electricity
                                    $11,449
Ferroalloy (EPA, 2015)
Taxes, insurance, administrative
                                    $1,350
Ferroalloy (EPA, 2015)
Capital recovery
                                    $3,312
Ferroalloy (EPA, 2015)
Labor
                                    $2,438
Ferroalloy (EPA, 2015)
Overhead
                                    $1,463
Ferroalloy (EPA, 2015)
Total Annual Cost
                                    $20,011
Ferroalloy (EPA, 2015)

Development of Unit Costs for ACI for BTF controls for HNR HRSG Main Stacks

      The ACI cost model from the Ferroalloy NESHAP RTR (EPA, 2015) was used to develop unit costs for HNR HRSG main stacks using specific data available for the coke industry. Table C-27 shows the ACI unit costs for HNR HRSG main stacks.

     Table C-27. ACI Unit Costs for BTF Controls for HNR HRSG Main Stacks
                                  Parameters
                                     Value
                               Source/Reference
Annual Operating Hours, hr/yr (H)
                                     8760
Coke oven test data
Exhaust Gas Flow Rate, acfm (Qa)
                                    389,927
Coke oven test data
Exhaust Gas Flow Rate, dscfm (Q)
                                    232,019
Coke oven test data
Operating Labor Rate, $/hr (LR)
                                    $29.44
BLS, 2023
Activated Carbon Cost, $/lb (ACC)
                                     $0.75
Ferroalloy (EPA, 2015)
Dust Disposal Cost, $/Ton (DDC, Non-Hazardous)
                                    $40.00
Ferroalloy (EPA, 2015)
Dust Disposal Cost, $/Ton (DDC, Hazardous)
                                    $400.00
Ferroalloy (EPA, 2015)
Capital Recovery Factor (CRF)
                                  0.098092192
CRF calculated assuming 20-year equipment life and 7.5% interest (FRED, 2023)
GDP, 2022
                                    126.45
BEA, 2023
GDP, 2008
                                    94.419
BEA, 2023
GDP, 1991
                                    65.783
BEA, 2023
ACI Adjustment Factor (AF)
                                     0.95
Calculated control efficiency
ACI Injection Rate (lb/MMacf)
                                      2.0
Ferroalloy (EPA, 2015)
Total Capital Investment, $ (TCI)
                                   $181,151
Calculated using algorithm 4,500 x (Q/1,976)0.6 x (1.2 retrofit factor) x CEPCI Adj.
Direct Annual Cost, $/yr (DAC)

Operating Labor
                                    $8,059
Calculated using (0.25 hr/8-hr shift) x H x LR
Supervisory Labor
                                    $1,209
Calculated using 0.15 x Operating Labor
Maintenance
                                   $36,230
Calculated using 0.2 x TCI
Activated Carbon
                                   $307,418

Dust Disposal (Non-Hazardous)
                                    $8,116
Calculated using ACI injection rate, 99% capture efficiency, and non-hazardous disposal cost
Dust Disposal (Hazardous)
                                    $81,158
Calculated using ACI injection rate, 99% capture efficiency, and hazardous disposal cost
Indirect Annual Cost, $/yr (IAC)

Overhead
                                    $27,299
Calculated using 0.6 x (Labor + Maintenance)
Property Tax, Insurance, & Admin
                                    $7,246
Calculated using 0.04 x TCI
Capital Recovery
                                   $17,769
Calculated using CRF x TCI
Total Annual Cost (Non-Hazardous)
                                   $413,347
Sum of DAC + IAC
Total Annual Cost (Hazardous)
                                   $486,389
Sum of DAC + IAC

Development of Unit Costs for WAS for BTF Controls for HNR HRSG Main Stacks

      The WAS cost model from the Portland Cement NESHAP (EPA, 2010) was used to develop unit costs for HNR HRSG main stacks using specific data available for the coke industry. Table C-27 shows the WAS unit costs for HNR HRSG main stacks.

     Table C-27. WAS Unit Costs for BTF Controls for HNR HRSG Main Stacks
                                 Capital Costs
Parameter
                                     Value
                               Source/Reference
Gas flowrate (dscfm)
                                    389,927
Coke oven test data
GDP 2010
                                    96.166
BEA, 2023
GDP 2022
                                    126.45
BEA, 2023
CC = Capital ($2022)
                                  $42,834,066
Portland Cement
(EPA, 2010)
                                 Annual Costs
Parameter
                                     Value

COSTKWH ($2022/kWhr)
                                  0.095199759
Portland Cement
(EPA, 2010)
Annual interest rate (fraction):
                                     0.075
FRED, 2023
Control system life (years):
                                      20
Portland Cement
(EPA, 2010)
CRF = Capital recovery factor:
                                  0.098092192
Portland Cement
(EPA, 2010)
                                   Facility
                                 Facility Type
                                 Type of Coke
                              Coke Production TPY
                           Operating Hours per year
                                 Fixed Costs
                         SO2 = lb SO2 per ton of coke
                                   Variable
                                     Costs
                                      TAC

                                Coke Oven Data
                                  Coke Oven
                                     Data
                          Portland Cement (EPA, 2010)
                                  Coke Oven
                                     Data
                Portland Cement (EPA, 2010 & Andover 2009)
                          Portland Cement (EPA, 2010)
SC-EastChicago-IN
                                      HNR
                                 Blast furnace
                                   1,300,000
                                     8,760
                                  $1,890,435
                                     1.17
                                    $52,420
                                  $6,144,542
SC-FranklinFurnace-OH
                                      HNR
                                 Blast furnace
                                    341,657
                                     8,760
                                  $1,792,784
                                     4.46
                                    $28,385
                                  $6,022,856
SC-GraniteCity-IL
                                      HNR
                                 Blast furnace
                                    428,412
                                     8,760
                                  $1,804,333
                                     3.56
                                    $30,561
                                  $6,036,581
SC-Middletown-OH
                                      HNR
                                 Blast furnace
                                    357,010
                                     8,760
                                  $1,794,907
                                     4.27
                                    $28,770
                                  $6,025,364
Note: CC = Capital ($2022) = 14,398*(DSCFM)[0.6].
Fixed costs include labor (operating, supervisory, and maintenance), maintenance materials, replacement parts, taxes, insurance, etc. FC = 38 * TPY[0.6] + 0.04 * CC.
Variable costs (VC) include consumption of limestone, power, and water plus generation of scrubber slurry. VC = (0.000844 * TPY * COSTKWH) + (0.013 * TPY * SO2) + (TPY * 0.025).
Total annualized cost (TAC) includes fixed annual costs, variable annual costs, and capital recovery interest rate, 20‐year lifetime, and a capital recovery factor: TAC = FC + VC + CRF * CC

BTF Costs per Facility for HNR HRSG Main Stacks

      It was assumed that the coke facilities will duct each HNR HRSG main stack to one BTF APCD configuration. The unit APCD costs were multiplied by the required number of APCD configurations to calculate the total BTF HNR HRSG main stack costs per facility. The Total BTF HNR HRSG main stack costs are shown in Table C-28.

          Table C-28. BTF Costs per Facility for HNR HRSG Main Stacks
                                   Facility
                            No. APCD Configurations
                            Total Capital Cost ($)
                             Total Annual Cost ($)

                                   Ductwork
                                      ACI
                                      WAS
                                     Total
                                   Ductwork
                                      ACI
                                      WAS
                                     Total
SC-EastChicago-IN
                                       1
                                    $33,761
                                   $181,151
                                  $42,834,066
                                  $43,048,978
                                    $20,011
                                   $486,389
                                  $6,144,542
                                  $6,650,943
SC-FranklinFurnace-OH
                                       2
                                    $67,522
                                   $362,302
                                  $85,668,132
                                  $86,097,956
                                    $40,022
                                   $972,779
                                  $12,045,712
                                  $13,058,514
SC-GraniteCity-IL
                                       1
                                    $33,761
                                   $181,151
                                  $42,834,066
                                  $43,048,978
                                    $20,011
                                   $486,389
                                  $6,036,581
                                  $6,542,982
SC-Middletown-OH
                                       1
                                    $33,761
                                   $181,151
                                  $42,834,066
                                  $43,048,978
                                    $20,011
                                   $486,389
                                  $6,025,364
                                  $6,531,764
Industry Total

                                   $168,805
                                   $905,754
                                 $214,170,330
                                 $215,244,889
                                   $100,056
                                  $2,431,947
                                  $30,252,200
                                  $32,784,203

BTF Emission Reductions for HNR HRSG Main Stacks

      Baseline emissions were estimated from coke oven CAA section 114 requests data. The coke oven stack test data were used to develop industry average Hg, PM, Non-Hg metal HAP, AG, and total PAH lb/hr default values for the units that were not tested, as shown in Table C-29.

                   Table C-29. HNR HRSG Main Stack Default
                      Baseline Emission Factors (lb/hr)
                                   Pollutant
                              HNR HRSG Main Stack
                                    (lb/hr)
Hg
                                   6.50E-03
PM
                                   3.76E+00
Non-Hg Metal HAP
                                   1.90E-02
AG
                                   2.92E+01
PAH
                                   1.29E-03

      The lb/hr coke emission factor developed for each HNR HRSG main stack source (i.e., coke oven test data or default emission factor) were multiplied by each source's corresponding annual operating hours (hours/year), as shown in Table C-30, and then divided by 2,000 to calculate TPY emissions.

          Table C-30. Annual Operating Hours per HNR HRSG Main Stack
                                   Facility
                                Emission Source
                            Annual Operating Hours
SC-EastChicago-IN
HRCCF MAIN STACK 001
                                     8,760
SC-FranklinFurnace-OH
P901- Coke Ovens (Battery A&B) - Main Stack AB
                                     8,760
SC-FranklinFurnace-OH
P902- Coke Ovens (Battery C&D) - Main Stack CD
                                     8,760
SC-GraniteCity-IL
0005 -Coke Ovens (Battery A&B&C) - Main Stack
                                     8,760
SC-Middletown-OH
P901- Coke Oven (Battery A-C) - Main Stack
                                     8,760

      The baseline PM and HAP emissions for HNR HRSG main stacks were summed for each facility. Table C-31 shows the baseline emissions.

Table C-31. Baseline PM and HAP Emissions from HNR HRSG Main Stacks Before BTF Controls
                                   Facility
                      Baseline PM and HAP Emissions (TPY)

                                      PM
                                      Hg
                               Non-Hg Metal HAP
                                      AG
                                      PAH
                                   Total HAP
SC-EastChicago-IN
                                      10
                                     0.049
                                     0.049
                                     236.3
                                    0.0079
                                      236
SC-FranklinFurnace-OH
                                      33
                                     0.057
                                     0.167
                                     255.5
                                     0.011
                                      256
SC-GraniteCity-IL
                                      16
                                     0.028
                                     0.083
                                     127.7
                                    0.0056
                                      128
SC-Middletown-OH
                                      23
                                    0.0077
                                     0.12
                                     19.2
                                    0.0034
                                      19
Industry Total
                                      82
                                     0.14
                                     0.42
                                     638.7
                                     0.028
                                      639

      Table C-32 shows the control efficiencies of each APCD that were used to calculate the BTF emission reductions as shown in Table C-33.

       Table C-32. Pollutants, APCD, Control Efficiency for BTF Controls
                                   Pollutant
                                     APCD
                              Control Efficiency
Hg
                                      ACI
                                      95%
PAH
                                      ACI
                                      80%
PM
                                      WAS
                                      95%
Non-Hg Metal HAP
                                      WAS
                                      95%
AG
                                      WAS
                                     99.9%

Table C-33. Reductions in PM and HAP Emissions for HNR HRSG Main Stacks due to BTF Controls
                                   Facility
                   BTF PM and HAP Emission Reductions (TPY)

                                      PM
                                      Hg
                               Non-Hg Metal HAP)
                                      AG
                                     PAH
                                  Total HAP
SC-EastChicago-IN
                                      10
                                     0.047
                                     0.046
                                     236.0
                                    0.0063
                                      236
SC-FranklinFurnace-OH
                                      31
                                     0.054
                                     0.16
                                     255.2
                                    0.0090
                                      255
SC-GraniteCity-IL
                                      16
                                     0.027
                                     0.079
                                     127.6
                                    0.0045
                                      128
SC-Middletown-OH
                                      22
                                    0.0074
                                     0.11
                                     19.2
                                    0.0027
                                      19
Industry Total
                                      78
                                     0.14
                                     0.40
                                     638.1
                                     0.023
                                      639

      The remaining emissions (TPY) were calculated by subtracting the emission reductions (TPY) from the baseline emission values (TPY) per pollutant, as shown in Table C-34.

Table C-34. Remaining PM and HAP Emissions for HNR HRSG Main Stacks After BTF Controls
                                   Facility
            Remaining PM and HAP Emissions After BTF Control (TPY)

                                      PM
                                      Hg
                               Non-Hg Metal HAP
                                      AG
                                     PAH
                                   Total HAP
SC-EastChicago-IN
                                     0.51
                                    0.0025
                                    0.0024
                                     0.24
                                    0.0016
                                     0.24
SC-FranklinFurnace-OH
                                      1.6
                                    0.0028
                                    0.0083
                                     0.26
                                    0.0023
                                     0.27
SC-GraniteCity-IL
                                     0.82
                                    0.0014
                                    0.0042
                                     0.13
                                    0.0011
                                     0.13
SC-Middletown-OH
                                      1.1
                                    0.00039
                                    0.0059
                                     0.019
                                    0.00068
                                     0.026
Industry Total
                                      4.1
                                    0.0071
                                     0.021
                                     0.64
                                    0.0056
                                     0.67

BTF Cost Effectiveness for HNR HRSG Main Stacks

      To calculate $/ton cost effectiveness values, annualized costs (shown in Table C-28 above) were divided by the emission reductions (shown in Table C-33 above), as shown in Table C-35. Note, the values presented were calculated from unrounded emissions and cost values.

Table C-35. BTF Cost Effectiveness for HNR HRSG Main Stacks due to BTF Controls
                                   Facility
                          Cost Effectiveness ($/Ton)

                                   PM w/ WAS
                                   Hg w/ ACI
                            Non-Hg Metal HAP w/ WAS
                                   AG w/ WAS
                                  PAH w/ ACI
                       Total HAP w/ Ductwork + ACI + WAS
SC-EastChicago-IN
                                   $638,671
                                  $10,403,650
                                 $132,439,323
                                    $26,035
                                  $77,048,210
                                    $28,168
SC-FranklinFurnace-OH
                                   $385,193
                                  $17,980,159
                                  $76,047,707
                                    $47,196
                                 $107,654,422
                                    $51,120
SC-GraniteCity-IL
                                   $386,071
                                  $17,980,159
                                  $76,221,005
                                    $47,304
                                 $107,654,422
                                    $51,227
SC-Middletown-OH
                                   $278,294
                                  $66,165,532
                                  $53,797,105
                                   $313,627
                                 $178,600,852
                                   $337,839
Industry Total
                                   $386,957
                                  $66,165,532
                                  $54,020,996
                                   $314,932
                                 $178,600,852
                                   $339,136
Note: Total HAP=Hg+Non-Hg Metal HAP+AG

C.5 HNR HRSG Bypass/Waste Heat Stack BTF Analysis

      For HNR HRSG bypass/waste heat stack sources, Hg, PM, AG, Total PAH, and Formaldehyde MACT limits were developed, as described above in Section 3.0 and Appendix B. The BTF analysis includes the cost of adding ACI, WAS, and regenerative thermal oxidizer (RTO) to HNR HRSG bypass/waste heat stacks ducted together to reduce Hg, PM, AG, Total PAH, and Formaldehyde emissions further than the MACT limit.

Input Parameters for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks

	The actual and standard exhaust flowrates and stack temperatures (°F) were compiled from the coke oven stack testing of Hg, PM, AG, Total PAH, and Formaldehyde at the HNR HRSG bypass/waste heat stack sources. Overall average exhaust flowrates and stack temperature were calculated from the stack tests to use as inputs for calculating BTF controls for HNR HRSG bypass/waste heat stack sources. Table C-36 shows the average stack parameters for the HNR HRSG bypass/waste heat stack sources. Copies of the coke oven stack test data are included in the coke oven PQBS docket (Docket ID No. EPA-HQ-OAR-2002-0085). The flowrates used for SC-Vansant-VA waste heat stacks were further adjusted to account for the oven per stack ratio, similarly to how the TPY emissions were adjusted, as described in the Coke Ovens Risk and Technology Review: Data Summary memorandum ( EPA, 2023A).

  Table C-36. Average Stack Parameters for HNR HRSG Bypass/Waste Heat Stacks
                                   Facility
                                     Unit
                               Pollutant Tested
                              Flow Actual (acfm)
                           Flow Dry Standard (dscfm)
                             Temp Stack Gas (°F)
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      Hg

                                    52,474
                                     1,275
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      Hg

                                    48,744
                                     1,353
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      Hg

                                    54,456
                                     1,322
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                 PM Filterable

                                    52,474
                                     1,275
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                 PM Filterable

                                    48,744
                                     1,353
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                 PM Filterable

                                    54,456
                                     1,322
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      AG
                                    199,250
                                    49,898
                                     1,402
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      AG
                                    206,413
                                    48,646
                                     1,517
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      AG
                                    212,791
                                    56,009
                                     1,303
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      HCN
                                    199,752
                                    49,475
                                     1,408
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      HCN
                                    202,042
                                    46,157
                                     1,505
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      HCN
                                    205,236
                                    49,979
                                     1,416
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      PAH

                                    52,658
                                     1,376
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      PAH

                                    52,292
                                     1,371
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                      PAH

                                    53,545
                                     1,487
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                    D/F TEQ

                                    52,658
                                     1,376
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                    D/F TEQ

                                    52,292
                                     1,371
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                    D/F TEQ

                                    53,545
                                     1,487
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                     VOHAP
                                    202,369
                                    50,021
                                     1,408
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                     VOHAP
                                    201,547
                                    46,112
                                     1,505
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                     VOHAP
                                    211,675
                                    51,493
                                     1,409
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                 Formaldehyde

                                    50,566
                                     1,408
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                 Formaldehyde

                                    46,067
                                     1,505
SC-GraniteCity-IL
Coke Oven Battery C - Bypass Vent 5
                                 Formaldehyde

                                    53,007
                                     1,402
Average

                                    204,564
                                    51,134
                                     1,410

Development of Unit Costs for Ductwork for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks

      It was assumed that SC-EastChicago-IN and SC-Vansant-VA will duct eight of their sixteen HNR HRSG bypass/waste heat stacks together and route to a series of air pollution control devices, for a set of two APCD configurations per facility; SC-GraniteCity-IL will duct their six HNR HRSG bypass/waste heat stacks together and route to a series of air pollution control devices, for one APCD configuration; SC-FranklinFurnace-OH will duct five of their ten HNR HRSG bypass/waste heat stacks together and route to a series of air pollution control devices, for a set of two APCD configurations; and SC-Middletown-OH will duct their five HNR HRSG bypass/waste heat stacks together and route to a series of air pollution control devices, for one APCD configuration.

      The ductwork cost model from the Ferroalloy NESHAP RTR (EPA, 2015) was used to develop unit costs for HNR HRSG bypass/waste heat stacks using specific data available for the coke industry. Table C-37 shows the ductwork unit costs for HNR HRSG bypass/waste heat stacks.
Table C-37. Ductwork Unit Costs for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks
                                  Parameters
                           Ductwork Unit Cost Values
                               Source/Reference

                               SC-EastChicago-IN
                          Ducting 8 Stacks Together
                                 SC-Vansant-VA
         Ducting 8 Stacks Together, adjusted for Oven-to-Stack Ratio
                 SC-GraniteCity-IL Ducting 6 Stacks Together
                             SC-FranklinFurnace-OH
                          Ducting 5 Stacks Together
                               SC-Middletown-OH
                          Ducting 5 Stacks Together

Ducts: Cost Base Date:  GDP 1993
                                    68.877
                                    68.877
                                    68.877
                                    68.877
                                    68.877
BEA, 2023
Cost Escalation: GDP 2022
                                    126.45
                                    126.45
                                    126.45
                                    126.45
                                    126.45
BEA, 2023
-- Inlet stream flowrate (acfm):
                                   1,636,512
                                    731,316
                                   1,227,384
                                   1,022,820
                                   1,022,820
Coke oven test data
-- Duct velocity (ft/min):
                                     3,800
                                     3,800
                                     3,800
                                     3,800
                                     3,800
Ferroalloy (EPA, 2015)
-- Duct length (ft):
                                     1200
                                     1200
                                      900
                                      750
                                      750
Engineering judgement
-- Material of construction:
                                 Sheet-galv CS
                                 Sheet-galv CS
                                 Sheet-galv CS
                                 Sheet-galv CS
                                 Sheet-galv CS
Ferroalloy (EPA, 2015)
-- Insulation thickness (in.): (text input)
                                       0
                                       0
                                       0
                                       0
                                       0
Ferroalloy (EPA, 2015)
-- Duct design:
                             Circular-longitudinal
                             Circular-longitudinal
                             Circular-longitudinal
                             Circular-longitudinal
                             Circular-longitudinal
Ferroalloy (EPA, 2015)
-- Cost equation parameters:

          a:
                                     2.03
                                     2.03
                                     2.03
                                     2.03
                                     2.03
Ferroalloy (EPA, 2015)
          b:
                                     0.784
                                     0.784
                                     0.784
                                     0.784
                                     0.784
Ferroalloy (EPA, 2015)
-- Cost equation form:
                                       1
                                       1
                                       1
                                       1
                                       1
Ferroalloy (EPA, 2015)
-- Control system installation factor:
                                       0
                                       0
                                       0
                                       0
                                       0
Ferroalloy (EPA, 2015)
   (if no system, enter '0')

-- Fan-motor combined efficiency (fraction):
                                      0.6
                                      0.6
                                      0.6
                                      0.6
                                      0.6
Ferroalloy (EPA, 2015)
Design Parameters

-- Duct diameter (in.):
                                      76
                                      76
                                      76
                                      76
                                      76
Ferroalloy (EPA, 2015)
-- Pressure drop (in. w.c.):
                                       2
                                       2
                                       2
                                       2
                                       2
Ferroalloy (EPA, 2015)
CAPITAL COSTS

Ductwork Cost ($)--base:
                                    $72,650
                                    $72,650
                                    $54,487
                                    $45,406
                                    $45,406
Ferroalloy (EPA, 2015)
Ductwork Cost ($)--escalated:
                                   $133,377
                                   $133,377
                                   $100,032
                                    $83,360
                                    $83,360
Ferroalloy (EPA, 2015)
Purchased Equipment Cost ($):
                                   $144,047
                                   $144,047
                                   $108,035
                                    $90,029
                                    $90,029
Ferroalloy (EPA, 2015)
Retrofit Adjustment (25%)
                                   $180,058
                                   $180,058
                                   $135,044
                                   $112,537
                                   $112,537
Ferroalloy
(EPA, 2015)
Total Capital Investment ($):
                                   $270,088
                                   $270,088
                                   $202,566
                                   $168,805
                                   $168,805
Ferroalloy (EPA, 2015)
ANNUAL COST INPUTS

Operating factor (hours/year):
                                    1138.8
                                     8760
                                      312
                                      192
                                      312
Coke oven test data
Electricity price ($/kWhr):
                                     0.067
                                     0.067
                                     0.067
                                     0.067
                                     0.067
Ferroalloy
(EPA, 2015)
Annual interest rate (fractional):
                                     0.075
                                     0.075
                                     0.075
                                     0.075
                                     0.075
FRED, 2023
Ductwork economic life (years):
                                      20
                                      20
                                      20
                                      20
                                      20
Ferroalloy
(EPA, 2015)
Capital recovery factor (system):
                                  0.098092192
                                  0.098092192
                                  0.098092192
                                  0.098092192
                                  0.098092192
Ferroalloy (EPA, 2015)
Taxes, insurance, admin. factor:
                                     0.04
                                     0.04
                                     0.04
                                     0.04
                                     0.04
Ferroalloy (EPA, 2015)
Labor, $/hr
                                    $29.44
                                    $29.44
                                    $29.44
                                    $29.44
                                    $29.44
BLS, 2023
ANNUAL COSTS

Item
                                  Cost ($/yr)
                                  Cost ($/yr)
                                  Cost ($/yr)
                                  Cost ($/yr)
                                  Cost ($/yr)

Electricity
                                    $49,973
                                   $171,781
                                    $7,701
                                    $3,291
                                    $5,348
Ferroalloy (EPA, 2015)
Taxes, insurance, administrative
                                    $10,804
                                    $10,804
                                    $8,103
                                    $6,752
                                    $6,752
Ferroalloy (EPA, 2015)
Capital recovery
                                    $26,493
                                    $26,493
                                    $19,870
                                    $16,558
                                    $16,558
Ferroalloy (EPA, 2015)
Labor
                                    $2,438
                                    $2,438
                                    $2,438
                                    $2,438
                                    $2,438
Ferroalloy (EPA, 2015)
Overhead
                                    $1,463
                                    $1,463
                                    $1,463
                                    $1,463
                                    $1,463
Ferroalloy (EPA, 2015)
TOTAL ANNUAL COST
                                    $91,170
                                   $212,978
                                    $39,574
                                    $30,502
                                    $32,559
Ferroalloy (EPA, 2015)

Development of Unit Costs for ACI for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks

      The ACI cost model from the Ferroalloy NESHAP RTR (EPA, 2015) was used to develop unit costs for HNR HRSG bypass/waste heat stacks using specific data available for the coke industry. Table C-38 shows the ACI unit costs for HNR HRSG bypass/waste heat stacks.

Table C-38. ACI Unit Costs for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks
                                  Parameters
                             ACI Unit Cost Values
                               Source/Reference

                               SC-EastChicago-IN
                          Ducting 8 Stacks Together
                                 SC-Vansant-VA
          Ducting 8 Stacks Together, Adjusted for Oven-to-Stack Ratio
                 SC-GraniteCity-IL Ducting 6 Stacks Together
                             SC-FranklinFurnace-OH
                          Ducting 5 Stacks Together
                               SC-Middletown-OH
                          Ducting 5 Stacks Together

Annual Operating Hours, hr/yr (H)
                                    1138.8
                                     8760
                                      312
                                      192
                                      312
Coke oven test data
Exhaust Gas Flow Rate, acfm (Qa)
                                   1,636,512
                                    731,316
                                   1,227,384
                                   1,022,820
                                   1,022,820
Coke oven test data
Exhaust Gas Flow Rate, dscfm (Q)
                                    409,074
                                    182,805
                                    306,805
                                    255,671
                                    255,671
Coke oven test data
Operating Labor Rate, $/hr (LR)
                                    $29.44
                                    $29.44
                                    $29.44
                                    $29.44
                                    $29.44
BLS, 2023
Activated Carbon Cost, $/lb (ACC)
                                     $0.75
                                     $0.75
                                     $0.75
                                     $0.75
                                     $0.75
Ferroalloy (EPA, 2015)
Dust Disposal Cost, $/Ton (DDC, Non-Hazardous)
                                    $40.00
                                    $40.00
                                    $40.00
                                    $40.00
                                    $40.00
Ferroalloy (EPA, 2015)
Dust Disposal Cost, $/Ton (DDC, Hazardous)
                                    $400.00
                                    $400.00
                                    $400.00
                                    $400.00
                                    $400.00
Ferroalloy (EPA, 2015)
Capital Recovery Factor (CRF)
                                  0.098092192
                                  0.098092192
                                  0.098092192
                                  0.098092192
                                  0.098092192
CRF calculated assuming 20-year equipment life and 7.5% interest (FRED, 2023)
GDP, 2022
                                    126.45
                                    126.45
                                    126.45
                                    126.45
                                    126.45
BEA, 2023
GDP, 2008
                                    94.419
                                    94.419
                                    94.419
                                    94.419
                                    94.419
BEA, 2023
GDP, 1991
                                    65.783
                                    65.783
                                    65.783
                                    65.783
                                    65.783
BEA, 2023
ACI Adjustment Factor (AF)
                                     0.95
                                     0.95
                                     0.95
                                     0.95
                                     0.95
Calculated control efficiency
ACI Injection Rate (lb/MMacf)
                                      2.0
                                      2.0
                                      2.0
                                      2.0
                                      2.0
Ferroalloy (EPA, 2015)
Total Capital Investment, $ (TCI)
                                   $254,570
                                   $157,007
                                   $214,212
                                   $192,015
                                   $192,015
Calculated using algorithm 4,500 x (Q/1,976)0.6 x (1.2 retrofit factor) x CEPCI Adj.
Direct Annual Cost, $/yr (DAC)

Operating Labor
                                    $1,048
                                    $8,059
                                     $287
                                     $177
                                     $287
Calculated using (0.25 hr/8-hr shift) x H x LR
Supervisory Labor
                                     $157
                                    $1,209
                                      $43
                                      $26
                                      $43
Calculated using 0.15 x Operating Labor
Maintenance
                                    $50,914
                                   $31,401
                                   $42,842
                                   $38,403
                                   $38,403
Calculated using 0.2 x TCI
Activated Carbon
                                  $1,290,226
                                   $576,570
                                   $967,669
                                   $806,391
                                   $806,391

Dust Disposal (Non-Hazardous)
                                    $4,428
                                    $15,221
                                     $910
                                     $467
                                     $758
Calculated using ACI injection rate, 99% capture efficiency, and non-hazardous disposal cost
Dust Disposal (Hazardous)
                                    $44,281
                                   $152,214
                                    $9,099
                                    $4,666
                                    $7,582
Calculated using ACI injection rate, 99% capture efficiency, and hazardous disposal cost
Indirect Annual Cost, $/yr (IAC)

Overhead
                                    $31,271
                                    $24,402
                                    $25,904
                                    $23,164
                                    $23,240
Calculated using 0.6 x (Labor + Maintenance)
Property Tax, Insurance, & Admin
                                   $10,183
                                    $6,280
                                    $8,568
                                    $7,681
                                    $7,681
Calculated using 0.04 x TCI
Capital Recovery
                                   $24,971
                                   $15,401
                                   $21,013
                                   $18,835
                                   $18,835
Calculated using CRF x TCI
Total Annual Cost (Hazardous)
                                  $1,453,051
                                   $815,537
                                  $1,075,425
                                   $899,343
                                   $902,462
Sum of DAC + IAC

Development of Unit Costs for WAS for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks

      The WAS cost model from the Portland Cement NESHAP (EPA, 2010) was used to develop unit costs for HNR HRSG bypass/waste heat stacks using specific data available for the coke industry. Table C-39 shows the WAS unit costs for HNR HRSG bypass/waste heat stacks.
Table C-39. WAS Unit Costs for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks
                                   Parameter
                              Capital Cost Value

                               SC-EastChicago-IN
                          Ducting 8 Stacks Together
                                 SC-Vansant-VA
          Ducting 8 Stacks Together, Adjusted for Oven-to-Stack Ratio
                 SC-GraniteCity-IL Ducting 6 Stacks Together
                             SC-FranklinFurnace-OH
                          Ducting 5 Stacks Together
                               SC-Middletown-OH
                          Ducting 5 Stacks Together
                               Source/Reference
Gas flowrate (dscfm)
                                    409,074
                                    182,805
                                    306,805
                                    255,671
                                    255,671
Coke oven test data
GDP 2010
                                    96.166
                                    96.166
                                    96.166
                                    96.166
                                    96.166
BEA, 2023
GDP 2022
                                    126.45
                                    126.45
                                    126.45
                                    126.45
                                    126.45
BEA, 2023
CC = Capital ($2022)
                                  $44,083,937
                                  $27,188,923
                                  $37,095,150
                                  $33,251,281
                                  $33,251,281
Portland Cement (EPA, 2010)
                                 Annual Costs
                                   Parameter
                                     Value
                               Source/Reference
COSTKWH ($2022/kWhr)
                                  0.095199759
Portland Cement (EPA, 2010)
Annual interest rate (fraction):
                                     0.075
FRED, 2023
Control system life (years):
                                      20
Portland Cement (EPA, 2010)
Capital recovery factor:
                                  0.098092192
Portland Cement (EPA, 2010)
                                   Parameter
                               SC-EastChicago-IN
                        Ducting 8 Stacks Together Value
                                 SC-Vansant-VA
                           Ducting 8 Stacks Together
               SC-GraniteCity-IL Ducting 6 Stacks Together Value
                             SC-FranklinFurnace-OH
                        Ducting 5 Stacks Together Value
                               SC-Middletown-OH
                        Ducting 5 Stacks Together Value
                               Source/Reference
Coke Production TPY
                                    650,000
                                    372,500
                                    428,412
                                    341,657
                                    357,010
Coke oven test data
Operating Hours per year
                                    1138.8
                                     8760
                                      312
                                      192
                                      312
Coke oven test data
Fixed Cost
                                  $1,880,181
                                  $1,171,206
                                  $1,574,777
                                  $1,409,473
                                  $1,411,595
Portland Cement (EPA, 2010)
SO2 = lb SO2 per ton of coke
                                     0.30
                                      1.8
                                     0.13
                                     0.098
                                     0.15
Coke oven test data
Variable Cost
                                    $18,878

                                    $18,198

                                    $11,450

                                    $9,003

                                    $9,660

Portland Cement (EPA, 2010 & Andover 2009)
Total Annual Costs
                                  $6,223,350
                                  $3,856,424
                                  $5,224,972
                                  $4,680,167
                                  $4,682,946
Portland Cement (EPA, 2010)
Note: CC = Capital ($2022) = 14,398*(DSCFM)[0.6][.] Fixed costs include labor (operating, supervisory, and maintenance), maintenance materials, replacement parts, taxes, insurance, etc.: FC = 38 * TPY[0.6] + 0.04 * CC. Variable costs include consumption of limestone, power, and water plus generation of scrubber slurry: VC = (0.000844 * TPY * COSTKWH) + (0.013 * TPY * SO2) + (TPY * 0.025). Total annualized cost (TAC) includes fixed annual costs, variable annual costs, and capital recovery interest rate, 20‐year lifetime, and a capital recovery factor: TAC = FC + VC + CRF * CC

Development of Unit Costs for RTO for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks

      The RTO cost model from the Portland Cement NESHAP (EPA, 2010) was used to develop unit costs for HNR HRSG bypass/waste heat stacks using specific data available for the coke industry. Table C-40 shows the RTO unit costs for HNR HRSG bypass/waste heat stacks.

Table C-40. RTO Unit Costs for BTF Controls for HNR HRSG Bypass/Waste Heat Stacks
                                   Parameter
                               SC-EastChicago-IN
                          Ducting 8 Stacks Together
                                 SC-Vansant-VA
          Ducting 8 Stacks Together, Adjusted for Oven-to-Stack Ratio
                 SC-GraniteCity-IL Ducting 6 Stacks Together
                             SC-FranklinFurnace-OH
                          Ducting 5 Stacks Together
                               SC-Middletown-OH
                          Ducting 5 Stacks Together
                                    Source/
                                   Reference
Flowrate (dscfm)
                                    409,074
                                    182,805
                                    306,805
                                    255,671
                                    255,671
Coke oven test data
GDP 2010
                                    96.166
                                    96.166
                                    96.166
                                    96.166
                                    96.166
BEA, 2023
GDP 2022
                                    126.45
                                    126.45
                                    126.45
                                    126.45
                                    126.45
BEA, 2023
Total Capital Investment (TCI)
                                  $29,388,075
                                  $18,125,199
                                  $24,729,077
                                  $22,166,604
                                  $22,166,604
Portland Cement (EPA, 2010)
Total Annual Costs (TAC)
                                  $11,531,628
                                  $6,360,886
                                  $9,298,077
                                  $8,125,425
                                  $8,125,425
Portland Cement (EPA, 2010)
Note: TCI = 25280000 * (DSCFM/502312)^0.6 * GDP2022/GDP2010. TAC = 14177 + 8.3 * DSCFM + 0.1824 * TCI * GDP2022/GDP2010

BTF Costs per Facility for HNR HRSG Bypass/Waste Heat Stacks

      It was assumed that the coke facilities will duct either five, six, or eight of their HNR HRSG bypass/waste heat stacks together and route to one BTF APCD configuration. The unit APCD costs were multiplied by the required number of APCD configurations to calculate the total BTF HNR HRSG bypass/waste heat stack costs per facility. The total BTF HNR HRSG bypass/waste heat stack costs are shown in Table C-41.

   Table C-41. BTF Costs per Facility for HNR HRSG Bypass/Waste Heat Stacks
                                   Facility
                               No. APCD Configs
                            Total Capital Cost ($)
                             Total Annual Cost ($)

                                   Ductwork
                                     ACI
                                     WAS
                                     RTO
                                    Total
                                   Ductwork
                                     ACI
                                     WAS
                                     RTO
                                    Total
SC-EastChicago-IN
                                       2
                                   $540,175
                                   $509,141
                                  $88,167,875
                                  $58,776,151
                                 $147,993,341
                                   $182,340
                                  $2,906,102
                                  $12,446,699
                                  $23,063,255
                                  $38,598,396
SC-FranklinFurnace-OH
                                       2
                                   $337,610
                                   $384,030
                                  $66,502,563
                                  $44,333,207
                                 $111,557,410
                                    $61,004
                                  $1,798,686
                                  $9,360,334
                                  $16,250,849
                                  $27,470,873
SC-GraniteCity-IL
                                       1
                                   $202,566
                                   $214,212
                                  $37,095,150
                                  $24,729,077
                                  $62,241,005
                                    $39,574
                                  $1,075,425
                                  $5,224,972
                                  $9,298,077
                                  $15,638,048
SC-Middletown-OH
                                       1
                                   $168,805
                                   $192,015
                                  $33,251,281
                                  $22,166,604
                                  $55,778,705
                                    $32,559
                                   $902,462
                                  $4,682,946
                                  $8,125,425
                                  $13,743,392
SC-Vansant-VA
                                       2
                                   $540,175
                                   $314,014
                                  $54,377,847
                                  $36,250,398
                                  $91,482,434
                                   $425,956
                                  $1,631,074
                                  $7,712,849
                                  $12,721,773
                                  $22,491,652
Industry Total

                                  $1,789,331
                                  $1,613,413
                                 $279,394,716
                                 $186,255,436
                                 $469,052,896
                                   $741,433
                                  $8,313,749
                                  $39,427,800
                                  $69,459,379
                                 $117,942,361

BTF Emission Reductions for HNR HRSG Bypass/Waste Heat Stacks

      Baseline emissions were estimated from coke oven CAA section 114 requests data. The coke oven stack test data were used to develop industry average Hg, PM, non-Hg metal HAP, AG, PAH, and formaldehyde lb/hr default values for the units that were not tested, as shown in Table C-42.

                 Table C-42. HNR HRSG Bypass/Waste Heat Stack
                  Default Baseline Emission Factors (lb/hr)
                               Pollutant Tested
                       HNR HRSG Bypass/Waste Heat Stack
                                    (lb/hr)
Hg
                                   2.55E-03
PM
                                   7.59E+00
Non-Hg Metal HAP
                                   1.29E-01
AG
                                   3.05E+01
PAH
                                   2.91E-04
Formaldehyde
                                   2.35E-02

      The lb/hr coke emission factor for each HNR HRSG bypass/waste heat stack source (i.e., coke oven test data or default emission factor) were multiplied by each source's corresponding annual operating hours (hours/year), as shown in Table C-43, and then divided by 2,000 to calculate TPY emissions.

    Table C-43. Annual Operating Hours per HNR HRSG Bypass/Waste Heat Stack
                                   Facility
                                Emission Source
                            Annual Operating Hours
SC-EastChicago-IN
                              Venting Stack 1-14
                                    1,138.8
SC-FranklinFurnace-OH
                          HRSG Bypass Vent Stack 1-10
                                      192
SC-GraniteCity-IL
                          HRSG Bypass Vent Stack 1-6
                                      312
SC-Middletown-OH
                          HRSG Bypass Vent Stack 1-5
                                      312
SC-Vansant-VA
                              Venting Stack 1-16
                                     8,760

      The TPY emissions for SC-Vansant-VA were further adjusted to account for the oven per stack ratio, as described in the Coke Ovens Risk and Technology Review: Data Summary memorandum ( EPA, 2023A). The baseline PM and HAP emissions for HNR HRSG bypass/waste heat stacks were summed for each facility. Table C-44 shows the baseline emissions.

                  Table C-44. Baseline PM and HAP Emissions
          from HNR HRSG Bypass/Waste Heat Stacks Before BTF Controls